What You Should Know About Planning a Beverage System

Designing a commercial bar or restaurant space is no small feat. From customer flow and aesthetics to functionality and efficiency, architects and interior designers have countless variables to consider. However, one area that is often underestimated during early design phases is the beverage system layout.

Whether it's beer on tap, cocktails, coffee, sparkling water, or nitro drinks, poor planning of beverage systems can lead to costly corrections during construction or frustrating limitations post-installation.

This comprehensive guide aims to help architects and bar designers avoid common mistakes by outlining critical considerations for equipment spacing, trunk line planning, tower placement, gas storage, refrigeration sizing, ADA compliance, and future expansion strategies.

Why Beverage System Design Matters in Early Planning

Beverage systems are not just utilities—they're core components of the guest experience and revenue generation. Improperly placed towers, overcrowded equipment rooms, or trunk lines routed without foresight can quickly create operational inefficiencies, higher maintenance costs, and unsatisfactory beverage quality.

Integrating beverage planning into the architectural design phase ensures smooth installation, aesthetic cohesion, and long-term functionality. Early coordination prevents expensive rework and allows you to optimize the entire bar environment from the start.

Budget Early and Realistically for Your Beverage System

One of the most overlooked and costly mistakes in bar and restaurant design is treating the beverage system as an afterthought. Waiting until the build is nearly complete to plan for draft beer, wine, or cocktail dispensing systems can lead to expensive rework, equipment compromises, or system failures after opening.

Don't Be Surprised by the Cost

Make sure you budget for a quality system and for good reason. Beverage systems involve commercial-grade equipment, gas systems, glycol chillers, precision regulators, and skilled installation. A properly designed draft system can cost anywhere from $5,000 for a simple direct-draw setup to $50,000+ for a multi-tap glycol-cooled system with custom towers.

Budgeting early allows you to make thoughtful decisions about tower styles, line runs, gas configurations, and cooling systems. Trying to cut corners with low-cost materials or DIY installations often leads to foamy beer, inconsistent pours, temperature fluctuations, or expensive retrofits.

Hiring a reputable beverage system installer ensures you get a layout that works, performs, and complies with safety standards. Quality installations reduce operational headaches and protect your investment.

Measure Your Keg-to-Tap Distance Early

One of the most critical planning steps is determining the distance between your keg cooler and your taps. This single measurement drives your entire system design.

Direct Draw (Short Distances): Suitable for distances under 10 feet. Kegs are stored directly beneath or behind the taps with no insulated trunk line. This is the simplest and most affordable option.
Long Draw (Longer Distances): Necessary for distances exceeding 15 feet. Requires insulated trunk lines, glycol chillers, and secondary cooling to maintain proper beverage temperature during transport.
Transition Zone (10-15 feet): A gray area where you can use either system, but must carefully manage line insulation and temperature control.

Measure from your proposed keg cooler location to each tap location. Document distances both horizontally and vertically (floors, walls, etc.). This measurement determines whether you need basic air-cooled refrigeration or a more complex glycol circulation system.

Choosing Between Direct Draw and Long Draw Systems

The choice between these two core system types fundamentally shapes your bar layout and equipment needs.

Direct Draw (Air-Cooled) Systems

How it works: Cold air from a refrigeration unit is blown through tubes surrounding the beverage lines. The kegs sit directly in the cooler, and taps are mounted on top or nearby. Beer travels the shortest distance possible to the tap.

Best for: Compact bars, small restaurants, cafes with limited space
Advantages: Lower initial cost, simpler installation, fewer moving parts, easier maintenance
Disadvantages: Limited tap placement flexibility, cooler must be adjacent to bar
Ideal line distance: Under 10 feet

Long Draw (Glycol-Cooled) Systems

How it works: A glycol chiller circulates a propylene glycol and water mixture through insulated trunk lines alongside beverage lines. This keeps drinks at the perfect temperature from the cooler all the way to the tap, regardless of distance.

Best for: Large bars, multi-level venues, restaurants with remote keg storage areas
Advantages: Maximum flexibility in equipment placement, supports multiple taps, consistent quality across long distances, allows basement or separate room for kegs
Disadvantages: Higher initial cost, more complex installation, requires maintenance of glycol system
Ideal line distance: 15+ feet

CO2 Room and Gas Storage Planning

Proper gas storage and delivery is essential for both safety and system performance. Plan your CO2 storage room early in the design process.

Location: Choose a cool, well-ventilated area away from heat sources. Basements or dedicated storage rooms work well. Avoid direct sunlight.
Ventilation: Ensure adequate airflow to prevent CO2 buildup. Install a CO2 monitor in the space—this is required by code in many jurisdictions and protects staff health.
Tank Size: Determine how many kegs you'll serve per week, then size your tank accordingly. A 50-pound cylinder serves roughly 5-8 kegs of beer, depending on carbonation levels.
Secondary Regulator: Install a secondary regulator at your dispensing tower to fine-tune pressure for different beverages.
Safety Equipment: Include a shut-off valve, pressure gauges, and CO2 monitors to detect leaks and dangerous accumulations.

