This article was written by our expert who is surveying the industry and constantly updating the business plan for a craft brewery.
Planning your craft brewery space is one of the most critical decisions you'll make as a new brewery owner.
Getting your square footage wrong can cost you thousands in wasted rent or force expensive relocations when you need to expand production capacity.
If you want to dig deeper and learn more, you can download our business plan for a craft brewery. Also, before launching, get all the profit, revenue, and cost breakdowns you need for complete clarity with our craft brewery financial forecast.
Craft breweries require careful space planning to accommodate production equipment, storage, and customer areas while maintaining efficiency and allowing for future growth.
The industry standard ranges from 1.6 to 4.6 square feet per barrel of annual production capacity, with most successful breweries targeting around 2.16 square feet per barrel for optimal efficiency.
| Area | Space Requirement | Key Considerations |
|---|---|---|
| Brewhouse | 300-2,500 sq ft (varies by system size) | Size for Year 3 projected volume, include expansion space |
| Fermentation/Brite Tanks | 32-43 sq ft per tank | Scale linearly, plan modular layout for additions |
| Cold Storage | 150-300 sq ft | Based on inventory turnover and distribution needs |
| Raw Ingredient Storage | 100-200 sq ft | Climate-controlled for malt and hops preservation |
| Packaging Operations | 150-400 sq ft | Include staging areas and loading dock access |
| Tasting Room/Taproom | 1,000+ sq ft or 30-50% of total space | Revenue generator, size based on customer capacity |
| Flexible/Expansion Space | 10-20% of total facility | Critical for equipment upgrades and growth phases |
How many barrels per year is the brewery expected to produce at full capacity?
Your craft brewery's annual barrel production at full capacity depends directly on your brewhouse system size, fermentation tank capacity, and brewing frequency.
Small craft breweries with 3-5 barrel (BBL) systems typically produce several hundred barrels annually, while mid-size operations with 10-30 BBL systems can reach 5,000 to 15,000 barrels per year. Each barrel contains 31 US gallons, so a 10 BBL system produces 310 gallons per batch.
Your maximum capacity calculation involves multiplying your system size by brewing frequency and available fermentation tank turns. For example, a 7 BBL system brewing twice weekly with adequate fermentation capacity could theoretically produce around 700 barrels annually, though practical capacity is usually 70-80% of theoretical maximum.
Most successful craft breweries size their initial system for projected Year 3 volume rather than immediate needs, allowing room for market growth without major equipment overhauls.
What is the typical square footage required per barrel of annual production capacity?
Industry data shows craft breweries require between 1.6 and 4.6 square feet per barrel of annual production capacity, with the median at 1.6 square feet per barrel.
For efficient planning, target approximately 2.16 square feet per barrel as your benchmark, which provides 99% confidence in having adequate space for operations. This ratio accounts for all brewery functions including production, storage, packaging, and support areas.
Higher ratios often result from generous tasting room allocations, extensive storage areas, or inefficient layouts. Lower ratios may indicate cramped conditions that could limit operational efficiency or future expansion capabilities.
You'll find detailed market insights in our craft brewery business plan, updated every quarter.
How much space is needed for the brewhouse itself, considering the chosen system size and future expansion?
| System Size | Space Required | Expansion Considerations |
|---|---|---|
| 3-5 BBL | 300-500 sq ft | Compact systems suitable for brewpubs, limited expansion potential |
| 7-10 BBL | 550-800 sq ft | Good starter size, allows tank additions without brewhouse changes |
| 15 BBL | 800-1,200 sq ft | Mid-size production, plan for additional hot/cold liquor tank space |
| 20 BBL | 1,200-1,800 sq ft | Commercial scale, requires overhead crane access planning |
| 30+ BBL | 1,800-2,500 sq ft | Large production systems, extensive utility infrastructure needed |
| Hot Liquor Tanks | Additional 100-200 sq ft | Essential for larger systems, consider multiple tank configurations |
| Future Upgrades | 20% buffer space | Allow for equipment modifications, additional vessels, or system upgrades |
What are the recommended ceiling heights and floor load requirements for the brewing and fermentation areas?
