Improving Safe Access At Tuatara Brewery With Stair And Platform.
3 minute read
Published 19 February 2025
Tuatara Brewery operates a busy food and beverage manufacturing facility in Upper Hutt, New Zealand, managing brewing, packaging, and site operations in house. With multiple elevated process areas across the plant, safe and reliable access is essential for daily production, cleaning, and maintenance.
As the brewery expanded and equipment layouts evolved, existing access arrangements no longer met operational requirements. Temporary solutions did not provide the consistency or long term structure required within a growing food and beverage manufacturing environment. Tuatara identified the need for a purpose designed modular stair and platform system that would deliver defined access routes, stable stair geometry, and secure pedestrian movement across elevated areas.
A Purpose Built Modular Stair and Platform System
SlotPro worked closely with the Tuatara team to design and supply a modular stair and platform system tailored to the layout and operational requirements of the brewery.
The system was constructed using aluminium T slot extrusion profiles selected for structural strength, corrosion resistance, and long term durability in a food and beverage environment. Using SlotPro’s modular aluminium framework allowed the stair and platform configuration to be precisely designed around existing production equipment.
The completed modular stair and platform system includes:
- Dual stair flights providing access from both sides
- A central elevated platform for operator movement
- Continuous handrails for secure pedestrian access
- Modular aluminium framing assembled with standard connectors
Key profiles used within the modular stair and platform system included 40 x 160 SlotPro 10 Slot Standard Extrusion, 80 x 80 SlotPro 8 Slot Standard Extrusion, and SPS step profiles suited to industrial stair applications.
All components were installed using mechanical connectors and fixings, eliminating the need for onsite welding. This approach enabled efficient assembly while minimising disruption to brewing and packaging operations.
Designed for Food and Beverage Manufacturing
In food and beverage manufacturing environments, access systems must support both safety and hygiene requirements. The aluminium construction of the modular stair and platform system provides durability and corrosion resistance suited to washdown and production conditions.
The structured geometry of the stair flights ensures consistent step spacing and stable foot placement. Intermediate platforms provide safe transition points between levels, while continuous handrails support secure pedestrian movement during routine operation and maintenance tasks.
By introducing a defined modular stair and platform system, Tuatara Brewery now has clearly established access routes across elevated process equipment. This supports predictable movement through the production area and improves usability for operators and maintenance staff.
Supporting Ongoing Facility Development
One of the key advantages of a modular stair and platform system is its adaptability. As equipment positions or workflows change, the aluminium T-slot framework can be adjusted, extended, or reconfigured without major structural modification.
For Tuatara Brewery, this flexibility ensures the access solution can evolve alongside the facility. Future expansion or layout changes can be accommodated within the existing modular system, protecting the initial investment while supporting continued growth.
The finished stair and platform installation integrates cleanly with the surrounding plant layout. It provides a permanent, structured access solution that supports daily operations while maintaining the flexibility required in a modern manufacturing environment.
Projects such as this demonstrate how a well designed modular stair and platform system can enhance safety, improve access consistency, and support operational efficiency within active production facilities. For manufacturers seeking durable and adaptable elevated access, the stair and platform system provides a practical and scalable solution.