Improving Safe Access Across Tuatara Brewery’s Production Facility.

Background

Tuatara Brewery is a New Zealand craft brewery operating a busy production facility with multiple elevated process areas. Based in Wellington, the brewery manages brewing, packaging, and site operations in house, with a strong focus on safety, consistency, and efficient day to day workflows.

As the brewery has expanded and equipment layouts have evolved, Tuatara identified the need for a more structured and permanent access solution. Existing access arrangements were no longer ideal for regular operator use or maintenance activities, prompting the requirement for a purpose designed modular stair and platform system.

Project Overview

Customer: Tuatara Brewery
Purpose: Industrial Stair and Platform Access
Country: Upper Hutt, New Zealand
Industry: Food and beverage manufacturing
Built Item: Modular stair and platform system
SlotPro Products Used: 40 x 3 SPS Aluminium Tube, 40 x 160 SlotPro 10 Slot Standard Extrusion, 40 x 100 SPS Step Profile, 40 x 150 SPS Step Profile, 80 x 80 SlotPro 8 Slot Standard Extrusion, 40 x 80 SlotPro 6 Slot Standard Extrusion, 4 Series Universal Connector, SPS 45° Y Connector, SPS X Connector, SPS 45° L Connector, SPS Cross Connector, SPS 90° T Connector, SPS Side Base, SPS Side Stair Plate

The Solution

SlotPro worked with the Tuatara team to design and supply a modular stair and platform system using a combination of aluminium T-slot extrusion profiles suited to the required loads and access heights. The system incorporated stair flights, intermediate platforms, and continuous handrails to provide consistent access geometry and secure movement around elevated areas.

All components were selected for durability, corrosion resistance, and compatibility within the SlotPro system. The stair and platform assemblies were installed using standard connectors and fixings, allowing efficient onsite assembly without welding or specialised tools. The finished structure delivers a clean, structured access solution that supports current operations while allowing for future adjustment or expansion as the brewery continues to evolve.

The Results

The completed stair and platform system provides Tuatara Brewery with consistent, permanent access to elevated process equipment across the production area. Operators now have defined access routes with stable stair geometry, secure platforms, and continuous handrails, supporting safe movement during routine operation, cleaning, and maintenance tasks.

The modular aluminium construction allowed the system to be installed efficiently with minimal disruption to brewery operations. The finished installation integrates cleanly with the existing plant layout and provides a structured access solution that supports daily use while maintaining flexibility for future changes within the facility.

The Impact

The new stair and platform access system has improved both safety and usability within Tuatara Brewery’s production facility. Operators and maintenance staff now have defined, stable walkways over and around process equipment, providing safe pedestrian access across elevated areas as part of normal day to day operations.

By replacing temporary or informal access paths, the system supports more predictable movement through the production space and reduces risk during operation, cleaning, and maintenance activities. The modular design also allows the stair and platform layout to be adjusted or extended if equipment or workflows change in the future, supporting ongoing development of the facility without major structural modification.