Boston Beer acquired a former Diageo facility situated in Lehigh Valley, Pennsylvania. The plant had once been used for mixing and packaging clear malt beverages, but the brewhouse had deteriorated after more than a decade of abandonment.
As part of a master plan effort, Dennis Group conducted a full facility evaluation to determine which assets were salvageable. Significant environmental and structural challenges surfaced early, including extensive mold abatement, asbestos remediation, and replacement of roughly 85% of the roof.
From there, major upgrades transformed the site’s brewing and utilities infrastructure, adding new systems for grain handling, vacuum railcar unloading, screening, filtration, and CIP. Other upgrades consisted of the conversion of an existing warehouse to accommodate additional filling and packaging lines, including a keg filling line and a variety pack line. The project also included a new 92-foot-tall Product Release Center equipped with 27 tanks, each with a 2,000-barrel capacity.
Since the first major facility renovation, Dennis Group has continued to work with the nation’s second-largest craft brewer to upgrade the plant which produces more than two-thirds of Boston Beer’s annual 4.3 million barrels.
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