Tag Archives: Brewery Business Plans

34 days out …. sneak peak at our Layout

Not much to say on this post.  I am a little foggy this morning, and needing to get 2 blog posts out as I missed one from yesterday.  The first post today will be around the finalized layout and look of our tasting room, and the exterior elevation of our space

We agonized for months over how exactly to design and locate the entire production and front of house spaces.  There were likely 5 or 6 meetings with our architects to get this correct, and hopefully at the end of the day, we got it right from a production standpoint, but also a tasting room standpoint.

Some keys about the front of the house:

  • The tasting room has a direct connection to the brewhouse, where most of the fun stuff happens in brewing beer
  • The art gallery is directly connected to the tasting room, allowing people to view some artwork while they visit the brewery
  • We have 2 long communal tables, which is a direct result of bring people together through beer.  If you want to come to our brewery and sit quietly on your own, you might have a tough time
  • We will have lots of natural light.  There are about 14 windows across the front, that will provide heaps of natural light into the space
  • There is a moderately separated retail area from the tasting room, which will allow the patrons of each to not interfere with each others good time
  • The lines from our serving tanks to the tasting room are crazy short, as the cooler is right there
  • The front of the house has really high ceilings, something you can’t really see in the drawings, hopefully making the space very interesting and welcoming

As for the exterior of the building, not much to do other than clean it up, repaint and put a few new doors in to make the building secure and a little more functional.

There was a lot of found value in the space, which we have tried to salvage and add to in a positive and authentic manner.  Both Iain and like things that are authentic and interesting, and we hope to have created a space that is, if nothing else, both of these things.  We hope you pop-in and say hi the next time you are in the area.

Architectural drawings Oct 31.2014

 

36 days out … Use a Notebook and to do list!

Of the many things this process has taught me, there are several that stand out as key learnings overall.  Its hard to say how one should practice for these things, but likely knowing about them, reading books about them, and talking with others about them are a huge help.

The first thing that I have learned is how to get things done.  I feel like I have always been quite productive in my life.  Not quite sure where I got this, but ever since I turned 30, I have increasingly become a highly productive machine.  To that end, one of the best books I read for preparing for this venture was Getting Things Done by David Allen.  You will not be disappointed if you make the time to read this book.  It will help you be more productive with your days, and organize your life to stay on top of all the details.

Another trait that I knew was deep inside me, but never really exposed is an ability to work long hours with little sleep.  Normally, I am a high energy guy, so when it comes to sleep I like to get 7 hours of bed time a night.  Continuing to exercise and stay fit means that sleep is important.  However, for the past couple months, this has been shaved down to about 5.5 – 6 hours per night, with one night a week at 12.  I find I am capable of this, definitely a little more grumpy, unhappy, etc, but that should be expected.  Find your ability to work long and hard, and you will be in a good position to succeed.

One last trait, one that might just possibly be the most important trait is the ability to not get overwhelmed by the gravity of this situation.  Really, this is one of the most stressful and intense situations an average person could go through, and with the help of friends and family, I have managed to stay positive and on track.  If you have a tough time dealing with stress and multi-tasking, you will need to either take course, read or learn to deal with this possibility.

Another huge help is always having a notebook that contains a to do list.  Make sure you cross things out when they are complete, so you can get the satisfaction of accomplishing something. To do lists are key as are notebooks with all your notes from meetings and discussions.  I can’t tell you how many times I have referenced the book to find something I have been looking for.

Until next post, keep on keeping on!

General Ramblings

A lot of the things we have been planning for sometime now are taking shape.  The big decisions we had to make early on have all been made, and now we are left to make them all fit within the scope of this project, which is changing a daily basis.  As such, things like tap location, size of custom cabinetry, location of bar sinks, and hundreds of other little decisions need to be looked at.

We have made many errors both big and small along the way, as making so many decisions is bound to result in a bad decision or 2 ….. or 20!  So here are the mistakes we have made that come to the top of my mind, and things you should be mindful of not doing.

