case studybeveragesvendors

How a DIY Syrup Maker Scaled to 1,500-Gallon Tanks: Growth Lessons for Beverage Programs

cconcessions

2026-01-27

12 min read

Practical scaling lessons from Liber & Co.'s rise — small-batch testing, QC, co-packing, and equipment choices for concession beverage programs.

Hook: From stove-top test to 1,500-gallon tanks — what concession operators need to know

Scaling a beverage program often means choosing between brittle supply chains, inconsistent flavor, and the capital cost of industrial equipment. That’s exactly the crossroads many concession operators face when moving from small-batch syrups and cocktail mixes to high-volume, repeatable production for stadiums, festivals, and concession stands. Liber & Co.’s journey — famously described as starting with “a single pot on a stove” and growing into production in 1,500-gallon tanks — holds concrete lessons you can apply today.

“It all started with a single pot on a stove.” — Chris Harrison, Liber & Co.

Executive summary: The most valuable lessons for B2B buyers

Quick takeaways for operations managers and small business owners who buy or run beverage programs:

Use small-batch testing to lock flavor and SOPs before scaling. See our notes on running pilot runs and staged growth in the pilot playbook.
Standardize quality control and documentation to keep flavor consistent across larger tanks. For reverse-flow and returns planning, consider reverse-logistics thinking from reverse logistics to working capital.
Know when to co-pack — and how to choose a co-packer that protects margins and brand integrity. Our recommended approaches echo lessons from event operators and venue partners in the field review on pop-ups and partners.
Scale equipment incrementally (pilot → 100–500 gal → 1,500+ gal) to avoid costly rework. Field gear testing and scaling considerations are similar to event equipment guidance in this field-gear review.
Manage your supply chain for seasonality, traceability, and ingredient risk — read up on multi-sourcing and regional growth strategies in the local-to-global growth playbook.

The Liber & Co. arc: Why their story matters to concession programs in 2026

Liber & Co. began with founders experimenting on a kitchen stove in 2011 and grew to serve bars, restaurants, coffee shops and consumers worldwide. By 2026 they produce in industrial-scale tanks while keeping a hands-on, product-first culture. For concession operators, the parallels are direct: you want the quality of craft syrups but the throughput and reliability of scaled production.

Why this is timely in 2026: demand for premium non-alcoholic and craft beverage options at events has accelerated since late 2023, and venue operators now expect suppliers to meet higher standards for traceability, sustainability, and rapid replenishment. Liber & Co.’s path shows how to keep an artisanal product profile while industrializing production.

Lesson 1 — Small-batch testing: preserve flavor, reduce risk

Scaling should start with relentless small-batch experimentation. Liber & Co. tested recipes in tiny pots — and they never stopped testing as they scaled. For concession operations, the process looks like this:

Create a master recipe at 1–5 gallons. Document ingredients, order of addition, temperature, time, and yield.
Run multiple blind panels with front-line staff and a subset of customers to assess flavor, sweetness, acidity and dilution behavior (how it mixes on your soda guns or bar lines).
Record sensory and objective metrics (Brix, pH, solids %, yield loss) so you can reproduce and troubleshoot at larger volumes.

Actionable tip: Always capture pH and Brix on every pilot batch. These two numbers tell you if the syrup will taste the same after scaled heating, filtration, or pasteurization.

Lesson 2 — Build SOPs and a quality-control backbone

What keeps a syrup tasting the same in a 5-gallon pot and a 1,500-gallon tank is repeatability. Liber & Co. kept manufacturing in-house through much of its scale-up, which forced development of Standard Operating Procedures (SOPs) and QC checklists early.

Core elements to implement immediately:

Batch record template: ingredient lots, weights, start/end times, temperatures, pH, Brix, operator initials.
Incoming ingredient QA: COAs, visual checks, weight verification, and quarantining until release.
In-process checks: scheduled sampling (e.g., every 500 gallons) for microbial load, pH, and soluble solids.
Finished-product testing: shelf-life simulation, PET stress tests if using plastic packaging, and labeling verification.

Actionable checklist: If you don’t have a formal QC program, start with a one-page batch record, and require two in-process data points (pH, Brix) plus a final sample from each tank.

Lesson 3 — Pilot before you buy: equipment scaling strategy

Jumping from countertop to 1,500-gallon tanks overnight is tempting but costly. Liber & Co. scaled in steps, learning how heat transfer, extraction times, and ingredient interactions change at scale. Use a staged equipment plan:

Lab/pilot kettles (10–50 gal) for recipe confirmation and extraction time tuning.
Intermediate processing (100–500 gal) to test mixing dynamics and sanitary fittings.
Production tanks (1,000–1,500+ gal) with CIP, steam jackets, and sanitary pumps.

