Buffalo Trace Distillery Bottling Facility & Warehouse
Accommodating the Bourbon Boom.
Buffalo Trace Distillery has been making whiskey for more than 200 years, making it the oldest continuously operating distillery in America. Sazerac, the parent company of Buffalo Trace, and Gray have partnered on multiple projects including a new distribution warehouse facility for Buffalo Trace Distillery and Buffalo Trace Distillery Mash House. In order to accommodate more visitors and future growth in the company, Buffalo Trace selected Gray to expand and relocate the existing bottling hall to another area on its campus.
- LocationFrankfort, KY
- Square Footage103,000 s.f.
- Operational17 months
A former distribution center is now a new bottling hall with two additional buildings that include a packaging/process area, warehouse area, lab, and office area.
Some critical factors on this project included reducing product loss, improving operability and maintenance of the process, and maintaining the historic nature of the site.
The project included tilt-up concrete walls with brick veneer embeds. The site team executed multiple crane picks for these as well as for roof top units within tight quarters of very old existing buildings. Additionally, working on an over 200-year-old facility presented a challenge because even the most recent drawings did not provide an accurate visual. Gray utilized a Ground-Penetrating Radar (GPR) for better visualization, and in some instances, brought in a hydro excavator to avoid any ground disturbances.
Process & Packaging Systems Engineering
Automation & Controls
Custom equipment Ovens & cookers Process skids Batching equipment Clean-in-place systems Bioreactors Extruders Distributed products Mixers & blenders
The mash house is the heart of the bourbon process; the place where the cooking of the grains takes place and the “bourbon” begins to take shape. After nearly 75 years since it was built, Buffalo Trace Distillery determined its original mash house needed a renovation.
Buffalo Trace Distillery has been making whiskey for more than 200 years, earning it the reputation of being the oldest continuously operating distillery in America. Sazerac, the parent company of Buffalo Trace, and Gray have partnered on multiple projects including the Buffalo Trace Distillery Bottling Facility & Warehouse and Buffalo Trace Distillery Mash House. This project for the partners involved the design and build of a new 84,267 s.f. distribution facility for Buffalo Trace Distillery.