  1. Make sure you agree to delivery dates for equipment and services provided to your brewery.  If you don’t have specified drop-dead dates, you can’t hold people to a timeframe in getting things done.  For example, if your website needs to be created by June 1st, but you don’t have this in your contact with your web designer, then you are left with no recourse should things take longer.
  2. The marathon of this is truly day in and day out a grind.  I love what I am doing, and it is a passion and dream all rolled into one, but it is still a grind.  The first 6 months seem to go by quickly, and your energy reserves are used, the next 6 months you have moments of highs and lows, and then the next 6 months hit.  I would say this is where we are.  We don’t celebrate our accomplishments enough, we are knee deep in financial duress, and we are about 2-3 months away from making any money.  Take 1 day off a week, as it will do your mind good.
  3. Its better to have stuff arrive when you need it, not before or after.  This is virtually impossible, but getting a big piece of equipment early is in a way just as bad as getting it early.  Get your stuff delivered when you need it, and shade a little to the earlier side of things.
  4. There is an endless amount of forms you need to fill out for the Government, so always keep on top of this.  I try to spend a couple hours a week reviewing our progress and making sure we are doing all that we can to keep these things moving forward.
  5. Schedule meetings wit your partner.  I can’t tell you how many times my partner and I try to meet about something and it gets interrupted or cut short because of something else.  We are realizing it might be best to have meetings elsewhere that are important.  Planning the business is more important than working in the business
  6. Finding time to do social media is the hardest thing some days.  When you are working on building a brewery, your free time evaporates and days just cruise by.  Always find time to connect with people on social media.  For some that is doing it as the day goes on, and for me that means doing it twice per day.  We have learned so much from others, and connected with so many great people, it would be a shame not to have done this.
  7. Include your landlord in decisions that effect the building.  If you have an amazing landlord like we do, they will want to be a part of things, so it is important to let them have some say.  After all, it is their building and your business is their business.
  8. Always have a plan B ready for action, especially when it comes to your financials and marketing.  Getting stuck with one idea, or one way of doing things is a real challenge in any aspect of this process.  It evolves so much, that it is much better to wave in the wind like a flag and go with the flow.
  9. You will need money, lots of money, and you will likely need more as the process goes on.  If you think you are different than everyone else who has started a business, or undertaken a massive renovation, then do so at your own peril.  We thought we would be good after 4 or 5 revisions to our budget, only to have the wrench of a delay resulting in us needing more money.  My advice would be to research as much as possible, and leave a bucket of money with about 15% of your overall budget to get to day 1 so that you can mitigate these risks.
  10. Marketing needs to represent who you are.  Since we are a team of 2, it is harder to get this right, as we are both very different in what we like.  Also, we wanted something other than what represented who we were for some time.  Once we decided to go with our gut, we found a path to happiness and cool branding, representative of our beliefs and opinions.
  11. If you are having a tasting room like us, the front of the house is a big enigma that is full of unknowns and expensive items.  Walk carefully through this minefield.  We messed up tap locations, counter top height, layout, approval process, etc.  A lot can go wrong so make sure you think this through.
  12. Don’t forget about these electronic items/systems:  POS ($5,000) AV ($2,500) Security system ($1,500) and CCTV ($4,000).  They add up to a lot, but we couldn’t imagine not getting these things right.  Also, try to include these items on your electrical contractors scope of work early on, as it will save you $$$.
  13. Spend too much money on non-critical things.  Don’t spend a lot of money on a forklift, but get a used one.  Don’t pay any of your carpenters to clean up at $55 per hour, do it yourself. Don’t get a bin until you are ready for it, do a couple dump runs on your own.  You get the idea.

I am sure throughout today, I will make 10 decisions with my partner, 7 of which we get right, 1 we are not so sure about and 2 that are wrong … only we won’t know it until some later point.  The point is sometimes you need take your time and make the right decision, and others you need to make any decision, just make one immediately to keep things moving forward.  The key is to think about when key decisions need to be made, and factor that into your approach.  If a decision doesn’t need to made, take a day to sleep on it.

I am sure I would be able to add about 10 more things to this list if I had the time or more mental horsepower right now.  Hopefully you can add more to this list via the comments below. Thanks for reading and until my next entry.

Marketing Decisions

One thing I have underestimated up until now is the number of decisions that need to be made for marketing.  I always thought the big marketing decisions were the tough ones, but now walking through this process, it is the small ones that suck all your time and cause the most headaches with the schedule.  Paying others to do some of your work will help bring in a fresh opinion, move things forward, and get you to a place you wouldn’t otherwise have gotten.  It will still take hard work and lots of re-working things to get them right.

As a craft brewery, we kind of thought that marketing was secondary to making really great beer, and having a great tasting room to hang out in.  For the most part, it still is but the gap has narrowed quite measurably.  With so many amazing breweries swinging open their doors in the past few years (Brassneck, Parallel 49 Brewing, Powell Street Brewing, Postmark, 33 Acres, Steel and Oak, Yellow Dog, Main Street, and many more), it is now imperative that your brand be spot on.  Don’t get me wrong, I don’t think you need to have a perfect brand for customers to see, rather I think you need to achieve a few important things in your message:  Authenticity, why you did this, and what makes you so different.

