Used Equipment Done Right: Capacity, Cost, and Fit Before the Bid w/First Key Consulting
With brewery closures and shifting market conditions creating more opportunities in the used-equipment market, many brewers are asking the same question: is that auction deal a smart growth move, or the start of an expensive integration problem? This session will help brewery owners, operators, and production leaders evaluate used brewhouse, cellar, packaging, and utility equipment through a practical, capacity-first lens. Rather than chasing bargains, attendees will learn how to connect equipment decisions to real production needs, operating constraints, layout realities, utility capacity, total landed cost, and long-term scalability. The presentation will walk through common pitfalls including technology mismatch, missing automation support, unreliable maintenance history, access and footprint issues, rigging surprises, and hidden refurbishment costs, showing how early planning can reduce risk before a bid is placed. Using real-world integration case studies, including a used brewhouse project and a can filler evaluation, the session will highlight the difference between apparent value and true total cost of ownership. Virtual attendees will leave with a practical framework for defining capacity needs, talking to OEMs before purchase, inspecting equipment properly, confirming facility fit, budgeting contingencies, and sequencing equipment additions strategically. The goal is simple: help breweries capture the cost, lead-time, and sustainability benefits of used equipment without inheriting someone else’s operational headaches.
Kayla Johnson is Senior Advisor, Engineering Services at First Key Consulting, bringing more than 15 years of engineering and brewing industry experience. She supports clients with process, packaging, and utilities engineering; capital project management; and operational excellence. Before joining First Key, Kayla held several leadership roles at Anheuser-Busch InBev, including Senior Quality Assurance Manager, Resident Engineer, Director of Learning & Development for Supply Chain, and Assistant Brewmaster. Her experience spans food safety, internal and external quality, powerhouse operations, facilities, maintenance, IT, capital projects, employee capability building, and large-scale brewery operations. She has led teams across major North American facilities, supported greenfield brewery design, launched new brands, and contributed to equipment installation, testing, and start-up. Kayla holds a Bachelor of Science in Chemical Engineering, Cum Laude, from the University of North Dakota, along with Six Sigma and Learn2Serve certifications. Outside work, she volunteers in her community and enjoys fitness, travel, cooking, and pickleball.
Garrett Meier is Vice President Brewery Operations at Full Sail Brewing where he is responsible for leading brewery performance and operational execution. Prior to Full Sail, Garret was 10 years at Anheuser-Busch, supporting the North American brewery network, including sustainability efforts across 18 breweries focused on energy, water, carbon reduction, and capacity management. He also led beyond beer supply initiatives, including co-manufacturing network development, new brand integration, and the successful scaling of ready-to-drink products within a large production system. Earlier roles gave him direct responsibility for production teams, engineers, process managers, technicians, operators, budgets, P&L performance, and maintenance strategy. Garrett earned a Bachelor of Science in Industrial and Manufacturing Systems Engineering from the University of Missouri-Columbia. His professional credentials include Certified Cicerone, Advanced Cicerone, Agile Scrum Master, Lean Six Sigma Green Belt, and Brewing Diploma certifications. Garrett enjoys exploring the craft and culture of beer and spending time in the outdoor community around Hood River.
Mike Gerhart is Senior Advisor, Technical Services at First Key Consulting, where he works with breweries on quality and process optimization initiatives. His work includes operational oversight and management support, developing reporting metrics and SOPs, supporting employee development, and contributing to business plans and feasibility studies. Mike partners with both start-up and established brewery clients on facility design, equipment procurement, construction oversight, operational readiness, and commissioning. He also supports new product innovation, process upgrades, the development and implementation of education and training programs, and provides expert witness services related to brewery operations, quality, and process performance. Prior to joining First Key, Mike accumulated more than 20 years of experience working with breweries including Hill Farmstead, Dogfish Head, Otter Creek, and Coors. At Hill Farmstead, he served as Chief Operating Officer, during which time the brewery consecutively earned the distinction of Best Brewery in the World from RateBeer.com. Mike obtained his Master of Brewing from the Versuchs- und Lehranstalt für Brauerei (VLB) in Berlin and holds an undergraduate degree from Johnson State College in Vermont. Outside of First Key, Mike enjoys spending time with his two daughters, snowboarding, being outdoors, and enjoying a good beer at the end of the day.”