Kenya Breweries Limited (KBL)

Overcoming challenges to deliver a state-of-the-art brewery in Kenya within a tight timeframe.

Client

Diageo / Kenya Breweries Limited (KBL)

Project date

Appointed 2017

In 2017, Diageo/Kenya Breweries Limited planned a new brewery on the site of an old bottling hall and brewery in Kisumu that had been redundant for around 20 years. Zutari was appointed to develop the structural and civil engineering design for the project.

The redevelopment involved transforming the existing facility into a modern, state-of-the-art brewery, including the installation of new brewery equipment and provision of office facilities, all within an exceptionally tight 11-month programme.

The opportunity

Rehabilitating the brewery required upgraded designs for the brewhouse, keg plant, boiler room, and tank farm foundations, as well as for roads, stormwater management, and underground piped services. Zutari was also responsible for procuring geotechnical, topographical, and pipe condition surveys.

Two major challenges were the short delivery timeframe and the lack of existing information. The brewery’s original infrastructure was constructed more than 40 years ago, leaving the project with limited reliable information. High levels of site presence and close engagement with all project stakeholders were essential to overcoming this and meeting the tight deadlines. The project team also had to adapt designs to suit local building practices, available materials, and limited local skill levels.

What we did

Zutari began by conducting detailed site surveys using 3D cameras to capture the existing conditions of the long-unused brewery. These surveys provided an accurate digital record of the facility, which formed the foundation for all structural and civil engineering designs. All new designs were created in 3D using Revit, enabling the team to detect potential clashes, optimise layouts, and ensure constructability before work began on site.

To manage the tight 11-month schedule, Zutari implemented a fully integrated digital workflow. Tablets with customised software allowed engineers and site managers to produce instant site reports, track progress in real time, and quickly resolve emerging issues. This approach improved decision-making and streamlined coordination between teams.

We also managed the procurement and analysis of geotechnical, topographical, and pipe condition surveys to ensure that foundations, underground services, and structural elements could support the new brewery equipment. Designs were carefully adapted to reflect local building practices, material availability, and skill levels while maintaining international standards of quality and safety.

Throughout the project, Zutari maintained close engagement with all stakeholders, including KBL, contractors, and suppliers, providing on-site engineering support and guidance. This hands-on approach enabled rapid problem-solving, ensured alignment across design, procurement, and construction, and kept the project on track to meet the challenging timeline.
Digital tools enhanced decision-making and enabled real-time site reporting.

The outcome

The project was completed on time and within budget, with minimal design revisions. The upgraded brewery now operates as a modern, high-capacity facility that meets international standards and supports KBL’s production growth.

The KBL Brewery project demonstrates how innovative engineering, digital tools, and close stakeholder collaboration can overcome complex challenges to deliver world-class industrial infrastructure in a tight timeframe.

“We provided effective site managers who were quick to adapt to the site environment and achieve international best practice standards. We are proud to have been involved in such a high-profile project.”

Faan Calitz

Zutari Technical Director: Structural Engineering

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