Yes, yes the quality of beer is still paramount.  Make crappy beer or have the same selection of beer at your brewery week in and week out, and you will find yourself floundering.  At the end of the day, consumers care most about this.  But the people that spend their hard earned dollars at breweries also want to see a brand that meets their expectations.  What makes it harder for a brewery to meet these expectations, is that no 2 people have the same ones.  Some want authentic, and others want playful, some want seriousness, and others want unique.  What do you want?

Getting back to my original point, we decided to go in the direction of making something we think is representative of us.  Authentic, Fun, and pretty straight forward.  However, what you set out to do, like everything in this process, is not necessarily what we are going to end up with.  You see, making thousands of decisions over a period of months, if not years, puts you down a path that you didn’t necessarily intend.

For instance, we always wanted our brand to be what it has become.  But to think that we named our company Strange Fellows Brewing is somewhat comical.  My partner and I always wanted a more serious name, but through indecision, other names being taken (this is huge) and the input of others, we ended up with Strange Fellows.  This set off a cascade of events that has slowly morphed our brand into something that neither of us could have imagined.

Also changing where we ended up is the list of decision that we needed to make, with each of these decisions having hundreds of little decisions to make the big decision:

  • website design and look and feel – hundreds of decisions in this bucket
  • can versus bottle versus growler – design, size and look
  • label for all product
  • logo – you will need to pick something that works on its own, with your can design, and in sizes all the way up to a decal on your car to sign-post at your brewery
  • bottle cap
  • merchandise
  • growler design
  • your story and how it relates to your brand
  • business cards
  • tasting room design meshed with your personal taste, budget and consumers taste

Each of these, and many others, have hundreds of layers to the decisions you need to make.  Its not as simple as just making the choice and living with it in a bubble.  Your decisions are not mutually exclusive, as one decision will impact another, often forcing you to rethink exactly what you are doing.  Let me give you an example.

We knew we wanted to put our beer into cans, so we charged ahead with this.  However, we didn’t know what kind of beer to put into cans.  So we had to decide which of our favourites we were going to brew, and put that out there to the world, without ever actually brewing these beers.  Which means you need to talk about flavour, alcohol percentage, etc without ever having tasted the beer.  Then you need to make a description of the beer, a beer name, a theme to your beer, create a UPC code, get preliminary approval from the LDB, get all the details on the can correct and be happy with where it is at about 10-12 weeks before you plan on packaging this product.  You see, cans need to be manufactured and that takes some time, which means before you even do anything, you need to have all your marketing complete.

It also means that once you make decisions, going back on those decisions will change other aspects of the design.  Invariably you will makes changes, and while you have your head down in the sand making all these decisions and changes, you end up with a can that may be great, but also may be quite far from where you intended to end up.  We’d be lying if we didn’t admit to this, as well as every other craft brewery in the Province.  So go easy on those people who have missed the mark with their marketing, as they may have gotten to a place they didn’t intend, and have no way of getting out.

To me, marketing matters most in terms of how much I connect with a brand.  This is everything from; what are the owners like, what is their message, what does the beer taste like, what are their thoughts on craft beer, why are they making beer, is this their passion, what other breweries do they like, and are they helping to keep Vancouver at the forefront of craft beer.  If a brand conveys all this information to me, or if I pick up on these things along the way, my decision on whether I like the brand is already made.  A company could miss 2 or 3 of these things and be alright, but if they miss 2 or 3 of these things and one of them is the quality of the beer, then I will move on.

For us, we’ve had the luxury of time, which has been our worst enemy for cash, but our best friend for crafting our story.  Having a brewery build-out that has taken about 9 months, in addition to a 12 month period that we were actively working on our brand, which comes after about 1 year of starting the process.  All this has meant we’ve been able to work out the kinks, and get it where we are pretty happy.  We could still make a few changes to our marketing, but for the most part we are pretty stoked about it.  I went through my diaries and have the following summaries from just our name selection:

  • January 2010 started working with my brother on a brand called The Crafty Monk
  • Over the next 18 months came up with a logo, and design for label
  • January 2012 met Iain Hill and started our partnership.
  • March 2012 Iain and I agree that we need to come up with a name together that is indicative of both us.
  • July 2012 changed name to Low Countries Brewing
  • Sept 2012 worked with Iain’s wife Christine on logo and branding.  We had a really tough time making the name look interesting and work well.
  • October 2013 after a year working with Low Countries Brewing, we decided to ditch the name as it was boring and not exactly what we wanted to do anymore,
  • January 2014 false start on Allegory brewing
  • February 2014 with our partnership about to dissolve over indecision about our name, we finally agree to Strange Fellows.
  • March 2014 to present we worked on our branding and marketing to end up where we are, which we hope is a pretty good place.

