From Bottleneck to Batch Control: How BevPro Solutions Uses In-House Cannabinoid Testing to Keep Hemp Beverage Production Moving
The Customer
Company: BevPro Solutions
Location: Texas, US
Operation: Canned hemp beverage co-manufacturing and production
Technology: LightLab 3 BEV Cannabis Analyzer by Orange Photonics
Primary Use Cases: Raw material verification / pre-packaging dosage verification
Secondary Use Cases: Product development
For a hemp beverage co-manufacturer, production efficiency largely depends on how quickly a product can be batched and packaged. Every day a finished beverage remains in a tank awaiting dosage verification is a day that production capacity cannot be used for the next job. For Texas-based beverage co-manufacturer BevPro Solutions, waiting on outside analytical laboratories meant production delays and, ultimately, lost income.
BevPro specializes exclusively in the co-manufacture of canned beverages and has been producing hemp-derived THC beverages for nearly six years. Its production operation includes seven 2,000-gallon tanks, with typical batch sizes ranging from 1,500 to 2,000 gallons. Over time, one operational limitation became increasingly difficult to ignore:
BevPro needed a faster way to independently verify potency and keep production moving.
The Challenge
Production Decisions Depended Exclusively on Outside Data
Before bringing LightLab 3 BEV Cannabis Analyzer onsite, BevPro had no practical way to independently verify cannabinoid potency during production. The company relied largely on information supplied by emulsion providers or customers to determine how much cannabinoid ingredient should be added to a batch to reach a specific dosage.
That created two related challenges:
1. Incoming emulsions did not always perform exactly as expected.
Small discrepancies could develop between supplied specifications and the material received at BevPro. For a manufacturer responsible for producing beverages to defined potency targets, even relatively small differences matter.
2. Outside testing could introduce significant delays into the manufacturing process.
John Culp, Founder & Owner of BevPro Solutions, recalled one customer workflow in which the team would batch a beverage, send a tank sample to an outside laboratory, and wait for approval before packaging. That could leave a production tank occupied for two additional days while the company waited for results. Only after receiving verification could BevPro package the beverage.
For a co-manufacturer, idle tank time directly affects production capacity and revenue. As Culp explains, “We don’t make money until product leaves. So, the faster we can get product out of the tank and the faster we can rotate tanks, the better”
BevPro needed faster access to reliable potency data to keep production moving, improve tank utilization, and maximize revenue.
The Solution
Bringing Cannabinoid Verification In-House with LightLab
BevPro Solutions implemented LightLab 3 BEV Cannabis Analyzer to give its production team the ability to verify cannabinoid potency onsite instead of relying exclusively on information supplied by outside parties. LightLab became part of BevPro’s existing internal quality-control environment.
The goal was not to replace required third-party compliance testing, but to answer critical quality questions before and during production:
- Does the incoming cannabinoid emulsion match expectations?
- Does the formulation need to be adjusted before batching?
- Is the finished batch within BevPro’s target range?
- Can the team confidently move the product into packaging?
Culp summarized the original challenge simply:
“We didn’t have a way to verify anything.”
With LightLab onsite, they do.
The Workflow
How BevPro Uses LightLab During Beverage Production
BevPro uses LightLab at key decision points before and during batching.
Verify Incoming Cannabinoid Emulsions
Before batching, the team tests incoming raw materials, including nano-emulsions, to confirm potency.
BevPro has observed small discrepancies in incoming materials due to factors such as degradation over time, transportation conditions, and heat. Testing before production allows the team to account for those differences before an entire batch is made. As Culp explains, “We’ll test before we’re ready to batch, and then we can adjust our formula for emulsion amounts.”
Finished Batch Dosing Verification
Once a beverage has been batched, BevPro tests it in the tank to confirm that cannabinoid potency is within the intended target range. The team regularly monitors Delta-9 THC, CBD, and CBG as part of this process.
If the batch is off target, the team can make the necessary adjustment while the product is still in the tank and retest before packaging. If the batch is where it needs to be, they can move directly into packaging rather than holding the tank while waiting for an outside potency result.
This helps BevPro keep tanks turning, maintain production efficiency, and move product through the facility more quickly.
The Results
Greater Control. Greater Efficiency. Greater Business Impact.
By bringing cannabinoid verification onsite, BevPro has gained greater control over its production process and reduced the delays and uncertainty that previously came with relying on outside data.
The results include:
1. Greater confidence in formulations, improved dosage consistency, and less rework
Access to real-time, internal data, allows the team at BevPro to begin the production of every batch with confidence. By identifying potency discrepancies early and making adjustments before or during batching, BevPro is better able to keep finished beverage dosages on target, avoiding costly or time-consuming rework later in the process.
2. Increased production capacity and increased revenue opportunity
The team can verify the dosage of finished batches in-house and move product into packaging sooner rather than waiting on outside potency results. Faster tank turnover frees up production tanks for the next batch sooner. This allows BevPro to make better use of existing equipment and produce more within the same operating footprint.
For BevPro, the operational gains translate into financial returns. Culp confirmed, “LightLab is making us money.”
Faster access to reliable potency data means greater control over product quality, more efficient use of production capacity, and a direct impact on the bottom line.
The Added Value
Support Beyond Standard Testing
BevPro also produces its own hemp-derived beverage line, Mid, with multiple dosage options, including a 50 mg beverage that pushed beyond the range of many typical cannabinoid drinks.
When the team encountered a testing challenge with that higher-potency product, Orange Photonics worked directly with BevPro to identify the issue and establish the appropriate testing parameters.
For BevPro, that support extends the value of LightLab beyond the analyzer itself. When the team moves into higher-potency or unfamiliar testing scenarios, Orange Photonics is available to troubleshoot, guide the process, and help keep testing on track.
The Customer Perspective
Confidence Through Independent Verification
For BevPro Solutions, LightLab provides confidence by giving the team direct access to real-time, in-house potency data. Instead of relying solely on supplier specifications, customer information, or outside testing, BevPro can independently verify results throughout production and move forward with greater certainty.
“We have to hit a mark. LightLab lets us know we’re going to be where we need to be.” — John Culp, Founder & Owner, BevPro Solutions
Frequently Asked Questions
Why test cannabinoid emulsions before making a hemp beverage batch?
Testing confirms the potency of the ingredient actually entering production. BevPro Solutions uses LightLab to check incoming emulsions and adjust ingredient amounts before batching, reducing the risk of off-target beverages.
When should a hemp beverage manufacturer verify finished-batch potency?
Verify potency while the beverage is still in the tank, before packaging. BevPro tests completed batches, adjusts those outside its target range, and retests before canning.
How can in-house potency testing improve beverage production capacity?
Faster potency verification frees tanks for subsequent batches. BevPro previously experienced two-day tank holds awaiting outside results; onsite testing helps move beverages into packaging sooner.
Which cannabinoids does BevPro monitor during beverage production?
BevPro regularly monitors delta-9 THC, CBD, and CBG using the LightLab 3 BEV Cannabis Analyzer to check finished beverages against intended potency targets.
Does BevPro use LightLab to replace required third-party compliance testing?
No. BevPro uses LightLab for internal quality control, including ingredient verification and pre-packaging dosage checks.
