Sean Costigan & Matt Blofield Method Brewing: From a Post-COVID Dream to a Newcastle Icon. Discover How They Scaled to 80,000L a Year with Smart Financing, Bold Branding, and a Community Built on Passion for Fresh Beer. (Episode 8 - Sean & Matt Blofield)

1. What was your background before you came into Method Brewing?

Sean Costigan began brewing in 2012, starting at a homebrew shop—ironically, now home to Method Brewing. He later joined Murray’s Brewery, spending eight years there and serving as Head Brewer for half that time. After leaving in 2020, he briefly ran his own house-painting business before returning to his true passion—beer.
Matt Blofield, a qualified builder with experience in construction and mining, transitioned into brewing at Hope Estate Brewery, starting on the packaging line. He completed his brewing diploma there and later used his building expertise to help construct Method Brewing from the ground up while balancing new fatherhood.

2. How did the concept come together of saying, hey, let’s do something?

Matt Blofield and Sean Costigan shared that the idea for Method Brewing started casually—just friends chatting over beers on Gav’s back deck, wondering if they could one day start their own brewery. Matt and Gav had been discussing it for nearly two years, inspired by trips to breweries in Marrickville, believing they could build something similar. At that time, Matt was just entering the brewing industry while Sean was leaving Murray’s. Eventually, they realized that if they didn’t take the leap together, they’d always wonder “what if.” Pooling their complementary skills, shared vision, and limited resources, the three partners—Matt, Sean, and Gav—decided to turn the idea into a real business.

3. How did you fund the business when you were getting it off the ground?

Matt Blofield and Sean Costigan explained that Method Brewing was built on a tight, self-funded budget. The three partners—Matt, Sean, and Gav—decided not to bring in outside investors or risk their homes. Instead, they pooled personal savings and took out small personal loans, carefully managing every expense. A major help was equipment financing, which allowed them to secure their brewing system without heavy upfront costs—the equipment itself acted as collateral. They emphasized that timing was key; during the brewing boom, lenders were more open to funding small breweries. Their goal was simple: grow sustainably while keeping full ownership and financial safety.

4. How do you run your business? Who manages the back end — finances, wages, expenses, etc.?

Matt Blofield and Sean Costigan said that running Method Brewing has been a process of learning and adapting. While they had a business plan, their exact roles evolved naturally based on each person’s strengths. Sean handles most of the administration, including emails, finances, compliance, and bookkeeping, while Matt focuses on brewing operations and production. Their third partner, Gav, originally worked full-time in the brewery but later returned to his paramedic job to support his growing family and provide extra income for the business. They also rely on an accountant and occasional external reviews to ensure financial compliance and maintain smooth operations.

5. What sort of brew house do you have, what capacity, and why did you choose that type?

Sean Costigan explained they operate a 10-hectoliter, three-vessel brew house from Brutique, supplied by Neil Cameron. It’s a gas-fired system capable of double batching in around 9–10 hours, making it efficient for their production scale. They later invested in a Thermal Craft automation system from Melbourne, improving temperature precision, mash consistency, and brewing accuracy. Sean said the system allows them to focus on quality and repeatability while keeping operations manageable for a small team.

6. How important is consistency as a local brewpub?

Both founders stressed that consistency is everything. With a loyal local following, many customers return for the same beer every visit—especially their flagship Hazy Pale Ale. Matt Blofield said automation helps hit targets precisely, while Sean Costigan emphasized that reliable processes build customer trust. They agreed that pre-COVID, inconsistency was more forgiving, but now people expect every pint to taste just as good as the last, making repeatability central to their success.

7. What does success look like in your eyes with your business?

For Matt and Sean, success means running a sustainable, lifestyle-friendly brewery rather than chasing mass production. They define it as being commercially viable, maintaining consistent beer quality, and having a steady flow of locals through their taproom. Long-term, they want to spend more time with family and less time tied to day-to-day operations—delegating routine work while continuing to create great beer and community experiences. Success, to them, is about balance, quality, and freedom.

8. If you had your time all over again, would you do it again?

Both Matt Blofield and Sean Costigan said “absolutely, yes.” Despite the sleepless nights, long hours, and challenges of building during post-COVID uncertainty, they wouldn’t change a thing. Matt juggled fatherhood and construction during the build, while Sean managed operations and brewing, yet both found the journey deeply rewarding. They’re proud of creating something lasting and personal—saying they’d “never work for anyone else again.