Without the time we had available to us, we might have ended up with a name like The Crafty Monk, or Allegory, both of which would have led us down a path that is much different than where we are today.  So take your time in making decisions, as creativity knows no time boundaries.  It would also relate to this entire process, as for us, getting all aspects of this project correct the first time is the most important thing.

 

50 days out update … this may be my last

For a long time this blog has been a pleasure to write.  I enjoyed going over my notes of things, and putting that into the greater community.  The response and positive energy I received along the way was amazing and helped encourage me to continue writing, especially at times that I was either tired or busy (which seems like all the time).  About 2 months ago, the blog started becoming more of a burden, as the amount of time I spent working at the brewery and on my computer increased weekly.  Add in a complete gut of a house my wife and I purchased, and all of a sudden all of my free time evaporated.  Poof!

So given the state of my personal and professional life, and for the sanity and health of my family life and longevity in business, I have made the decision to free myself from the burden of having to write this blog.  Rather than see a note pop up in my calendar every Sunday night to write a blog post, I have removed the reminder from my calendar, and will let things run their course.  For those of you who follow my blog with regularity, feel free to email me with questions you have.  Also, I promise to continue taking my notes, and should I not find the time to blog about this process until the day we open, I will catch up afterwards.  That way this process will be complete.

So for now, this last blog post may actually be 4 or 5 posts rolled into one, as I update all the different aspects of starting a craft brewery that happen about 2 months out from opening.

Brewhouse:  Ideally, you will have your brewhouse arrive about 60 days prior to opening,  Definitely make sure you put any coatings on your floor.  Also make sure you have your installation procedure decided well in advance.  I am sure by this point you know what you are doing, but it had to be said.

Tank Farm:  Big or small, your tank farm should also be in about 60 days prior to opening, most ideally just before or just after your brewhouse goes in.  Be sure to have your Glycol system scheduled for installation, which needs to be done before you can move your tanks into position.  Also plan for your unloading of tanks for the truck and installation into position.  This can be a really finicky process that needs an experienced touch.

Kegs:  You ideally would get these delivered with about 30 days to go until opening.  Getting them delivered too soon (like we did) means you lose valuable real estate in your brewery that could be used for some other things.  More on use of real estate later.  At the end of the day, get the kegs early, but not too early.

Electrical:  If you are getting major upgrades as we are, make sure you the majority of the work done as soon as possible.  Don’t use an electrician who doesn’t commit to getting things completed by certain dates.  More important than saving a few thousand is someone who works with your schedule, and is always ahead of the game.

Mechanical:   I could literally write the same thing again for this heading that I did for electrical.  Make sure the work gets completed when there is the space and option of doing it.  Never wait for stuff to get done.

Marketing:  Holy crap, the marketing becomes a beast by this point in time.  The decisions you make mean the brand you are creating is formally taking shape.  The big important decisions are long complete, but there are a million and one details.  And the saying goes that the devil is in the details.  Some of the important balls in the air right now are:  Website, content for website, business cards, merchandise, increasing social media presence, glasses, sell sheets, coasters, keg labels, etc.  I would say marketing at this point will likely be taking you about 15 hours per week if you are doing anything similar to us.

Tasting Room:  This is one of the last things to get finished, as the production equipment needs to prioritized, but certainly by now the tasting room is well on its way to completion.  You are definitely making the finer decisions now on this.  Things like designing tables, finishing of walls, merchandise area, etc are all needing decisions to keep things moving forward.  We are about to start on construction of a bar, and I can tell you that there are a lot of factors that go into putting this together, and I promise to one day blog about it.

Accounting:  By now, I hope you have figured out a system for managing your books.  It is easily something that gets left, and before you know it, your GST reporting is due, and instead of a few hours work, you have 3 days worth of book keeping to catch up on.  Dave at Powell Street Brewing gave me the recommendation early to do your accounting every 2 weeks, and while I haven’t yet gotten to that frequency, I can see why he recommends it.

