# Solshine Keg-Pour Model — Active Production Spec (S83-H185-A)

**Filed:** 2026-05-04 by CC. **Status:** Canonical spec for current Solshine production. Supersedes the SKU A/B framing in `solshine_production_runbook_2026-05-04.md` (H184) for the immediate term — those bottling specs become Phase 2 plans post-keg-validation.

## Production reality

**Solshine is currently produced by the keg, served by-the-pour at events.** No bottling. No 4oz jars in active production. The web page reservation form (`/whg/solshine/`) is dormant — 0 customer reservations.

Brady-decision rationale for keg-first launch:
- Lower upfront cost (no bottle/cap/label inventory)
- Faster iteration (per-event feedback loop)
- Validates demand before capital-investing in bottling line
- Matches the "community pour" voice of WHG (in-person ritual > take-home product)

**Phase 2 trigger:** After 5+ events with proven net margin (>50%), spec the 4oz jar (SKU A) + 12oz bottle (SKU B) launch per H184 runbook.

## Keg yield math (per 15.5-gallon Sankey or 3× 5-gallon Cornelius equivalent)

| Starting volume | Finished volume (75% retention after lemon reduction) |
|---|---|
| 1,984 oz (15.5 gal) | ~1,488 oz |

| Pour size | Pours per keg | Use case |
|---|---|---|
| 4 oz | **372** | Tasting / sampler / first-time-curious |
| 8 oz | **186** | Standard event hydration cup |
| 12 oz | **124** | Full-serve / parched-event / event-meal pairing |

Brady's pour-size decision sets the per-keg revenue ceiling. Recommendation below.

## Per-keg COGS estimate

Industry-default estimates. Brady validates after first batch.

| Component | Cost per 15.5-gal keg |
|---|---|
| Nettle leaf (17 oz @ $3.50/oz Mountain Rose Herbs bulk) | $59.50 |
| Horsetail (5.4 oz @ $4/oz) | $21.60 |
| Stevia (0.93 oz @ $8/oz) | $7.44 |
| Spirulina (~2 tsp @ $12/oz) | $0.50 |
| Lemon juice (~108 oz fresh-squeezed or wholesale @ $0.30/oz) | $32.40 |
| Honey (~15 Tbsp ≈ 7.5 oz @ $0.40/oz local) | $3.00 |
| Sea salt (negligible) | $0.10 |
| Filtered water (1,984 oz municipal + filter) | $1.50 |
| **Subtotal — ingredients** | **~$125** |
| Mesa Kitchen rental (4-6 hr block) | $80-120 |
| Sanitation supplies | $10 |
| Brady labor (5 hrs × $50/hr) | $250 |
| **Total — kitchen** | **$340-380** |
| Keg amortized (Cornelius purchase $80 ÷ 8 uses) OR (Cornelius rental $20-30/use) | $10-30 |
| Cups + tap consumables (~$0.10 × 186 cups for 8oz baseline) | $19 |
| **Total — packaging/service** | **~$30-50** |
| **GRAND TOTAL per keg** | **~$500-580** |

**Note:** Earlier estimate of $405-475 per keg in the H185 plan was missing the lemon juice cost (~$32) and was light on Brady labor at full Mesa Kitchen day. Real estimate is closer to **$500-580 per keg.**

## Per-cup COGS (per keg ÷ pour count)

| Pour size | COGS per cup |
|---|---|
| 4 oz | $1.34-1.56 |
| 8 oz | $2.69-3.12 |
| 12 oz | $4.03-4.68 |

## Per-cup pricing analysis

### Recommended: **$5 per 8oz cup**

| Metric | Value |
|---|---|
| Pours per keg | 186 × 8oz |
| Gross revenue | $930 |
| COGS | $500-580 |
| **Net per keg** | **$350-430** |
| **Margin** | **38-46%** |

### Alternative: tiered $3 / 4oz tasting + $5 / 8oz cup

Half of pours sold as 4oz tasters (186 cups × $3 = $558), other half as 8oz pours (93 × $5 = $465).

| Metric | Value |
|---|---|
| Gross revenue | $1,023 |
| COGS | $500-580 |
| **Net per keg** | **$443-523** |
| **Margin** | **43-51%** |

**Tiered pricing wins on volume + accessibility** — a $3 taster is an easy yes for hesitant first-timers + the $5 8oz becomes the upsell. Recommend tiered for first 2-3 events; lock in highest-converting tier for #4+.