Key equipment specs to prioritize for syrups and concentrates:

Material: 304 or 316 stainless steel for food-contact surfaces.
CIP (clean-in-place): ensure full circulation and temperature control for sanitation between runs.
Agitation: variable-speed anchor or turbine agitators to handle high-solids syrups without aeration.
Heating/cooling: steam jackets or glycol systems for consistent hold temperatures.
Pumps and fittings: sanitary positive displacement pumps and tri-clamp fittings for easy cleaning.

Practical sizing tip: 1,500 gallons ≈ 5,678 liters. When planning plant logistics, assume each full tank requires space for filling, headroom for agitators, and access for sampling and cleaning. Plan your floor layout around flow: raw ingredient → mixing → holding → filling → packaging.

Lesson 4 — Co-packing: when to outsource versus keep in-house

Co-packing is a strategic lever. Liber & Co. used both in-house and outsourced partners throughout growth. For many concession operators looking to scale, co-packers offer speed and capital-light expansion — but they can also erode margin or dilute control.

Decision criteria to consider:

Volume threshold: if your monthly production exceeds your capital budget or you need to meet rush event seasonality, co-packing is attractive. In practice, many brands move to co-pack when they consistently need 500–2,000+ gallons/month of finished syrup.
Packaging complexity: co-packers can handle glass, PET, bag-in-box and kegs — useful for venue needs like bag-in-box syrup for soda guns or kegs for pre-mixers.
Regulatory and QA capability: pick a co-packer with documented HACCP/FSMA compliance, traceability systems, and testing labs.

How to qualify a co-packer (practical RFP checklist):

Request equipment lists and photos of the line (mix tanks, CIP, fillers).
Ask for lot traceability examples and sample batch records.
Require proof of insurance, HACCP plan, and recent audit results.
Confirm MOQ, lead times, and packaging capabilities (and pilot run fees).
Negotiate quality clauses — dispute resolution for off-spec lots and product hold periods.

Actionable negotiation tip: Build an SLA that ties payment terms to passing QC. Insist on joint inspections for first 3 production runs.

Lesson 5 — Packaging choices that serve concession environments

Packaging affects logistics, cost-per-serve, and on-site uptime. Liber & Co. sells across channels and learned that packaging must match the use case.

Bag-in-box (BIB): Best for high-throughput concession lines and soda guns. Low shipping weight, fast swap-outs, and low breakage. Consider BIBs with integrated tap fittings for speed.
Kegs (Cornelius or Sanke): Good for premixed cocktails or high-margin drinks at venues with draft systems.
PET bottles and pump dispensers: Useful for back-bars and small kiosks where appearance and portion control matter.
Glass retail bottles: Premium look for DTC but not ideal for stadium logistics due to breakage and weight.

Cost model reminder: compare cost-per-serve (package + syrup dilution + labor to swap) rather than cost-per-unit. Concessions win when they reduce downtime and labor per pour.

Lesson 6 — Supply chain and ingredient risk management

Scaling exposes you to ingredient volatility. Liber & Co. built supplier relationships and diversified sources. In 2026, climate-driven crop variability and logistics shifts make this even more important.

Practical steps:

Qualify multiple suppliers for key ingredients (sugar, citrus, botanicals). Keep at least two approved vendors for critical items — local and regional strategies are covered in the local-to-global growth playbook.
Use contracts with price-band clauses for major commodities; negotiate lead-time protections for peak event seasons.
Implement lot traceability and digital inventory management to track FIFO and recall readiness.
Stock strategic safety inventory for high-risk items but optimize with inventory turns — don’t over-capitalize on slow-moving SKUs.

2026 trend note: Nearshoring and ingredient traceability (blockchain/QR codes) have matured. B2B buyers increasingly expect QR-linked traceability from vendor to venue.

Lesson 7 — Food safety & compliance for B2B buyers

Concession operators must ensure vendors meet food-safety expectations. Liber & Co.’s experience emphasizes traceability and in-house control, but co-packing partners must meet the same standards.

Minimum compliance checklist:

HACCP plan and documented FSMA compliance.
Sanitation records, allergen controls, and pest management logs.
GMO and organic certifications if you claim them on labels.
Shelf-life validation and storage-temperature limits (critical for outdoor events).

Actionable procurement demand: Require vendors to provide a food-safety dossier (HACCP summary, COAs, lab results, recall plan) before signing a purchase agreement.

Lesson 8 — Pricing, margins, and SKU rationalization

As Liber & Co. scaled distribution and product lines, SKU rationalization became essential to keep operations lean. For venues and concession managers, less is often more.

How to approach SKUs:

Prioritize 6–8 core SKUs that meet 80% of demand (e.g., classic simple syrup, lemon, ginger, premium cocktail concentrate).
Use limited seasonal runs for high-margin, promotional drinks — keep them off the continuous production schedule.
Calculate contribution margin per SKU after packaging, labor for pour, and payout — retire bottom-performers.

