Scaling Up Success: A 10BBL Brewhouse Expansion for a Top-Rated Oregon Brewery

Project Title: Powering Growth with a Precision-Engineered 10BBL System Designed for Recipe Consistency

Client: "Riverbend Aleworks," a highly popular and award-winning brewpub in Bend, Oregon, famous for its iconic "Cascade Peak" West Coast IPA.

Location: Bend, Oregon, USA

Introduction

"Riverbend Aleworks" had the best problem a brewery can have: they couldn't make beer fast enough. Their 3BBL pilot system, once the heart of their operation, was now a bottleneck. Their taproom was constantly running out of their flagship IPA, and they were forced to turn down lucrative keg accounts from local bars and restaurants. The decision to expand to a 10BBL system was easy; the challenge was finding a partner who could build a system that would perfectly replicate their most important asset—the award-winning flavor profile of their beer.

The Challenge: Scaling Quality Without Compromise

For an established brewery, expansion is a high-stakes endeavor. The project's success depended on mastering four critical areas:

1. Flawless Recipe Replication: This was the #1 priority. Their "Cascade Peak" IPA's specific bitterness, aroma, and mouthfeel were the result of their unique process on the small system. The new 10BBL brewhouse had to reproduce these characteristics exactly. Any deviation in flavor would risk alienating their loyal customer base.

2. Efficiency and Throughput: The goal was to dramatically increase production without dramatically increasing labor. The new system needed to be highly efficient, allowing for faster brew days, quicker cleanup, and the ability to perform "double brew days" to maximize cellar capacity.

3. Seamless Integration and Footprint: The new, larger equipment had to fit within a specific, pre-existing space in their facility, integrating smoothly with their existing fermentation cellar, utilities, and workflow.

4. Rock-Solid Compliance and Reliability (UL/ASME): As with any US installation, strict adherence to UL (electrical) and ASME (pressure vessel) standards was non-negotiable for securing permits and insurance. The system needed to be built for long-term, reliable production.

CASSMAN's Solution: The 10BBL "Consistency Machine"

CASSMAN engineered a 10BBL 3-Vessel Brewhouse (Mash/Lauter Tun, Kettle, Whirlpool) specifically designed to give the brewer absolute control over the process, ensuring perfect recipe replication at scale.

Key System Features:

• Engineered for the Perfect IPA: To replicate their flagship beer, the brewhouse included:

• An oversized mash/lauter tun for accommodating high-gravity, grain-heavy recipes.

• A steam-heated kettle with an internal calandria, providing a powerful, rolling boil crucial for hop isomerization and DMS volatilization.

• A dedicated whirlpool with a precisely calculated tangential inlet, creating the perfect vortex for hop aroma extraction during hop stands.

• Allen-Bradley PLC Control for Repeatability: The system was equipped with an Allen-Bradley CompactLogix PLC and a large HMI touchscreen. This industry-leading platform allowed the brewer to save their recipes, automate step-mashing temperatures, and control boil times with digital precision, ensuring every batch was brewed exactly the same way.

• UL & ASME Certified as Standard: The control panel was engineered and built to UL 508A standards, and the cellar tanks (fermenters and brite tanks) were manufactured according to ASME code, providing a complete, inspection-ready package.

• 3D Modeling for Perfect Integration: CASSMAN's engineers created a detailed 3D model of the entire system and placed it within the client's provided building layout. This allowed them to verify every pipe run, pump placement, and service access point, guaranteeing a flawless fit on-site.

Project Execution: A Partnership in Scaling

Our process was collaborative, focusing on a seamless transition from the old system to the new.

1. Recipe Deep Dive: The project began with in-depth consultations with Riverbend's head brewer. We analyzed their existing process, timings, and temperatures to ensure the new system's geometry and heating capabilities would mirror the dynamics of their original brewhouse.

2. Phased Installation Planning: We worked with the client to schedule the delivery and installation to minimize downtime. The new brewhouse was installed and commissioned while they continued to serve beer from their existing inventory.

3. On-Site Commissioning & Recipe Calibration: A CASSMAN engineer was on-site for the first brew day. This was a critical step. Together with the Riverbend brewer, they ran the first batch of "Cascade Peak" IPA, fine-tuning flow rates and temperature settings to dial in the system and achieve a perfect match.

4. Comprehensive Training: We provided extensive training on the new Allen-Bradley PLC system, empowering the brewing team to build their own recipe library and take full advantage of the system's automation features.

The Result: More Beer, Same Soul

The expansion was a complete success, transforming Riverbend Aleworks' business.

• Identical Flavor Profile: The ultimate test was passed with flying colors. In a side-by-side blind tasting, the brewers and their regulars could not distinguish between the IPA brewed on the old 3BBL system and the first batch from the new 10BBL system.

• Production Capacity Tripled: Riverbend immediately tripled its production capacity. They were finally able to keep their taproom fully stocked while also launching a robust local distribution program, significantly increasing their revenue.

• Increased Efficiency: Brew days became faster and more predictable. The brewers could now confidently run double batches in a single day, a task that was impossible on their old system.

• A Foundation for Future Growth: The head brewer commented, "CASSMAN understood that we weren't just buying a bigger brewhouse; we were scaling our identity. They obsessed over the details with us, and the result is a system that lets us make more of the beer our customers love, without changing a thing about it. They were true partners in our growth."

Conclusion

The Riverbend Aleworks project showcases CASSMAN's expertise in helping successful breweries navigate the critical phase of expansion. We deliver more than just stainless steel; we provide precision-engineered solutions that protect a brewery's most valuable asset—its recipes. By focusing on consistency, efficiency, and compliance, we empower our partners to scale their success and meet the growing demand for their craft.

For breweries ready to grow, CASSMAN is the engineering partner that ensures your quality grows with you.