The Client faced mounting pressure to enhance beer quality, operational consistency, and overall production effectiveness across two brewery locations operating near capacity. Reactive maintenance practices, gaps in quality systems, and unclear organizational responsibilities hindered reliability and growth. Core risks, including insufficient CO₂ monitoring, improper chemical storage, limited structured training, and the absence of a skills matrix, created variability and constrained throughput. With expansion plans underway and increasing demand across a diversified craft portfolio, the Client required a comprehensive, data‑driven review to benchmark current performance and identify actionable opportunities for sustainable improvement.
To address these challenges, First Key conducted on‑site quality and technical reviews at both brewery locations, assessing brewing operations, equipment effectiveness, quality assurance processes, safety practices, and organizational structure. The team developed a proposed skills matrix, advised on key hiring needs, and strengthened safety and quality systems through recommendations for CO₂ monitoring, chemical storage, and CIP documentation. First Key introduced preventive maintenance schedules, root cause analysis tools, and structured training frameworks while also developing capital expenditure plans to support growth, including investments in ozone systems, fermenters, pasteurization, boilers, and condensate recovery. The team further advanced digital transformation by recommending SOP templates, dashboard tools, and integrated management systems, supported by capacity modeling and value‑stream mapping.
The engagement delivered a clear and actionable roadmap that improved safety, quality, and operational efficiency across both sites. Recommendations were projected to reduce downtime by 20–30% through enhanced preventive maintenance and structured training, while improved microbiological testing and sanitation standards strengthened product consistency. Capital investment strategies positioned the Client to scale to 25,000 bbl/year at one facility and optimize 15,000 bbl/year at the other. Digital management systems and KPI dashboards established real‑time performance visibility, while strengthened organizational structure and workforce development improved engagement and retention, unlocking a measurable foundation for long‑term growth.
