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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.

  • Location
    Frankfort, KY
  • Square Footage
    103,000 s.f.
  • Operational
    17 months
Buffalo Trace Distillery Bottling Facility & Warehouse
Frankfort, KY
103,000 s.f.
17 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.


Explore Services

  • Process & Packaging Systems Engineering

    Civil/Building Engineering

    Mechanical/Electrical Engineering

  • Architecture


    Sustainable Design

  • Pre-Construction



  • Automation & Controls

    Production-First IT



  • Custom equipment Ovens & cookers
    Process skids Batching equipment
    Clean-in-place systems Bioreactors
    Extruders Distributed products
    Mixers & blenders
  • Feasibility Studies


    Incentive Coordination

    Land Acquisition

    Construction Financing

    Build-to-Suit/Sale Leaseback

  • Master Planning

    Front-end Services

    Strategy Consulting

About Gray

Gray is a fully integrated global service provider specializing in engineering, design, construction, digital, equipment manufacturing, and real estate services.