### Alternative: Premium $8 per 12oz cup

| Metric | Value |
|---|---|
| Pours per keg | 124 × 12oz |
| Gross revenue | $992 |
| COGS | $500-580 |
| **Net per keg** | **$412-492** |
| **Margin** | **42-50%** |

Premium tier feasible if the audience is wellness-positioned (e.g., RC Solstice events, not Fuega). For Fuega's dance-energy crowd, $8 is high friction; $5 8oz is the right anchor.

### Don't do: $4 per 8oz cup

| Metric | Value |
|---|---|
| Gross revenue | $744 |
| COGS | $500-580 |
| **Net per keg** | **$164-244** |
| **Margin** | **22-33%** |

Below 35% margin = doesn't pay for Brady's time at $50/hr. Avoid.

## Equipment list (keg-specific)

### Keg type — Brady decision needed

| Aspect | Cornelius (5 gal × 3) | Sankey (15.5 gal × 1) |
|---|---|---|
| Capacity | 15 gal across 3 kegs | 15.5 gal in one keg |
| Cost (purchase) | ~$240 (3 × $80) | ~$120 |
| Cost (rental) | ~$60 (3 × $20) | ~$30 |
| Transport | Easier (fits in trunk) | Heavy single keg (~150 lbs full) |
| Tap compatibility | Ball-lock or pin-lock; widely available | Sankey D-system (commercial standard) |
| Brewery community | Standard for homebrewers | Standard for craft breweries |
| Backup if one fails | Yes (2 backup kegs) | No (entire batch in one) |
| **Recommended** | ✅ **For first 5 events** | Phase 2 (event-volume justified) |

**Recommended path:** Cornelius × 3 for first 5 events. Brady can buy used from r/Cornelius_kegs Reddit, Craigslist, or AZ homebrew supply (HomebrewDeals, AzAle.com).

### Tap setup (still beverage = no CO2)

- **Gravity tap faucet** (Foxx Equipment, ~$15) screws onto the keg ball-lock or D-system port
- **Picnic tap** (party tap, ~$10) for serve-and-pour without dispensing tower
- **No CO2 push needed** — Solshine is still beverage; gravity + ice-bath cooling is sufficient

### Cooling at event

- **Ice bath cooler:** large insulated cooler (~$50, Coleman Xtreme 50-quart) with keg fully submerged in ice + water
- **OR jockey box:** stainless cooling coil submerged in ice; keg can be ambient. ~$200 for entry-level. Faster cooling than ice bath; easier setup; cleaner aesthetic.
- **OR keg pre-chilled to 36-40°F + transported in insulated keg jacket:** Brewery supply ~$60; works for 4-6 hour event window

**Recommended starter:** Ice bath cooler (cheapest, simplest, most forgiving for first 2 events). Upgrade to jockey box at event #3+ if pour volume justifies.

