Breweries Business Guide
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We documented 12 challenges in Breweries. Now get the actionable solutions — vendor recommendations, process fixes, and cost-saving strategies that actually work.
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- All 12 documented pains
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All 12 Documented Cases
Inconsistent Batches from Stalled Fermentations
Batch rework/dump losses (quantified by automation ROI)Without real-time tracking, breweries miss slow/hung ferments, over-foaming, or off-flavor risks from supersaturation, leading to rework, dumps, or quality rejects. Snapshot manual sampling provides insufficient data (~1,000x less than automation), causing undetected yeast stress or process deviations. This results in recurring poor quality costs across batches.
Extended Fermentation Tank Turnaround Time
20% capacity reduction (translates to lost batch revenue)Poor visibility into fermentation progress leads to prolonged tank occupancy from undetected slow or stalled ferments due to yeast issues or malt variations. Manual checks delay interventions, reducing batches per year and blocking capacity for new production. Real-time monitoring cuts average tank time, unlocking 20% more output as proven in implementations.
Frequent Packaging Line Stoppages and Downtime
Implied multi-million liter opportunity cost (industry avg 50% production time loss); £137,000/year total from poor efficiency including £90,000 operating costs[2][4]Brewery packaging lines suffer from short intervals between stoppages and low actual production time, leading to idle equipment and lost capacity. Industry average production time is just over 50%, with stoppages every 11-12 minutes, bottlenecking output. Optimization efforts highlight these as recurring drags on throughput.
Idle Capital Tied in Untracked Keg Inventory
Capital tied up equivalent to full keg fleet valueKegs stuck at distributors or customers due to poor tracking reduce available production capacity and working capital. Breweries must overbuy kegs to maintain supply, leading to excess inventory costs. Faster keg returns via tracking directly increase sales velocity.