The Client, a rapidly expanding brewing company, faced mounting risks to product consistency and brand reputation due to recurring quality control issues. They were experiencing microbiological contamination and dissolved oxygen excursions, symptoms of deeper operational gaps, including the absence of a formal quality management system, incomplete cleaning and sampling protocols, and inconsistent maintenance routines. These shortcomings threatened their readiness for record production volumes planned for Spring 2026 and put operational reliability at risk.
To address these challenges, First Key deployed a two phase approach combining remote diagnostics with a focused on site technical review. The team conducted targeted pre visit assessments, followed by a three day immersive onsite evaluation of procedures, infrastructure, and data. This analysis spanned quality assurance systems, dissolved oxygen control, operations, and long term capital planning. First Key delivered immediate risk reduction actions, such as enhanced cleaning protocols, expanded ATP swabbing, and revised sampling plans, while benchmarking current practices against industry standards. The engagement culminated in a robust capacity model and a prioritized action plan that provided the Client with clear direction for quality improvement and operational scaling.
The results positioned the Client for materially improved quality performance and accelerated growth. Immediate interventions reduced microbiological contamination risks and improved cleaning effectiveness, while the new capacity model identified brewhouse and fermentation bottlenecks and outlined viable pathways to support expansion to 270,000 bbl by 2029. Recommendations included twinning brewhouse output, high gravity brewing, extended production hours, and additional fermentation capacity, alongside capital upgrades such as flash pasteurization, buffer tanks, and automation. The Client also received benchmarking insights, SOP templates, and structured maintenance and sampling programs, establishing a scalable operational foundation and a clear roadmap for continued growth.