Organizing Trades:  We are sooooo thankful we have a general contractor.  Trying to organize and manage the schedule is a full time job, and one that we couldn’t have imagined not having the support of Graham Disher and his fine team.  They have helped us immeasurably every step along the way, and we are firm believers that paying someone to help is the best move we made.  Organizing trades and their schedule is so important as you come down to this point, as when things get done (or not) has a cascade on all the other things that have to happen after.  Any delays means a delay to every subsequent job.

Cold Room:  After going through the building of a cold room, we are really happy we did this, but man, we think getting a prefab cooler would be a lot better choice next time.  I know we will get exactly what we want and need, but the process of building a cooler is an expensive one, that takes a lot of time, and draws people away from other tasks they could be completing.  Depending on your space and the size of a cooler you need, strongly consider a pre-fab.

Cash Flow:  Hopefully you are meeting your budget, but most likely you are not.  This is where you need to make a decision if you have investors.  Do you take a bigger loan to cover your shortfall or do you raise more money.  In about another month we are going to be pressed with this decision, as we will be out of money.  Managing your cash flow until you get open is the most important part of this process and one that you need to keep on top of constantly.

Government Stuff:  Make sure you keep on top of all the interactions you have with government.  You can easily drop the ball on this one, and the resulting error could be catastrophic to your business.  In British Columbia the government has a website that itemizes all the things you need to do and I suggest you refer to this consistently.

Hiring of staff:  About 50 days out you need to figure out your staffing situation, and start getting ready to hire people.  For us that means people in the brewery and also in our tasting room.  We have been dragging our heels on this one, so do as I say and not as I do.

Other General stuff of note:

Use of Real Estate:  During the process of building a brewery, as you reach about 2 months out, your space is a mess.  There are a hundred things inside your brewery that are at various states of completion, which means there is a lot of stuff sitting in different areas.  For us, even though we are in 9,000 square feet, we are running out of room to put stuff.  We have kegs, barrels, packaging, tanks, wood, plywood, insulation, drywall, tools, work stations, etc taking up space all over.  My advice would be to work on being organized as best you can from day 1.  Don’t let the mess and organization become an issue, as it can overwhelm you.

Manage your Expectations:  I am someone who was raised by a very European father, who was adamant that we were never late for things.  While I am not 100% on time, I do think that making a scheduled deadline is important.  When it comes to something as complex as starting a brewery, just plan for 7 months of building if your size is 6,000 square feet or smaller.  And if you are over 6,000 square feet like us, plan for 8-9 months of building.  I know you will always be able to point to examples that go against this timeline, but do so at your own peril.  Just expect things to go wrong and problems to come up that add time.

Manage your sleep and stress:  For me, a lack of sleep goes hand in hand with being more prone to stress.  To give you an idea, right now I am working about 75 hours a week.  I easily work 12 hours per day 6 days per week, and I do try and take a 1/2 day off on the 7th day of the week.  The 2 things that I hate to lose is my sleep and my exercise.  If I do, I get more stressed, grumpy and unhappy.  So for me, I need to continue to exercise (a lot less intensely with all the physical work at the brewery) and get my 6.5 hours of sleep a night.  Any less than that, and I start to burnout.

Celebrate:  If you don’t stop once and while to celebrate the process, you will miss out on the process of following your dreams.  We are all following our dreams when you start a brewery, and if you don’t take a moment to recognize this, then the process will be less rewarding.

Decisions are now to save time or save money:  The process of making decisions has gone from really taking your time and agonizing over the details, to one that is marked by a lack of research and a plethora of going with your gut.  We are still trying to save money as we always have, but now there is a healthy dose of getting decisions made.  In fact, I would say the first question we usually ask is which option is the quickest?

Stay connected with your partner(s):  It is really easy to divide out a job and then not keep in good enough contact with your partner.  We are all guilty of this, but make sure you take time every day to speak with anyone that needs to be part of a decision.  It also helps to have a master sheet schedule, as I have talked about before, so you can itemize the decisions you need to make, who is doing it, and when the drop-dead date is.

Hopefully, with all this stuff going on you can understand why I am going to blog if and only if I have time over the next 50 days.  My to do list is insane, and I can’t keep up with all the items that need decisions.  I hope you understand!  As such, I am going to take off and get some of these things done.  Until next time …. and always email me with any questions.

 

 

 

10 BBL Brewhouse for Sale

During the process of starting a brewery and writing a blog about starting a brewery, I have met and continue to meet many fascinating people.  These are people who are willing to do as others have before us, and risk everything they have achieved in order to start a business.  You see all sorts of personalities and business ideas come through, and they run the range from amazing to crazy.  Some people have leased a space without even having a business plan, and others have strong marketing backgrounds, and others lots of home brewing but no commercial brewing experience, etc, etc.