Pro Tip: Plan your gas line routing alongside your beverage lines. Running them together in a single conduit keeps your system organized and easier to troubleshoot.

Refrigeration and Keg Cooler Sizing

Your cooler is the heart of your beverage system. Size it correctly to handle peak demand and future growth.

Capacity Calculation: Count the number of kegs you'll need on hand (typically 1.5x your average weekly kegs to ensure you don't run out). A standard half-barrel keg is 54 inches tall and 17 inches in diameter. Plan for 2-3 kegs per tap during busy periods.
Temperature Control: Maintain cooler temperature at 36-40°F (2-4°C) for beer. Wine requires slightly warmer storage (45-50°F). Nitro products may need different settings.
Cooler Location: Place close to your tap area (for direct draw) or in a separate room (for long draw systems). Ensure adequate electricity supply for the compressor.
Air Circulation: Make sure cold air can circulate freely around kegs. Avoid cramming equipment; allow 2-3 inches of space on all sides.
Drainage: Install a drain in the cooler floor to handle condensation and minor spills. Slope the floor toward the drain.

For large venues, consider a walk-in cooler. For bars with limited space, a horizontal or vertical reach-in cooler works well. Always choose commercial-grade equipment designed for 24/7 operation.

Trunk Line Routing and Placement

Trunk lines carry your beverages and cooling medium from the cooler to the taps. Proper routing prevents leaks, temperature loss, and equipment failure.

Line Diameter: Use 3/16-inch ID (inner diameter) for individual lines, or a single trunk with multiple lines inside for longer runs.
Insulation: All long-draw systems require foam insulation around trunk lines. Use at least 1-inch foam insulation for outdoor or unheated spaces.
Routing Path: Plan your route before installation. Avoid sharp bends (minimum 3-inch radius curves), extreme heat sources, and high-traffic areas where lines could be damaged.
Support and Protection: Secure lines every 2-3 feet with cable ties or clamps. Protect exposed sections with conduit or guards to prevent kinks and damage.
Accessibility: Keep connection points accessible for maintenance and cleaning. Don't bury lines in walls or permanently seal them.
Slope for Drainage: If possible, slope lines at a slight angle (1/8 inch per 10 feet) toward the cooler to promote drainage and prevent water pooling in lines.

Tower and Faucet Placement Considerations

Tower placement directly impacts bar efficiency, aesthetics, and guest experience. Strategic placement is critical.

Distance from Point of Service: Place towers close to where bartenders will serve. Minimize reach and movement during peak service.
Visibility and Aesthetics: Position towers where they're visible to customers and enhance bar ambiance. Consider custom tower designs that match your branding.
Height and Ergonomics: Mount towers at a height that reduces bartender strain (typically 36-42 inches from floor to tap handle). Avoid placing taps too high or too low.
Multiple Zones: In large bars, install towers in multiple locations to distribute customer demand and reduce bottlenecks during busy service.
Backup Faucets: Plan for redundancy. If one tower fails, guests can still order drinks from another location.
Product Variety: Use multi-product towers that support beer, wine, cocktails, water, and nitro coffee from a single tower. This maximizes flexibility in a compact footprint.

Drip Tray Sizing and Drainage

Drip trays catch spills and prevent slippery floors and sanitation issues. Size and position them correctly.

Size Calculation: A standard drip tray handles 1-3 taps. Larger towers need oversized trays. Calculate based on peak service traffic and potential pour volume.
Drainage: Every drip tray must drain to a floor drain or waste line. Slope the tray at 1/4 inch per foot to promote drainage.
Material: Use food-grade stainless steel (304SS) for durability and easy cleaning. Avoid plastic which stains and wears quickly.
Placement: Position the tray directly below all faucet handles. Leave adequate space around towers for cleaning and maintenance.
Cleaning Access: Design the tray to be easily removable or accessible for daily cleaning and sanitization.

ADA Compliance and Accessibility

If your bar is open to the public, ADA (Americans with Disabilities Act) compliance is mandatory. Plan for accessibility from the beginning.

Tap Height: At least one accessible tap should be mounted between 36-54 inches from the floor to accommodate wheelchair users and guests of varying heights.
Knee Space: Ensure at least 27 inches of clearance below the bar counter to allow wheelchair access and approach.
Service Area: Design at least one point of service to be fully accessible to disabled guests, including easy-to-reach faucet handles and controls.
Pathway Clearance: Maintain clear paths to the bar with minimum 36-inch width for wheelchair accessibility.
Signage: Mark accessible features clearly. Install braille labels if required by local code.

Consult your local ADA coordinator or accessibility specialist during the design phase to ensure full compliance.

