Bay Area Brewing Company Food Prep Supplies

In the case of Bay Area Brewing Company, a nano brewery owned by veterans and located in Rockport, Texas, it becomes apparent that there will come a time when every small brewery and taproom has to answer the question about what equipment to use for the purposes of safe food prep in a small kitchen, especially when the septic system has to be taken into account and the budget is limited.The answer lies not in building a $200,000 commercial kitchen, but rather in opting for a list of food-grade tools, sanitary tools, and cleaning processes, allowing to expand the operation.

The goal of this document is to identify the types of food prep supplies that need to be acquired by any brewery taproom, ranging from food-grade fittings and valves to prepping tables, cutting boards, to cleaning agents and costs associated with various manufacturers.

Briefly, food barang for a nano brewery such as Bay Area Brewing Company can be divided into categories: brewhouse sanitary equipment, which includes sanitary tri-clamp fittings, butterfly valves and sample valves, food-grade silicone tubing and cleaning chemicals, and kitchen equipment, which includes stainless steel prep tables, cutting boards, GN pans, food processors, and small refrigeration equipment. Equipment costs for a small taproom kitchen are generally in the range of $10,000-$40,000 which depends on refrigeration requirements, while restaurant kitchen equipment may cost from $50,000-200,000. Because our brewery works on septic, use PAA sanitizers and septic safe detergents instead of chlorine-containing ones, and make all surfaces that come into contact with food stainless steel (304/316L) or NSF-certified plastic.

The Bay Area Brewing Company Case: Nano Scale, Real Constraints

The Bay Area Brewing Company, which is located in Rockport, Texas, is the first nano craft brewery in the area that aims to offer a family-friendly atmosphere. The owners of the brewery, who are Will and Diedra Amaya, both veterans of the Navy, have put their money into the business by investing in a 2 BBL brewing system, or about 62 gallons in total batch processing. The brewery plans to expand its capacity by adding a 5 BBL system, serving beer directly from the bright tank systems, and featuring food trucks on the premises. Additionally, the establishment features a relatively small scale of operations due to its limited kitchen, only one restroom, and the existence of a septic system for waste disposal.

As far as the supply importance is concerned, there are three main factors that come into play. One of the issues is the scale of the operation: since the brewery is of 2-5 BBL size, it uses home-brewing equipment that is compliant with the standards of hygiene in the food processing industry. This means that the hoses that are used for cleaning must be at the level other than that of the plumbing store. Given that the operation employs a septic system, all cleaning products and materials must comply with environmental standards. Additionally, the brewery presents both a brewhouse and a food-preparing establishment, which means that it should be equipped with both types of supplies.

The Two Supply Systems: Brewing Sanitation and Kitchen Prep

In this article, each material falls under either of the two systems, which requires the reader to keep them separate in mind and in preparation of the purchase:

System 1 — Brewing sanitation: It incorporates all equipment directly used for beer-making purposes, such as tri-clamp fittings, valves, gaskets, pumps, transfer hoses, CIP spray balls, and cleaning/sanitizing agents. This equipment is essential for preserving the beer quality from mash tun to bright tank.
System 2 — Kitchen food preparation: It includes equipment that comes into contact with food, including stainless misc’n tables, cutting boards, knives, GN pans, food blenders, chillers, and small kitchen utensils. This equipment is essential for protecting food during preparation in the taproom and passing the health inspection.

Most supplies needed for food preparation in a nano brewery are referred to as System 2 but have an important part of System 1 as well, so the overlap point (where the beer is transferred for serving and cleaned up) is where the sanitary equipment lies.

Sanitary Fittings and Valves: The Brewery's Food-Grade Plumbing

Beverage manufacturing involves the plumbing system in its food chain since the beverage travels through the different plumbing fittings to reach the container. Any plumbing fitting that cannot be thoroughly cleaned is a source of contamination. This is why tri-clamp (or tri-clover) connection has become the industry standard. The tri-clamp consists of two grooved ferrules, a gasket, and a hinged clamp, which mean that it can be put together and removed for cleaning effortlessly.Tri-clamp joints are threadless, so there are no threads to trap beer, soil, or bacteria — the core principle of a sanitary fitting.

The first things needed for a small brewery:

The following go in the category of accessories; clamping kits which include a gasket composed of EPDM for beer contact and a gasket composed of PTFE for chemical purposes.
The second one is piping accessories including ferrules, elbow fittings, fittings such as tees and reducers, and end caps.
The next one is the butterfly valve which is a conventional valve for controlling liquids in all transferring processes.
Next in the line are sampling valves which can extract the beer and clean sample any time without turning off the line.
The last one is the sight glasses which are used for observing the flow and cleanliness inside the tank.