One of the groups that I have recently met purchased a brewhouse with the hopes of using it for their own purposes, but their circumstances have changed and they are looking to sell this.  So there isn’t much more to say than this:  If you are looking for a 10BBL brewhouse with all the parts and potentially someone to help consult with you, send me an email, and I can connect the two of you.  I don’t know the price, and I don’t even know all the equipment that is included in this set-up, but from the quality of the individual who is selling it, I am sure it will work out well.

If anyone you know is looking for used equipment, please pass along this information.  I know it is very difficult to find equipment in the marketplace, given the growth of craft beer throughout North America.  Having  an inside line like this can be a huge help in starting a business and saving cash on the most important part of your business.

As always, send any information to:

startingacraftbrewery@gmail.com

 

60 Days Out

Without a doubt, things get busier as you get closer to opening your brewery.  For us, there is so much going on right now at the brewery, it is hard to keep track of sometimes.  It is also a point that we are beginning to notice parts of the job getting significantly completed, and others that seemed so far off a few months ago, getting started.

One thing I know for sure, the less you have to complete and build in your space, the faster this project goes.  Since we have taken possession of our space early in the year, Yellow Dog has gone from building to finished, Moody Ales will go from start to finish before us, and a host of other breweries literally leapfrogged us during the past 6 months.  It is both an indication of the complexity of our project, but also the challenges we have faced and will continue to face with our space.

At 60 days from opening, there is a lot going on and as I said earlier, keeping on top of all that stuff can be a lot of work.  If you stop for a second and look down, you are going to miss what is coming at you.  Little things like Tap Handles, coasters, label deadlines, getting UPC codes, positioning of electrical outlets, timing of deliveries, and hiring of staff, can all creep up on you if you don’t think ahead and plan for the decisions you need to make.

One of the bigger issues we have right now is that there is so much going on in the brewery, its hard to schedule everyone at the right times.  We have electricians working overhead, sprinkler installation people, carpenters, mechanical contractors, floor coating technicians, welders, and our team of people helping where we can.  This means that with everyones tools, equipment and supplies, there is not a lot of room to work.  I would suggest that when you build your brewery, you encourage people to get their work done as quickly as possible and as early as possible.  The longer people wait to get stuff done, the more it makes your brewery busy and jam-packed.

Some of the big decisions we have to make are:

  • What beers are we going to launch with in the tasting room
  • Beer Names
  • Tap Handles
  • Order Chairs for tasting room
  • Beer Prices
  • Hiring of Staff
  • Hiring of General Manager for the front of the house
  • Delivery truck
  • Ordering of bottle caps
  • Ordering of 1st piece of new capital equipment
  • A million and one things in the brewery
  • Colours

Just writing this list gives me a strong desire to get working and stop blogging.  As such, I will carry on and leave this post here.  I could write more, so much more, but time would be better spent elsewhere.

The Cooler

Busy doesn’t even begin to describe our life right now.  We are so busy trying to get things organized with regards to all aspects of this brewery, it is literally starting to make us crazy.  We are dealing with it the best we can, but it seems we are taking less and less time to make constantly more important decisions.  There is just no time to think, it is more of a reactionary process now.  One of these things we have been reacting to over the past few months is the cooler.

Early on in the process of building a brewery, you will need to make some decisions around the cooler.  Most likely, the first will be where the heck to put the thing.  There is a bunch of factors in making that decision, like if you will have a tasting room, where are your shipping docks, how high are your ceilings all over the warehouse, how much space do you have, etc.  Generally speaking, if you are going for a model that has a tasting room, and you are planning for some production, make sure you put your cooler very near the tasting room, and make it big enough for whatever your beer sales are at year 3.

After you pick out the location, things start becoming more and more detailed in your decisions.  A big one is whether you want to have your cooler pre-fabricated or built on site.  A pre-fab cooler is a quicker option, but you may not get exactly what you want.  Also, depending on the size of the cooler, you may need to build a box around it to support it.  There are some coolers that are not meant to support any weight above them.  If you build your own, there are engineering costs, and the time and effort of putting the things together.  The bigger you build it, the more the costs for everything like labour, materials and professionals.

We also did a few extra things in our cooler that has made it more expensive, but will enable us to have a more functional cooler, and one that works better with our situation.