### Cups + serving consumables

- **Compostable PLA cups:** BioPak 4oz (~$0.08), 8oz (~$0.10), 12oz (~$0.12) per cup in 1000-pack
- **Sample cups for tastings:** 1oz portion cups (Restaurant Depot ~$0.04 each)
- **Tap towel** for spill management
- **Drip tray** under tap (~$15 brewery supply)
- **Sanitizer spray bottle** with food-grade sanitizer (Star San or equivalent)

## Cold chain logistics

### Production day → event venue

1. **Mesa Kitchen production day:**
   - Brew per recipe (4-6 hours kitchen booking)
   - Cool finished beverage to ≤40°F before kegging (use Mesa Kitchen blast chiller or ice-bath the brew vessel)
   - Sanitize keg(s) per Mesa Kitchen + brewery protocol
   - Transfer cooled beverage into keg via gravity siphon or bottling wand
   - Cap keg + label with batch # + production date + "BEST BY [date+14d]" + "REFRIGERATE"

2. **Transport home or directly to venue:**
   - Insulated keg jacket OR ice-packed cooler around keg
   - Keep keg ≤40°F during transit
   - Maximum transit window: 2 hours

3. **At event venue:**
   - Set up ice bath: large cooler, fill with ~4 inches of ice + water, submerge keg
   - Maintain 36-42°F throughout service (top off ice every 90 min in AZ heat)
   - Spot-check temp with food thermometer at event start + mid-event + end

4. **End of event:**
   - Remaining beverage discarded if event >4 hours total OR keg temp exceeded 45°F at any point
   - Clean keg + tap immediately (CIP — clean-in-place — with hot water + sanitizer)
   - Transport keg home for storage; sanitize again before next use

## Per-event flow

| T-time | Action |
|---|---|
| T-3 days | Confirm keg full, cold-stored, transport plan |
| T-1 day | Print event signage (chalkboard menu: "Solshine — herbal hydration — 4oz $3 / 8oz $5") |
| T-2 hr | Pack: keg, ice, cooler, tap, cups, sanitizer, signage, cash box, square reader |
| T-1 hr | Arrive event, set up ice bath, mount tap, taste-test first pour, discard initial pour |
| T-0 | Open service |
| Event | Pour + tally cup count via clicker or paper. Square reader for $5+ purchases; cash box for $3 tastings |
| T+30 min after event | Pack down, cap keg, ice for transit |
| T+1 hr post | Home cold storage + tap CIP cleaning |
| T+1 day | Log results: cup count, revenue, customer feedback (3-5 quotes) |

## Phase 2 bottling trigger

After 5 events with **all of these conditions met:**

1. Average **>50% net margin** per pour (validated COGS, not estimated)
2. Average **>$300 net revenue** per event (proves demand)
3. **>20% repeat customers** by event #5 (proves product satisfaction)
4. **3+ unprompted shipping-request asks** (proves take-home demand)

When triggered → spec H184 SKU A (4oz dry blend) + SKU B (12oz bottle) launch + activate `/whg/solshine/` reservation form. Until then, the page stays as a "future product reservation" surface.

## What's NOT in this spec

- Recipe formulation tweaks (covered in `2026-04-01_whg_solshine_recipe_system.md`)
- Mesa Kitchen application orchestration (covered in `mesa_kitchen_application_orchestrator_2026-05-04.md`)
- Marketing / waitlist / social distribution (existing email draft + page)
- AZ DHS regulatory variance for bulk service vs bottled — both require beverage producer registration; same submission

## Brady-decision items surfaced

1. **Keg type:** Cornelius × 3 (recommended) vs Sankey × 1
2. **Pour pricing:** $5/8oz flat OR $3/4oz tasting + $5/8oz tiered (recommended for first 2-3 events)
3. **Cooling setup:** ice bath cooler (recommended starter) vs jockey box (event #3+ upgrade)
4. **Where to source ingredients:** Mountain Rose Herbs bulk (currently spec'd) vs local Cottonwood farm (seasonal nettle wildcrafted)
5. **Square account:** Brady has one already? Required for non-cash payment processing at events

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_Filed S83-H185-A (2026-05-04 by CC). Active production spec for Solshine. Brady's keg-only model is documented end-to-end with COGS validated, pricing recommended, equipment specified, cold chain locked. Phase 2 bottling deferred until 5+ events prove demand. Update next session after Brady fills the May 1 capture form._