A poor brewery layout slows beer brewing, adds risk, and eats cash. Cramped aisles, hot spots, and awkward brewery equipment placement force rework. The fix is a clear brewery floor plan that follows the brewing process and scales cleanly.
Microbrewery layout planning maps every step—from raw material receiving to packaging line—onto a safe, efficient brewery floor. Start with a capacity target and floor plan zones (brewhouse, fermentation, cold room, packaging), then route people, product, and utilities with short, clean paths. Finally, check building codes and future growth before you buy.
Table of Contents
What is a brewery layout and why does it matter?
A brewery layout is the map of your brewery—where tanks sit, how grain and wort move, how staff, kegs, and forklifts flow. Good layout saves labor, cuts lift-and-carry, and prevents hot/cold conflicts. It also keeps your brewery operations tidy so cleaning, CIP, and brewing operation tasks happen fast.
Think of layout design as choreography for a modern brewery. When the layout aligns with your brewing process, you get smooth brewing, fewer mistakes, and a safer shop floor. A smart brewery layout – exactly what you need—guides airflow, drainage slope, hose length, and visibility.
“Design a space that works, then let it work for you every brew.”
How much floor space do I need when designing a brewery floor plan?
Everyone asks: “How much floor space do I need?” A good rule is planning by brewhouse size and tank count. Below is a quick floor plan guide with floor space needed for common scales. It helps you determine how much floor space before you order tanks.
| Brewhouse Size | Fermenters (FV) | Bright Tanks (BBT) | Approx. Floor Area (m²) | Notes |
| 5 bbl | 4 FV + 1 BBT | 1 | 80–120 | Tight brewery; minimal additional space |
| 10 bbl | 6 FV + 2 BBT | 2 | 150–220 | Room for packaging line and small cold room |
| 15 bbl | 8 FV + 2 BBT | 2 | 220–320 | Forklift aisles; utility corridor |
| 20 bbl | 10 FV + 3 BBT | 3 | 300–420 | Dedicated grain, kegging, and dry storage |
If you’re planning a brewery with a taproom, add guest aisles, ADA access, and egress widths, offering guests more space to relax while staff can still move kegs and pallets safely.
Sizing and options for brewhouses, tanks, and accessories are covered in these guides: 3-vessel brewhouse, stainless steel conical fermenter, beer can filling machine, bright beer tank.
Brewery floor plan zones: brewhouse, fermentation cellar, and cold chain
Brewhouse. The brewhouse is the heart of the brewery. A compact 2– or brewhouse 3-vessel system reduces steps and hose runs. Place the mill and grist case near a dust-controlled corner; keep the lauter-to-kettle path short.
Fermentation & BBT. Put FVs and BBTs in clean rows for easy CIP. Size aisles for racking arms and valves. Group by batch family to simplify scheduling.
Cold room. One well-insulated cold room near packaging shortens hose and pallet routes. It stabilizes craft beer quality and protects the packaging line from heat spikes.
How do I create a brewery layout that flows with the brewing process?
Start with arrows on paper: receiving → milling → mashing → lautering → boiling → whirlpool → chilling → fermentation → conditioning → packaging line → cold storage → taproom/shipping. That “process path – we design” on a single page.
When your layout flows with the brewing process, cleaning paths are shorter and tripping hazards drop. If a piece of equipment doesn’t fit, the entire design is thrown. If a tank doesn’t fit into the space, you’re stuck with costly rework. Protect your timeline with a quick CAD drawing of the space before placing orders.
Equipment layout tips: designing a brewery floor plan that works
Prioritize safety, slope, and service clearances. Allow headroom for manways, hoists, and vent piping. Keep the heat: kettle and HLT away from the cold chain. The equipment layout should reduce hose length and crossings.
You’ll map equipment needs by function and flow. Here’s the equipment you’ll need for a 10 bbl brewery: mill, grist case, mash/lauter, kettle/whirlpool, plate chiller, 6–8 FVs, 2 BBTs, a bright beer tank, pumps, CIP cart, and controls. Plan utility stubs (power, water, drains) and reserve additional space ahead of time for a filter or small canning line.
Specific skids and tanks: explore 10 bbl brewery equipment and cellar options like beer fermenters.
Utilities and glycol: keeping your brewery operations smooth
Utilities make or break a brewery. Route service corridors above tanks, not across walkways. Size the chiller and header for present demand plus 25–30%. Use insulated trunks; slope returns for easy balancing.
Glycol loops should be short and clean. Label drops at each FV/BBT and install isolation valves for maintenance. A reliable glycol skid turns chaos into smooth brewing and lets you expand without cutting lines.
Need specialty tanks or alternative beverage capacity? See cider brewing equipment and kombucha brewing equipment for system variants that integrate with the same utility backbone.
People flow, safety, and building codes: design accessible spaces
Great layout respects people. Mark forklift aisles, add anti-slip grates at wet entries, and keep chemical storage ventilated. Follow local building codes early; building permits in many states can take weeks.
Also design accessible spaces. ADA paths in the taproom and around a brewery matter. Place handrails and eye-wash stations where hot wort and chemicals live. Keep eyewash within 10 seconds of hazards and keep your brewery training fresh.
Packaging, warehouse, and shipping in the brewery floor plan
Your brewery floor plan needs a clear pallet loop: empty cans/bottles in; finished goods out. The packaging line wants 360° access and low dust. A single canning line near the cold room shortens the cold chain and preserves freshness.