  • We insulated the ground beneath our concrete to R20.  This was an extra few thousand dollars to do this in extra digging, dirt removal, labour and materials, but we hope the energy savings will benefit us moving forward.  Cool air falls after all, so we thought best to insulate the floors.
  • Since we poured new floors underneath the cooler, we put in drainage.  I think Iain would say that drainage is a must in a cooler, but it can be a time consuming and difficult process.  We just decided to put all new concrete down, so we didn’t have to worry about these things …. we just did it.
  • And since we put in new floors we also put a slope on the concrete so water would run to the drains.
  • Make sure you put footings all around the cooler for the walls to sit on.  Since the cooler will be wet and damp, you should avoid having the walls touch the ground.
  • We made our cooler structural, so that we could store boxes, pallets and other stuff up top of it.
  • Don’t use drywall on the inside of your cooler … even the stuff that is rated to handle wet situations.  You can talk to Dave Varga about that one, as he told us at 33 acres they want to rip it all out.  Use marine grade plywood.
  • If you have any breaks in your moisture barrier, you will moisture in your cooler.  So plug these holes.
  • Use a big door for your cooler, and have a second man door.  The bigger your door, the easier it is for a forklift or pump truck to move pallets in and out of the space.  You want to try and avoid turning on the inside of your cooler with the forklift.  Our cooler is about 25 feet wide, and our door is about 18 feet wide or so.
  • Use a little man door to walk in and out of to avoid needing to open the big door to get something little.
  • We incorporated a cooler very close to our tasting room, so that we could have really short runs for the beer we will have on tap.  Again, Iain could tell you exactly why we did this, but all I know is that it will save us a lot of headaches in the future.
  • We will have jacketed tanks, so this means they will not be inside the cooler.  This frees up a lot of space and will allow us to store finished product in a cool place, ensuring it lasts longer and stays as fresh as possible.  This goes back to making sure your cooler is big enough.
  • Retail doors are important.  One thing we like about Bomber Brewing is that their cooler is also a place to put packaged product.  So you can grab a 12 pack of cans directly from cooler doors and purchase them on site.  This means you don’t need to get a separate cooler to do this, saving energy and costs.
  • We are placing 4 double stacked 15 hectolitre tanks in the cooler for holding our beer.  This will mean we don’t have to change loads of kegs for our most popular beers.  We have been told how much of a challenge this is, as tanks of your most popular beers can run dry 3 or 4 times a day.

All of the decisions around this cooler are pretty much made, so it is just a matter of implementing what we have planned.  The last decision we have to make is whether to use spray foam insulation versus standard insulation.  There are major differences, not the least of which is price and ease of install.  Like every other decision we have made, I am sure the answer will come to us in time …. and hopefully soon.

That is about all I can think of when it comes to our cooler.  For us, we definitely underestimated the spend on an engineer for this, as there is much to figure out when you are building walls that are 14 feet high, and span a 25 foot length.  There are lots of plates and reinforcements you need to install so that this thing will stand through worst case scenarios.

Have a few questions that I am not thinking of???  Send them along and I can surely help you out.

 

90 Days Out?!?!

Give or take a few days, we are about 90 days from opening our brewery, and the list of stuff we need to do and decide on seems to have only gotten longer and bigger.  When you are about 90 days out, the major decisions have been made, but there is still a lot of decisions to be made that can change the outcome of this process.  Let me recap where we are in the process so you can see what needs to be done.

We have finished all the in-ground mechanical work.  So plumbing, running conduit, reinforcing of concrete for tanks, upgrading floors, pouring curbs, trade waste interceptor, flow meter, drains, and a bunch of other stuff has all been decided.  That means we have made decisions galore to get to this point.  Having someone on board like Iain Hill, who has experience in starting a brewery is huge.  He has been down this road before, and knows what is a need to have and a nice to have.

We are currently getting all of our walls built  for the brewery interior, and while there is little work for the partners to do, there a lot of office work for us to complete.  The work of our carpenters is really important, albeit very slow.  Building walls and making sure they are square, level and plumb is tedious work at best, and requires a crew to make sure it all goes well.  While construction is at this point, there is a lit of other things we need to accomplish.

Most of the items revolve around the front of house.  We need to take the bar from conceptual to design.  That means we need to know what we are putting in the bar, the dimensions of those items, where we want shelves, drawers and other items, where does the sink go, where the POS goes, how many POS, etc.  All of this information then gets meshed with the best practices of our architect and then created into a set of drawings for us to send out to tender.  Once we choose who makes them, they then need to be manufactured, delivered and installed. The whole process seems to take about 12 weeks, so timing is of the essence.

