CO2 Compliance for Breweries: A Quick Guide

Carbon dioxide (CO2) plays an essential role in the brewing process, from fermentation and carbonation to packaging and draft beer dispensing. While CO2 is a natural byproduct of brewing and an important part of beverage production, elevated concentrations can create serious safety hazards for brewery employees.

Unlike many restaurants and bars, breweries may encounter CO2 from both fermentation and pressurized gas systems, creating multiple potential sources of exposure throughout the facility.

Whether you're operating a small craft brewery, managing a large production facility, or opening a new taproom, understanding CO2 safety and fire code compliance is an important part of maintaining a safe environment.

This quick guide covers common CO2 hazards, monitoring requirements, and practical steps breweries can take to maintain safety and compliance.

Where Is CO2 Used in Breweries?

CO2 is commonly produced or used throughout brewery operations, including:

• Fermentation: Yeast naturally produces CO2 as sugars are converted into alcohol. Large quantities of gas may be released during active fermentation.
• Carbonation: Pressurized CO2 is used to achieve and maintain desired carbonation levels in finished beer.
• Draft Beer Systems: CO2 is commonly used to pressurize kegs and dispense beer in taprooms and serving areas.
• Packaging and Processing: CO2 may be used to purge tanks, bottles, cans, and other equipment to reduce oxygen exposure.
• Bulk CO2 Storage: Breweries often store CO2 in bulk tanks or compressed gas cylinders to support production and dispensing operations.

CO2 can escape through tank vents, fittings, regulators, piping, and equipment connections. Fermentation vessels may also release significant amounts of CO2 during normal operation.

Because CO2 is colorless and odorless, elevated concentrations may go unnoticed without appropriate monitoring equipment. CO2 is denser than air and can accumulate in low-lying or poorly ventilated areas, potentially creating hazardous conditions.

What Are the CO2 Monitoring Requirements?

The International Fire Code (IFC) establishes safety requirements for certain CO2 storage and use systems. However, brewery operations can involve different CO2 applications, and the applicable requirements may vary depending on how the gas is produced, stored, and used.

Depending on the applicable code edition, system configuration, and local jurisdiction, safety requirements may include:

• CO2 Detection: Fixed monitoring systems that continuously measure CO2 concentrations in designated areas.
• Audible and Visual Alarms: Devices that alert employees and occupants when CO2 concentrations reach specified alarm thresholds.
• Sensor Placement: CO2 sensors positioned in areas where gas may accumulate, often near the floor for relevant applications.
• Safety Signage: Warning signs identifying CO2 hazards and communicating appropriate safety precautions.
• Ventilation: Mechanical or natural ventilation designed to reduce the risk of dangerous CO2 accumulation.
• Automatic Shutoff Controls: Equipment that can stop the supplied CO2 flow when specified alarm conditions occur.
• Permitting: Construction or operational permits for qualifying CO2 storage and use systems, as determined by the local Authority Having Jurisdiction (AHJ).

Commonly referenced alarm thresholds for certain CO2 storage and use applications include:

CO2 Concentration	Typical Response
5,000 ppm (0.5%)	Supervisory notification
15,000 ppm (1.5%)	Intermediate alarm where configured
30,000 ppm (3.0%)	High-level alarm and occupant warning

These thresholds are not universal requirements for all brewery applications. Fermentation-related hazards, confined spaces, and other industrial processes may require additional protective measures and different system designs.

Even where CO2 monitoring is not explicitly required by local regulations, installing appropriate detection and safety equipment can help reduce the risk of dangerous CO2 exposure.

 

What Does a Brewery CO2 Safety System Typically Include?

A properly designed CO2 safety system helps detect elevated CO2 concentrations and alert employees before conditions become more dangerous.

CO2 Monitors and Sensors

Fixed CO2 monitors continuously measure concentrations in designated areas. Breweries may require multiple sensors to cover fermentation areas, bulk CO2 storage, packaging operations, and draft beer equipment.

Sensor locations should be selected based on potential release points, ventilation, room layout, and applicable safety requirements.

Audible and Visual Alarms

Warning devices notify employees when elevated CO2 concentrations are detected. Alarms may be installed inside and outside affected areas to help prevent employees from entering hazardous spaces.

Safety Signage

Clearly displayed warning signs identify CO2 hazards and communicate safety precautions near storage tanks, fermentation areas, and other designated locations.

Ventilation Systems

Appropriate ventilation helps prevent CO2 accumulation, particularly in enclosed production areas, tank rooms, and other spaces where gas may be released.

