The Client, a historic brewery with over a century of legacy, faced a critical operational bottleneck. Their temporary flash pasteurizer constrained racker throughput to just 50% of its designed speed, directly impacting production volumes and market responsiveness. The need to replace this unit with a new, high-capacity pasteurizer was urgent, but installation logistics were complex: the new equipment had to occupy the same footprint as the old, requiring precise coordination to minimize downtime. Further complicating the challenge, the Client opted not to invest in an integrated buffer tank, necessitating a creative solution for process continuity.
First Key developed a production schedule that enabled the Client to build inventory ahead of the installation window, ensuring uninterrupted supply. A cross-functional team of riggers, electricians, programmers, pipe fitters, and sanitary welders—was mobilized to execute a tightly sequenced decommissioning and installation. To address the buffer tank gap, First Key repurposed a decommissioned 60-barrel fermenter, demonstrating agile problem-solving. Post-installation, First Key delivered comprehensive SOP documentation and operator training, including “train the trainer” sessions to embed best practices within the Client’s team.
The project was completed on time and within budget, restoring the racker to full operational speed and unlocking latent production capacity. The Client realized immediate throughput gains, positioning them to respond faster to market demand. Additionally, the decommissioned temporary unit was sold to another First Key client, generating incremental value. This engagement not only delivered quantifiable operational improvements but also identified new business opportunities through asset redeployment and process optimization which reinforced First Key’s role as a strategic partner in driving growth and efficiency for beverage industry leaders.
