Profile Group Hautapu Manufacturing Facility

A 5 Green Star rated industrial facility designed to showcase manufacturing excellence

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Project Details

Client Appropriate Holdings Ltd.
Sector Commercial, Masterplanning
Location Hautapu
Discipline Architecture
Status Completed 2022
Size 49,000 sqm
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Sculpture in the Landscape

Designed as a sculpture in the landscape, the new flagship Profile Group Hautapu Manufacturing Facility provides a strikingly simple and elegant response to the challenge of designing infrastructure of enormous scale. Combining transparent ends with a shell of folded steel results in a building that is both boldly unapologetic and finely articulated. The project draws on the desire for transparency, simplicity of materials, and attention to detail characterised in the earlier APL Factory HQ which completed in 2015.

Within a footprint equivalent to the area of six rugby fields, this combined production plant and office facility represents the first stage in developing a major industrial manufacturing campus in Hautapu, on the outskirts of Cambridge. The long-term masterplan designed by Jasmax sets out a self-sufficient development, allowing the company to grow and evolve over the next 50+ years. Promoting advances in sustainability and efficiencies in the production of both aluminium joinery and double-glazing units, this 110m wide and 430m long development is part of a long-term strategy to accommodate business growth and set a benchmark for sustainable industrial development in Aotearoa New Zealand.

A Model for Future Manufacturing

The highly energy efficient building was awarded a 5 Green Star NZ v3 Industrial Design rating from the NZGBC in 2021 and is achieving a 40% reduction in energy use and CO2 emissions. Many sustainability features have contributed to this outcome, including the energy efficient façade design, warm roof, low carbon and green certified material selections, and low impact amenities such as LED factory lighting.

A special feature of the project was the installation of the new manufacturing plant during the construction of the building, resulting in programme and cost efficiencies, and early operation of the facility. Construction commenced from north to south in stages to accommodate delivery timeframes of the manufacturing plant, resulting in 50% of the warehouse being completed by the plant’s arrival. As a result, a five-month reduction to the construction programme was achieved.

A focus on staff wellbeing contributed to the inclusion of energy efficient design features such as hydraulic underfloor heating, to keep employees on the factory floor warm all year round. Similarly, a desire for access to natural daylight and exterior views led to the inclusion of skylights and vast areas of glazing allowing occupants to connect to the outdoors - something often missing from manufacturing facilities. The design also showcases products manufactured on site.

New campus landscaping addresses the significant stormwater management challenge resulting from the buildings sizable roof, diverting three million litres of stormwater run-off per year to a new pond and wetland with riparian planting that covers 20% of the site, improving biodiversity and providing a source of water for sanitary and emergency use.

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2023 NZ Commercial Project Awards - Industrial - National Category Winner
2023 NZ Commercial Project Awards - Sustainability Award
2022 PCNZ Awards - Green Building Award
2022 PCNZ Awards - Industrial Property Award
2022 PCNZ Awards - Commercial Property Award - Merit
2022 NZIA Local Awards - Commercial Architecture