Craft breweries require ceiling heights of 16-24 feet to accommodate tall fermentation tanks, facilitate equipment installation, and provide adequate clearance for maintenance operations.
Your floor must support concentrated loads of 2,000-4,000 pounds per square foot to handle filled fermentation tanks, heavy equipment, and forklift traffic. Concrete floors should be 6-8 inches thick with proper reinforcement and vapor barriers.
Fermentation tanks often reach 15-20 feet in height, requiring additional clearance for cleaning ports, sampling valves, and overhead utilities. Factor in an extra 4-6 feet above tank height for practical access and safety compliance.
Consult with your tank supplier and structural engineer early in planning, as retrofitting ceiling height or floor capacity after construction is extremely expensive and often impossible.
How many square feet should be allocated for fermentation tanks and brite tanks, and how does this scale with production growth?
Each fermentation or brite tank requires 32-43 square feet of floor space, including clearance for cleaning, maintenance, and safety access around the vessel.
A typical 20 hectoliter (17 BBL) tank needs approximately 35-40 square feet when accounting for proper spacing, with larger tanks requiring proportionally more space. Scale your tank area by multiplying your planned tank count by 40 square feet per tank for initial planning.
Plan your fermentation area in a modular grid pattern that allows adding tanks without major facility modifications. Most successful breweries design their initial layout to accommodate double their starting tank capacity within the same footprint.
Production growth typically requires adding 2-3 fermentation tanks for every increase in brewhouse capacity, so if you start with 6 tanks, plan space for 12-15 tanks to support future expansion phases.
What utilities must be factored into space planning, and how much room should be left for them?
Dedicated utility areas typically require 100-160 square feet total, covering water treatment systems, electrical panels, gas supply connections, drainage infrastructure, and HVAC equipment.
- Water treatment systems need 20-40 square feet with plumbing access for filter changes and maintenance
- Electrical panels and controls require 15-25 square feet with clear working space per electrical codes
- Gas supply and regulation equipment needs 10-20 square feet in a ventilated area
- Steam boiler or direct-fire systems require 30-60 square feet depending on capacity
- Compressed air systems and receivers need 15-30 square feet with drainage access
- HVAC equipment and ductwork require overhead space and wall clearances throughout the facility
- Drainage collection points and pump systems need strategic placement with 10-20 square feet allocation
How much dedicated space is needed for cold storage, keg storage, and raw ingredient storage?
| Storage Type | Space Required | Specific Requirements |
|---|---|---|
| Cold Storage (Finished Beer) | 150-300 sq ft | Refrigerated to 35-38°F, inventory turnover dependent |
| Keg Storage | 50-100 sq ft | Clean kegs separate from dirty, wash station access |
| Malt Storage | 60-120 sq ft | Dry environment, pest control, easy bulk delivery access |
| Hops Storage | 40-80 sq ft | Refrigerated or frozen, vacuum-sealed packages preferred |
| Yeast Storage | 10-20 sq ft | Refrigerated space, separate from other ingredients |
| Chemical Storage | 20-40 sq ft | Separated by compatibility, secondary containment required |
| Packaging Materials | 30-60 sq ft | Cases, bottles, cans, labels stored in clean dry area |
What is the standard square footage allocation for a tasting room or taproom relative to the brewing area?
Tasting rooms typically occupy 30-50% of your total facility area in brewpub models, or require a minimum of 1,000 square feet for dedicated taproom operations.
Your taproom size should align with your business model and local regulations, with successful operations allocating 15-20 square feet per customer seat including circulation areas. A 50-seat taproom therefore needs approximately 1,000-1,200 square feet including bar, seating, and support areas.
Consider your revenue strategy when sizing the taproom, as on-premise sales typically generate 3-4 times higher margins than wholesale distribution. Many craft breweries find their taproom becomes the primary profit center, justifying generous space allocation.
This is one of the strategies explained in our craft brewery business plan.
How much space should be reserved for packaging operations, whether canning, bottling, or kegging?
Packaging operations require 150-400 square feet depending on your chosen formats and automation level, with manual operations needing less space than automated canning or bottling lines.