Depending on the facility and applicable requirements, ventilation may be connected to CO2 monitoring equipment to activate when elevated concentrations are detected.

Automatic Shutoff Valves

Where appropriate or required, automatic shutoff valves can stop the flow of supplied CO2 when specified alarm conditions occur. These valves do not stop CO2 naturally generated during fermentation.

Power Supervision

Power supervision equipment can provide a trouble notification when electrical power to the CO2 monitoring system is interrupted, helping personnel identify a potential loss of monitoring protection.

The appropriate combination of equipment depends on the brewery's production processes, CO2 sources, facility layout, and applicable safety requirements.

Unique CO2 Safety Considerations for Breweries

Breweries present several safety challenges that differ from traditional restaurants and beverage dispensing facilities.

Fermentation-Generated CO2

During fermentation, yeast produces CO2 that must be safely released or captured.

Unlike pressurized CO2 supplied from a storage tank, fermentation-generated CO2 cannot simply be stopped using an automatic shutoff valve.

Proper ventilation, safe venting arrangements, monitoring, and operating procedures are particularly important in areas where fermentation gas may accumulate.

Confined Spaces and Low-Lying Areas

CO2 can accumulate in fermentation tanks, pits, trenches, cellars, and other enclosed or low-lying spaces.

Employees should never enter tanks or other potentially hazardous confined spaces without following applicable confined-space entry procedures, including atmospheric testing and appropriate safeguards.

Fixed CO2 monitors provide valuable area monitoring but do not replace confined-space atmospheric testing or entry procedures.

Multiple Monitoring Zones

Large breweries may have separate fermentation, packaging, storage, and taproom areas.

Because CO2 release sources and ventilation conditions differ throughout the facility, multiple monitoring zones may be necessary to provide appropriate coverage.

Production and Maintenance Activities

Routine activities such as transferring beer, changing gas cylinders, cleaning tanks, and maintaining equipment can introduce additional opportunities for CO2 exposure.

Employee training, equipment inspections, and safe operating procedures are important parts of reducing these risks.

CO2 Permitting and Inspections

Breweries with qualifying CO2 storage or use systems may need permits and inspections from their local fire department or other governing authority.

The process may involve:

1. Evaluating CO2 storage, production processes, and facility layout.
2. Identifying potential CO2 accumulation areas and appropriate safety equipment.
3. Preparing plans and documentation for the applicable AHJ.
4. Installing or modifying monitoring, ventilation, and other safety systems.
5. Completing required inspections and obtaining approval.

Depending on the facility, additional requirements may apply to compressed gas storage, ventilation, industrial processes, and confined-space operations.

For new breweries or production expansions, evaluating CO2 safety early in the design process can help avoid costly modifications and inspection delays.

Maintaining CO2 Safety Over Time

Installing CO2 monitoring equipment is only one part of maintaining a safe brewery.

Regular inspections, testing, maintenance, and employee training help ensure safety systems continue to function properly.

Recommended practices include:

• Testing CO2 monitors and alarm devices for proper operation.
• Calibrating CO2 sensors according to manufacturer recommendations and applicable requirements.
• Inspecting CO2 tanks, regulators, fittings, and piping for leaks or damage.
• Maintaining appropriate ventilation and verifying that exhaust systems operate as intended.
• Keeping warning signs visible and unobstructed.
• Training employees to recognize CO2 hazards, respond to alarms, and follow safe operating procedures.
• Maintaining records of inspections, testing, calibration, and maintenance.

Where required by the applicable fire code, CO2 detection systems must undergo periodic inspection, testing, and calibration, including annual servicing under applicable IFC provisions.

Even where annual recertification is not explicitly required, routine maintenance remains an important part of maintaining CO2 safety.

How Aerosphere Can Help

Aerosphere provides CO2 monitoring equipment and compliance services for breweries, taprooms, and other commercial facilities.

Whether you're opening a new brewery, expanding production, or evaluating the safety of an existing facility, our team can assist with:

• CO2 monitoring systems and safety equipment
• Site evaluations and system design
• Fire department permitting and coordination
• Professional installation
• Inspection support
• Annual recertification, testing, and maintenance
• Multi-zone CO2 monitoring solutions

Our goal is to help breweries identify potential CO2 hazards, implement appropriate safety measures, and navigate applicable compliance requirements.

Have questions about CO2 monitoring or compliance at your brewery?

Contact Aerosphere to learn more about CO2 monitoring systems, permitting, and compliance services. Or view our industry page for breweries to learn more.