Pricing model tip: Price for cost-per-serve. If one 1,500-gallon tank yields X drinks — compute ingredient and labor per pour and ensure margin with event overhead factored in.

Lesson 9 — Technology and forecasts: what’s new in 2026

By 2026, beverage manufacturers and co-packers increasingly use digital tools to manage demand spikes, especially for event-driven concession orders. Two trends to leverage:

AI-driven forecasting: integrates historical sales, event schedules, weather and marketing calendars to predict volumes. This reduces stockouts for seasonal peaks.
Digital procurement platforms: consolidated marketplaces for B2B buyers that offer contract pricing, automated reorders, and real-time inventory visibility across co-packer and in-house stock — consider integrations with modern headless checkout and procurement tooling like SmoothCheckout.

Actionable adoption: Ask your supplier if they can integrate EDI or API-based order flows to your POS and inventory system. Automated reorders tied to projected event schedules cut emergency freight costs.

Real-world checklist: 12-step plan to scale your concession beverage program

Run 3–5 small pilot batches (1–5 gal) and capture pH/Brix and sensory results.
Standardize a master recipe and create a formal SOP and batch record template.
Validate shelf-life and label claims with accelerated testing.
Implement a simple QC plan: incoming checks, in-process pH/Brix, final check and hold sample.
Plan equipment scaling in stages (pilot → intermediate → production) and budget for CIP.
Decide packaging by use-case (BIB/keg for stadiums; PET/pump for kiosks; glass for retail).
Qualify at least two suppliers per critical ingredient and build safety stock rules.
Create an RFP and audit process for co-packers (photos, audits, SLA, pilot runs).
Rationalize SKUs — keep the core line tight; run seasonal SKUs as promos.
Integrate forecasting tools and set up automated reorders for peak events.
Negotiate SLAs with co-packers (lead time, corrective actions, liability for off-spec product).
Train your front-line staff on pour ratios and product handling—consistency in the cup is as important as consistency in the tank.

Common pitfalls and how Liber & Co. avoided them

Many brands scale too quickly, lose flavor fidelity, or underestimate packaging logistics. Liber & Co. kept a hands-on culture and tested each step — preserving product quality while expanding distribution.

Pitfall: Scaling recipes linearly without pilot trials — outcome: off-flavor due to extraction or heat differences. Fix: run intermediate pilot batches and use field-tested checklists like those in the field-gear review.
Pitfall: Choosing the cheapest co-packer. Fix: require audit & QA documentation and align incentives in your contract.
Pitfall: Over-complicated SKU portfolio. Fix: focus on core best-sellers for events and rotate promotions.

Why these lessons matter for B2B buyers in food service and events

B2B buyers need reliable suppliers who understand seasonality, speed, and venue constraints. Liber & Co.’s history shows that artisanal roots don’t have to be sacrificed for scale — but they require deliberate systems: pilot testing, QC, co-packing discipline, and thoughtful packaging choices. Buyers who demand traceability, predictable lead times, and documented QA will reduce risk and improve margins across their venues.

Future-facing predictions for 2026 and beyond

Looking ahead, expect these forces to shape syrup manufacturing and concession beverage programs:

Higher traceability expectations: QR codes and validated trace logs will be standard on B2B deliveries — see practical examples in the sustainability and traceability note.
Sustainability rules: lightweight and recyclable packaging will be preferred by venues and required by more municipal procurement rules — packaging strategies are explored in paper & packaging guides.
Co-packer networks: flexible, on-demand micro co-packers will let brands scale regionally without centralized capital expansion — related operational playbooks appear in the pilot micro-event drops playbook.
Ingredient sourcing risk: climate variability will make multi-sourcing and contracts with price-band protections a necessity.

Final actionable checklist before you sign a supplier or co-packer agreement

See three recent batch records and QC results for the product you will buy.
Confirm lead times and emergency ramp-up charges for peak events.
Require a recall and traceability plan — test it with a hypothetical recall drill.
Get packaging specs and sample shipments to confirm fit with your service model.
Negotiate payment tied to QC acceptance, at least for the first 90 days.

Closing thoughts and call-to-action

Liber & Co.’s move from a kitchen stove to 1,500-gallon tanks is not just an inspiring growth story — it’s a playbook. Small-batch testing, rigorous SOPs, staged equipment investment, smart co-packing decisions, and modern supply-chain practices let you scale without sacrificing flavor or margin. For concession operators and event caterers, the opportunity is clear: apply these practical steps to transform your beverage program into a reliable, profitable line item for every event.

Ready to scale? Start with a pilot batch and a one-page QC plan this month — and if you need vetted co-packing partners, packaging options for venues, or equipment specifications tailored to concession environments, contact our procurement team. We’ll match you with suppliers who meet FSMA/HACCP standards and can ship on event timelines.

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