Nevertheless, it should be noted that materials come into play here. 304 stainless steel is considered a perfect choice in most cases. However, in situations when cleaning metals with alkaline cleaners and acidic solutions, it is better to select 316L stainless steel which contains additional molybdenum.The 304 vs 316L selection guide lays out when each grade earns its cost. Eagle produces this entire family - tri-clamp fitting, butterfly and ball valve, gaskets and reducers included - with 304 and 316L materials having the electropolished surfaces (Ra ≤ 0.8 µm) and with the compliance with 3A/FDA/ISO 9001 standards, selling them at factory prices ranging from about $16 to $55 for the small fittings being required most of the nano breweries (clamps prices vary between $3-$15, gaskets $1.50-$3.50, elbows $16-55, tees $20-60 and reducers $25-75).The tri-clamp fittings under $80 guide and the sanitary fittings measurement guide help you spec the exact sizes (1.5" and 2" dominate brewery transfer lines) without overbuying. When you need flow control, our tri-clamp ball valve guide compares ball vs butterfly valves for small systems.

Food-Grade Hoses and Transfer Supplies

Beverages and food comfortably flow through flexible tubing at any point of the process, and ordinary PVC or garden hoses would not be appropriate as they can give off plasticizers, carry bacteria, and alter the taste. The best option would be food-grade platinum silicone hoses — they are odorless, free from phthalates, resistant to CIP chemicals as well as steam sterilization and compliant with FDA 21 CFR 177.2600. For brewery transfer needs, platinum silicone hoses that have tri-clamp ferrules on the ends are directly connected to the sanitary fittings mentioned above. Prices for this material are about $3.50-25 per meter depending on gauge, the brewery may require around 10-30 meters of 1-1.5“ transfer hoses in addition to short lengths for serving lines which makes about $100-400 in total. Food-grade poly cutting boards and NSF-certified plastic containers should be used in the kitchen.

Cleaning and Sanitizing: Septic-Safe Chemistry

In the case of a facility that has a septic system, which is the exact case of Bay Area Brewing, the cleaning should take into consideration environmental concerns in addition to hygiene ones. The brewery itself has adopted a method whereby environmentally safe cleaning products are being used. The effective chemical rotation scheme employed by a nano brewery works as follows:

Alkali cleaner (caustic) – this is the main CIP detergent that is responsible for removal of organic dirt and beerstone precursors from lines and tanks;
Acid descaler – it is used to get rid of mineral scale and beerstone;
Peracetic acid (PAA) sanitizer – it is widely accepted as the best sanitizer at 100-500 ppm; it can be found in form of water, oxygen and acetic acid in septic systems and is eco-friendly.
Septic-safe degreasers and cleaners for kitchens – biodegradable products made of either PAA or quat should be used.

Note that the cost of 5 l jug of PAA concentrate is around 170-260 dollars and it may be used very long by a nano brewery at concentrations of 100-500 ppm; the same is applicable to alkali and acid cleaners. It is a cheap insurance.

Kitchen Prep Supplies: Tables, Cutting Boards, and Smallware

The kitchen element of a taproom food program — whether it is a small kitchen preparing bar snacks or a large one cooking a complete menu with assistance from food trucks — begins with the same essential list as any commercial kitchen; however, in the case of taprooms the items are smaller:

Preparation tables—these preparation surfaces can cost between $200 and $1,500 depending on their size and whether they have undershelves or refrigerators. A 48-72 inch stainless steel table with an undershelf represents the standard size for nano-kitchens ($200-$450).
Cutting boards—color-coded perforation system (red for raw meat, green for vegetables, etc.) for avoiding cross contamination; costs $50-$200 for professional quality sets.
Knives and small utensils—some quality chef knives, spare knives, and approved such utensils; $100-$400 for a basic kit.
GN Containers (gastronorm)—the standard container of any kitchen used for cooking and storage; $5-$50 (depends on size).
Stainless steel bowls and containers; $5-$30 each.
Food processor and slicers—needed in case the menu is volume-heavy; $500-$3,000 for the commercial one with standard; much less for the lighter one.
Hand sinks—are mandatory if food is cooked; hanging sinks cost around $130 plus installation.

Refrigeration and Storage

Cold storage generally accounts for the majority of the expenses incurred from a small food project. A two-door reach-in refrigerator can cost between $2,000 and $5,000. A refrigerated prep table costs between $240 and $700 for basic versions and about $1,500 and $6,000 for the more advanced versions. For a nano brewery, just one reach-in unit and one refrigerated prep unit is sufficient; walk-in refrigerators are for bigger operations.