While all of this is happening, our mechanical contractor is running pipes overhead, to and from all the important locations in the brewery, and our electrical contractor is upgrading our power and making things happen from an electrical point of view.

Now is also the time to start deciding on exterior colours and upgrades as we are nearing the time when this will need to be completed.  We have been working towards getting our sign ordered and it has been a bit of a mess in knowing who to use and what to get.  Our exterior sign is old and is going to cost a bunch of money to repair.  So do we pick something that is going to hold for a couple years, until we have cash to really replace it, or do we make the big upgrade now?  We are leaning towards saving the money as we have made a mess of our budget.  Saving money when we can seems really important.

All of our major equipment has been ordered, and we are just looking for odds and ends to round out the brewing side.  Iain is busy working on the draft system/growler fill area, and what we are going to do and how all that is going to come together.  I can’t say I know much, but what I know seems to confuse me.  Looks like we can go with a few different options, and each has pro’s and con’s, which I can fully describe at this time, as I haven’t been working in that bucket.

The schedule which I spoke about in my last post, gets changed almost daily, and drop dead dates are really important to adhere to.  So is having regular meetings to stay on top of all the decisions that each partner is making.  For instance, I have the exterior sign, website construction, marketing buckets to figure things out in, and Iain has the bar and equipment buckets to work in, and before you know it, you can make decisions in your own mind without talking to the other person.  So you seem to spend hours writing emails and following up on things with your partner, just so they know what they heck is going on.  A bit tedious, but sooooo important.

From here, we have lots more to do, and while we are very close, it feels in a way like we are so far away.  Its hard to think that in the next 90 days, all that is our space and mess of things, will get cobbled together into a usable brewery and tasting room.  Sometimes it still doesn’t feel like it will happen.

Quick Update on Things …

I think back to the days when we were first getting started with the brewery, and I can’t help but think how much time I had to do things.  It didn’t seem like I had a lot of free time, but in reality I did.  What I really had was the ability to get on top of things, which I have completely lost now. Let me try to explain.

When you first start writing your plan, you have time to dream, think about your beers, your brand, name, etc.  It is a natural part of things, and something that if we didn’t do, we wouldn’t be doing this.  As time moves on, you tend to get to more of the meat of the operation, and you need to start figuring out some details.  As time progresses, you think you have figured out a lot of the details of your space.  Things like brewhouse, packaging size, general location of warehouse.  You think you have made a lot of these decisions, but you haven’t.

You continue to work on your business plan, making what you think are decisions and changes of direction …. and then you do it.  You find a space to lease and you take possession.  This is when it starts to really happen.  You actually start making decisions, like general contractor, architect, brewhouse size, etc.  You think you are doing well, because you have made actual and concrete decisions.

What you don’t realize, is that you have only started on the tip of the iceberg.  There are thousands of decisions to make.  None of them are more or less important than any of the others.  Think of details such as these:  Size of cooler door to the inch, length of drainage trenches down to the inch, slope on concrete pour down to the degree, exact location of trade waste interceptor, etc, etc.  There is so many small decisions to make, it can become overwhelming.

Coming full circle, each of these decisions take time, and trust me when I say, you have very little of it.  Your funnel at the top is getting loaded faster than you can empty it.  About a year ago, you could pound out a good 60 hour week and be back on top of everything, but that is a pipe-dream now.  A 60 hour week will only mean that I have about 300 hours of unfinished work sitting around waiting for me to complete.  There is no way of catching up short-term, it is a matter of prioritizing and getting small jobs done.

Add to all this the work around the brewery.  I have been tying rebar and working around the brewery 7 days a week for the past few weeks, and there is still so much to do.  Take for example a typical day in my life.

  • Get up at 5am to 530am
  • Work in front of my computer until 745am
  • Get kids off to school and lunches made 830 to 9am
  • Drive into brewery to do work 930am
  • Manual labour all day at brewery until about 930 am to 3pm
  • Home to do work in front of my computer (accounting, marketing, business planing, etc) 330pm to 5pm
  • Down time, hang with family, 530pm to 8pm
  • After kids in bed, back to computer for more work 8pm to 11pm
  • Off to bed to do it again

This is a pretty standard day, and I know one that my partner also goes through.  If you are going to open a brewery, and you want to take an active role in starting it, be prepared for a day like this.

What you will find is that how badly you really want to do this will go a long way to making the above feel like work, versus feeling like a dream.  Luckily for Iain and I, the long days are a dream and the passion is burning brighter than ever, so we know we have made the right decision.