Industrial & Operations

Information architecture for inherited systems. Restore control. Reduce risk. Keep it boring.

Actisafe website screenshot.
LiveCatalog stabilization

Legacy build stabilized and catalog flattened. Migration to cleaner data model completed.

Actisafe

Snapshot

  • Operator: Industrial safety and storage supplier.
  • Inherited structure: 400+ SKUs scattered across brittle templates.
  • Risk class: Revenue-critical (catalog scale failure).
  • Observed failure mode: Admin paralysis and layout breaks on basic price edits.
  • Trajectory: Nonlinear admin cost, pricing errors, and revenue risk under growth.

Verdict

Continuing with one-page-per-SKU would have compounded breakage and turned routine price changes into revenue risk. Control required collapsing the catalog into structured product groups.

Migration focused on consolidating a sprawling 400+ page site into ~20 structured product groups, enforcing gated pricing for wholesale protection, and repairing a fragile Elementor/WooCommerce integration.

Timeline: ~10 weeks Budget band: $9k–$10k AUD Mandate: Catalog consolidation & Gated pricing

  • SectorIndustrial storage
  • StackWooCommerce, Custom MU Plugins, Elementor
  • LifecycleStabilization & Migration
  • Catalog strategy
  • Gated commerce
  • Performance
  • Information architecture

Structural constraints

  • WooCommerce templates tightly coupled to page-builder layouts over time.
  • Each new SKU increased admin friction instead of scaling linearly.
  • 2GB server storage limit triggered by unattached media duplication.
  • Product specs locked behind login, but client needed "teaser" visibility.

Leverage moves

  • Consolidated 400+ products into ~20 variable product groups.
  • Implemented fp-product-query-core to bypass heavy Woo queries for filtering.
  • Created custom "Guest Mode" logic: Price HTML swapped for Login link ($0.00).
  • Decoupled freight data from layout to ensure accurate shipping calcs.

Custom engineering: Removing plugin-driven fragility

Actisafe custom product listing showing faceted search, flattened variations, and gated pricing.
The Problem

Standard WooCommerce patterns and plugins would have increased fragility, query cost, and long-term maintenance risk when handling complex B2B gating and flattened variations.

The Fix

We built a bespoke query engine (fp-product-query-core) to drive this interface. It exposes child variations as first-class citizens, allowing specific attribute filtering (Material, Color) and enforcing server-side price removal for guests—all without the performance hit of standard loops.

Evidence
  • Pricing edits triggered layout breakage in live templates.
  • SKU-level changes required developer intervention.
  • Storage ceilings reached due to duplicated media artifacts.
Ruled out
  • Heavy membership plugins (MemberPress) for simple price gating.
  • Full custom Laravel build (timeline/budget mismatch).
  • Leaving legacy SKU structure (maintenance cost too high).

Before / After

  • Before: 400+ loose pages, broken layouts on edit, unverified freight data.
  • After: 20 structured parent products, variations grouped by attribute, safe admin edits.
Maintenance delta
  • Ops team can update pricing without developer intervention.
  • Stock status linked to single source of truth.
  • Update surface reduced from 400+ pages to 20 templates.
Decision log
  • Child theme isolation preferred for critical Woo templates.
  • Custom widgets preferred over plugin bloat for catalog navigation.
  • Unused image sizes disabled to strictly bound storage growth.

Irreversible outcomes

  • Freight data normalized (weight/dims), unblocking shipping automation.
  • Gated pricing logic hard-coded into the stack (guests cannot buy).
  • Single source of truth established for product taxonomy.
Intentionally boring
  • No new framework.
  • Standardized variable products.
  • Native Elementor widgets where possible.
  • PHP-based price hiding (no JS hacks).
Update discipline
  • Staged migration to keep cache warm.
  • Media library scan and thumbnail regeneration.
  • Rewrite rules flushed on plugin activation only.

Status

Stabilization and migration complete. Platform now supports incremental catalog expansion without reintroducing structural risk.

Role: Technical Lead / Developer. Mandate: Fix the catalog, gate the pricing, ensure scalability.

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