Where Each Supply Fits in the Workflow

Stage	Supplies Used	Sanitation Concern
Brewing (mash, boil, ferment)	Stainless vessels, tri-clamp fittings, butterfly valves, transfer hose	Food-grade materials; no crevices
Cleaning between batches	CIP spray balls, alkaline cleaner, acid descaler, PAA	Septic-safe chemistry; full soil removal
Bright tank & serving	Sample valves, sight glasses, serving line hose	Line cleaning on a schedule
Food prep (taproom kitchen)	Stainless prep tables, cutting boards, knives, GN pans	HACCP color coding; surface sanitizing
Storage & service	Reach-in refrigeration, prep tables, food storage containers	Cold chain; date labeling
Waste & water	Septic-safe detergents, drain strainers	No heavy chemicals into septic

Recommended Manufacturers and Price Ranges

In the brewhouse industry, sanitary fittings and valves are largely manufactured by companies like Alfa Laval, Swagelok, and Parker, which price their products very highly ($60-2,000 per fitting), while Eagle offers similar 304/316L variations much cheaper (down by about 30-80% at present time, or $16-1,250). Gaskets and hoses are available only from a small number of suppliers, such as EPDM/PTFE seals and platinum-cured silicone hoses. In the kitchen supplies field, there are well-known brands like MixRite, Culinox, Hobart, Vollrath, and Cambro (the last one specializes mainly in storage containers and GN pans) but there are also cheaper stainless steel table alternatives produced in Chinese factories ($30-250) available. Chemicals used for sanitation are supplied by specialized companies like Biosan, Chemron, and local distributors in volumetric variations from 5 to 1,000 L.

A Starter Budget for a Nano Brewery Taproom

Utilizing today's equipment prices, an estimated equipment budget for a nano brewery with a restricted kitchen:

Category	Realistic Range
Sanitary fittings, valves, gaskets (starter set)	$800-2,500
Food-grade silicone transfer hose	$150-500
CIP spray balls and cleaning cart	$500-1,500
Chemicals (first-season stock)	$500-1,200
Stainless prep tables (1-3)	$400-1,500
Cutting boards, knives, smallware, GN pans	$300-800
Reach-in refrigerator and/or prep unit	$2,000-5,000
Total starter package	$5,000-13,000

A full-fledged commercial kitchen for a restaurant costs at least $50,000; the above-mentioned program of the nano-brewery taproom is intentionally kept low to follow the Bay Area Brewing Company's own philosophy of keeping food preparation to a minimum while brewing on a small scale.

Frequently Asked Questions

What is a nano brewery and what supplies does it need?

A nano-brewery is a small brewery that typically has the establishing feature of a 1-5 BBL (approximately 31-155 gallons per batch) and sells its product straight from its taproom. It actually requires commercial-grade hygiene that is at a small scale requiring sanitary features like tri-clamp fittings and valves, food-grade silicone tubing, CIP spray balls and the chemicals involved as well as kitchen equipment (stainless steel tables, cutting boards, GN pans, and refrigerators if they serve food).

Do I need food-grade fittings for a brewery taproom kitchen?

Yes, to answer the question in two ways. Firstly, in respect of the brewing process, it should be required to ensure that every fitting that contacts beer be sanitary-grade stainless (tri-clamps, 304 or 316L) as beer is food. The second component of the answer implies that kitchen equipment should be food- contact approved as well, so it means that stainless or NSF-certified plastics should be used for equipment exposed to food.

How much does it cost to equip a small brewery kitchen?

The cost of setting up a budget taproom kitchen (prep stainless tables, cutting boards, utensils, GN pans, and one stand-in refrigerator) is in the range of $3,000- 8,000. But if we take into account brewhouse sanitation (fittings, tubing and CIP equipment) an investor should be prepared to spend about $5,000-13,000 for the complete start-up of a nano-brewery. By comparison, a restaurant kitchen would typically require $50,000.

What is the best material for brewery food-contact equipment?

304 stainless steel is the material which is considered to be the best for most beer and food contact equipment. It is food-safe material and therefore it is easy to clean and affordable. 316L stainless is an upgrade for corrosive conditions such as caustic CIP chemicals, acidic products, and coastal conditions which is important for the location of Rockport. Food-contact plastics should be NSF-certified, and tubing should be made of platinum-cured silicone.

Can I use regular PVC hose for beer or food transfer?

No. Common PVC or garden hoses do not meet food-grade requirements as they can make the product spoiling or affecting the flavor of food because of the internal surface of the pipeline which might have been polluted.

References

Conclusion

A nano brewery like Bay Area Brewing Company shows how good food safety and processing do not need restaurant-sized sanitation; rather, it needs only the correct resources and proper choice of supplies. The brewing side is cleaned out to the maximum; there are stainless fittings and valves, which can be disassembled for cleansing, and food-safe silicone pipes, which cannot spoil beer, simultaneous work with the septic-safe disinfectants. The kitchen part has exactly the same range of equipment as anywhere; there are stainless steel work surfaces, color-coded cutting boards, GN pans, and proper refrigeration. Adding to all this discipline of thorough cleaning after each batch allows to present a $5,000-$13,000 combination of suitable equipment. Regarding fittings and valves, they can be obtained from the companies certificate manufacturer — they offer the same 304/316L certified quality as big names do but for a fraction of the cost.