Manual kegging operations can function in 150-200 square feet, while semi-automated canning lines typically need 250-350 square feet including product staging areas. Fully automated packaging systems may require 400+ square feet plus additional space for case formation and palletizing.
Plan your packaging area adjacent to cold storage and loading dock access to minimize material handling. Include space for empty package storage, filled product staging, and quality control stations within your packaging allocation.
Most craft breweries start with manual or semi-automated systems and upgrade as production grows, so design your packaging area to accommodate equipment expansion without major facility modifications.
What are the safety and regulatory spacing requirements for aisles, exits, chemical storage, and loading areas?
Fire codes require main aisles of at least 36-48 inches width to accommodate emergency egress and forklift traffic throughout your craft brewery facility.
- Emergency exit requirements mandate two means of egress from any area larger than 1,000 square feet, with exit doors opening outward and remaining unlocked during business hours
- Chemical storage areas need secondary containment equal to 110% of the largest container volume, with incompatible chemicals separated by 20+ feet or fire-rated walls
- Loading dock areas require 14-16 foot ceiling clearance and 12x60 foot staging areas for truck maneuvering and pallet placement
- Eye-wash stations must be within 10 seconds travel time (approximately 100 feet) from any area where chemicals are handled or stored
- OSHA requires 30-inch minimum clearance in front of electrical panels, with 6.5-foot headroom and clear access for maintenance
How much extra square footage should be planned for offices, staff areas, and restrooms?
Office and staff support areas typically require 150-400 square feet total, scaling with your anticipated employee count and operational complexity.
Plan 80-150 square feet for management offices, 50-100 square feet for staff break areas with lockers, and minimum 60-100 square feet for employee restrooms based on occupancy calculations. Public restrooms serving taproom customers need additional 100-150 square feet depending on seating capacity.
Include space for record keeping, sample storage, and quality control documentation which are essential for regulatory compliance and business operations. Many craft breweries underestimate administrative space needs and later struggle with cramped working conditions.
We cover this exact topic in the craft brewery business plan.
What proportion of the overall space should remain flexible or unassigned to accommodate equipment upgrades and long-term expansion?
Reserve 10-20% of your total facility square footage as unassigned flexible space to accommodate future equipment upgrades, production increases, and operational changes.
This flexibility buffer allows you to add fermentation tanks, upgrade packaging equipment, expand cold storage, or reconfigure production flow without major facility modifications. Most successful craft breweries find this extra space becomes essential within 2-3 years of operation.
Consider designating specific areas as "expansion zones" rather than scattering unused space throughout the facility. This approach makes future modifications more cost-effective and less disruptive to ongoing operations.
The craft beer industry experiences rapid changes in consumer preferences, distribution methods, and production technologies, making adaptable facility design crucial for long-term success and profitability.
Conclusion
This article is for informational purposes only and should not be considered financial advice. Readers are encouraged to consult with a qualified professional before making any investment decisions. We accept no liability for any actions taken based on the information provided.
Planning your craft brewery space requirements is just the beginning of building a successful brewing business.
Understanding startup costs, equipment needs, and profitability projections will help you make informed decisions about facility size and layout that support your long-term business goals.
Sources
- Specific Engineering - Brewery System Sizing
- MicroBrewr - How Big Should My Brewery Be
- Allied Beverage Tanks - Production Brewery Equipment Selection
- Specific Engineering - Building Requirements
- Microbrewery System - Room Requirements
- Microbrewery System - Floor Space Planning
- MICET Group - Brewery Space Guide
- Restroworks - Brewery Setup Cost
- Craft Brewery Equipment - How Big Should My Craft Brewery Be
- Yolong Brewtech - Brewhouse Equipment
-Craft Brewery Startup Costs: Complete Guide
-Craft Brewery Business Plan: Essential Guide
-How Much Does it Cost to Open a Craft Brewery
-Craft Brewery Profitability: Complete Analysis
-Revenue Tools for Craft Breweries
-Craft Brewery Complete Guide
-Craft Brewery Equipment Budget Planning