Plan racking lanes, a small label rework table, and keg wash. One keg skid can serve both taproom and distributor needs. For beer brewing destined for wholesale, add dock bumpers and shaded staging if heat is a risk.
Explore beer bottling machine options to match your brewery’s throughput and footprint.
Planning for future growth: space planning that scales
Planning for future growth starts day one. Drop utility stubs for two more FVs per row. Leave a wall you can knock out. Choose modular platforms and cable trays so new equipment slides in without downtime.
Make planning for additional space ahead part of the spec. Order a chiller with spare tonnage. Add panel breakers now. That way, when you need and how much capacity rises, you can add vessels fast—with enough space to work, not just squeeze.
Budget, schedule, and team: starting a brewery the right way
Starting a brewery requires careful planning and a realistic budget. Include trench drains, slope, steam, and a water treatment line. Verify building codes with your AHJ. Some teams hire a design studio; others lean on vendors who specializes in brewery systems and provide drawings.
Before you sign, make a punch list of every piece of equipment by lead time. If any piece of equipment slips, re-sequence trades so the whole brewery keeps moving.
Sample 10 bbl commercial brewery floor plan (case study)
- This commercial brewery example shows a simple, clean layout:
- Brewhouse: 3-vessel on a short platform, grain-in at the back corner.
- Cellar: two rows of FVs, one row of BBTs, utility corridor overhead.
- Cold room: behind packaging; bright beer and packaged cases inside.
- Packaging equipment: depal → rinser → filler → seamer → QA → palletizer.
Why it works: shortest hot wort hose; shortest cold chain; easy CIP loops. If a piece of equipment doesn’t fit the intended area, the entire design is thrown off schedule—so verify alcoves with a quick CAD drawing of the space first.
Compare with examples and dimensions: microbrewery equipment (10 bbl class) and bright tank choices.
A practical guide to brewery space planning and facility layout
Use this quick checklist as your guide to brewery planning:
- Define brewery type (taproom-first or distro-first) and batch size.
- Designing the layout: draw the path, then place tanks.
- Confirm drain slope, steam routing, and chiller tonnage.
- Verify building permits in many states and fire ratings.
- Order long-lead tanks early; worked out what equipment you need.
- Plan to brew as much as you possibly can on day one, but reserve additional space for growth.
In other words, design a layout that follows the layout of your brewery operations. When you’re planning, block off utilities for future tanks so equipment you’ll add later can drop in without moving walls.
Common mistakes to avoid in brewery layout design
- Buying tanks before measuring doors. If the piece of equipment is wider than the hallway, nothing moves.
- Under-spec’d HVAC and glycol. Heat and moisture creep into the taproom; beers struggle to hit targets.
- Ignoring ADA and building codes. Rework costs real money and time.
- Forgetting spares. When a pump fails, downtime hurts craft breweries and customers alike.
Finally, directly represent your brewery layout with a scaled drawing. If equipment you’ll need shows up and doesn’t fit into the space, you’ll pay twice.
Example bill of materials: equipment you’ll need for a dream brewery
Below is a compact BOM for a 10 bbl brewery. It’s not exhaustive, but it’s a solid start—the equipment you’ll need to build your dream brewery.
- Milling: mill, grist case, auger
- Brewhouse: mash/lauter, kettle/whirlpool, brewing equipment controls
- Cellar: 6 FVs, 2 BBTs, hoses, clamps
- Cold side: bright beer tank, manifold, valves
- Utilities: chiller, glycol headers, steam, RO water
- QA: DO meter, hydrometer, microscope
- Packaging: packaging equipment, date coder, case taper
- Taproom: draft trunk, drip trays
Skid references and sizes: beer brewing systems (larger examples) and 2-vessel brewhouse layouts for compact rooms.
FAQs
What’s the first step to create a brewery layout?
Start with scale: target BBLs per week, then zone the room. Sketch arrows for your brewing process and utilities. A quick CAD drawing of the space de-risks lead-time purchases.
How do I size the chiller and headers?
Total jacket area × load factor × simultaneity. Then add 25–30% headroom. This supports expansion and tighter control during hot months.
Do I need a separate cold room from the BBT area?
Yes. A dedicated cold room near packaging protects finished beer and improves filler stability. It also shortens forklift paths.
What if a tank shows up and doesn’t fit into the space?
Pause trades, re-sequence tasks, and call riggers. But prevention is cheaper: verify alcoves with templates; if a piece of equipment doesn’t fit, the entire design is thrown off.
Should I outsource layout?
Some founders hire a design studio. Others partner with vendors who specializes in brewery systems, request a plan set, and iterate. Either way, get stamped drawings where required.
Can this plan work for distilling or alternative beverages?
Yes—with changes to code and utilities. See options for alcohol distillery equipment and temperature-sensitive lines like kombucha fermenter.
Sources & Notes
Layout and safety concepts align with widely accepted brewery best practices and code interpretations (e.g., ventilation, drainage slope, egress width). For deeper reading, see public guidance from the Brewers Association and local AHJ requirements.
Key takeaways (bookmark this)
- Draw the process first; place tanks second.
- Keep hot side and cold chain apart in your brewery.
- Short hoses, clear aisles, washable finishes, and visible drains.
- Size utilities with buffer; route a clean glycol backbone.
- Leave additional space stubs so you can grow without demolition.
- Verify codes early; schedule long-lead equipment with slack.
- Use this guide to brewery planning to pick a floor plan that fits today—and tomorrow.
If you’d like a quick cad drawing of the space based on your actual room and tank list, I can map a customized layout and share options that design a space that works for your team and goals.