Planning for Future Expansion

Build flexibility into your system to accommodate growth without major rework.

Extra Cooler Capacity: Size your cooler 20-30% larger than current needs to handle seasonal growth.
Gas Line Capacity: Install regulator and line sizes that can support future tap expansion without upgrades.
Trunk Line Conduit: Run extra (empty) tubes or conduit alongside your beverage lines. When you expand, pull new lines through without accessing walls or ceilings.
Tower Mounting Points: Pre-install mounting brackets or reinforcement in likely future tap locations.
Electrical Supply: Ensure adequate power circuits for additional refrigeration equipment, chillers, or dispensing components.
Drainage Capacity: Oversize your drip tray and floor drain to handle additional taps without overflow.

Working with Contractors and Installers

Successful beverage system implementation requires coordination between architects, bar designers, and experienced installers.

Early Coordination: Involve your beverage system installer in design meetings. Their input prevents costly surprises.
Detailed Plans: Provide installers with accurate measurements, floor plans, and elevation drawings showing keg cooler location, tap locations, and line routing.
Utility Coordination: Ensure electrical, plumbing, and HVAC contractors know about beverage system needs. Coolers need adequate power and ventilation.
Code Compliance: Confirm your installer is familiar with local health codes, building codes, and ADA requirements.
Quality Assurance: Request thorough pressure testing, line balancing, and system calibration before opening.
Staff Training: Your installer should train your team on daily operation, cleaning, pressure adjustment, and basic troubleshooting.

Common Planning Mistakes to Avoid

Learn from the mistakes others have made:

Installing taps too far from the cooler without glycol chilling: Results in warm beer and excessive foam.
Undersizing the cooler: Leads to warm kegs during peak service and customer dissatisfaction.
Routing trunk lines through hot areas: Temperature loss causes poor pour quality. Insulation is essential.
Placing towers in inconvenient locations: Slows bartender service and reduces efficiency. Prioritize function over aesthetics alone.
Ignoring drainage: Leads to slippery floors, bacterial growth, and sanitation violations.
Skimping on regulator quality: Poor pressure control causes inconsistent pours and wasted product.
No contingency planning: If your single tower fails, your entire service stops. Plan for backup.
Forgetting about cleaning access: Lines need regular cleaning. Design with maintenance in mind from day one.

What to Have Ready Before Ordering Equipment

Before contacting equipment suppliers, gather this essential information:

Accurate floor plan with keg cooler location, tap locations, and all distances
Elevation drawings showing floor-to-ceiling heights and any level changes
Number of taps needed now and in future (expansion plan)
Types of beverages (beer, wine, cocktails, water, nitro coffee, etc.)
Estimated weekly keg usage
Local building code and health code requirements
Electrical service availability near cooler location
Available space for cooler (dimensions, access for maintenance)
Budget range for equipment and installation
Timeline for completion

Having this information ready accelerates the design process and ensures accurate quotes from equipment suppliers.

Product Recommendations and Resources

Wholesale Beer Parts offers a complete selection of components to support your beverage system design:

Glycol & Air-Cooled Systems | Towers & Drip Trays | Trunk Line & Hose | Gas Regulators & Equipment | Refrigeration & Coolers

Beverage System Planning Checklist

Measure keg-to-tap distances for all tap locations
Determine direct draw vs. long draw system type
Size cooler capacity (current + 25% growth buffer)
Plan CO2 storage location with proper ventilation
Design trunk line routing with adequate insulation
Select tower locations for optimal bar flow
Plan drip tray placement and drainage
Verify ADA accessibility requirements
Plan for future expansion (extra capacity, conduit)
Install CO2 monitor in storage area
Coordinate with all trades (electrical, plumbing, HVAC)
Hire experienced beverage system installer
Request detailed system design and pressure testing
Schedule staff training before opening

Getting Professional Help

While this guide covers the essentials, every bar is unique. Professional design and installation ensure your system works perfectly from day one.

Wholesale Beer Parts connects bar owners and designers with experienced beverage system installers and consultants. We help you navigate everything from initial planning through final installation and staff training.

Contact Wholesale Beer Parts today for personalized beverage system planning assistance. Our team has helped hundreds of bars, restaurants, and venues create efficient, beautiful, and profitable beverage programs.

Whether you're designing a cozy neighborhood bar or a large hospitality venue, we have the expertise and products to make it happen.

Conclusion

Planning your beverage system during the architectural design phase, rather than treating it as an afterthought, saves money, prevents headaches, and creates a system that serves your customers and your bottom line for years to come.

By considering keg-to-tap distances, choosing the right cooling system, planning gas storage, sizing refrigeration, routing trunk lines strategically, placing towers for efficiency, ensuring proper drainage, meeting accessibility standards, and building in expansion capacity, you create a beverage program that's both functional and profitable.

Start your beverage system planning today. Your future self—and your customers—will thank you.