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Buffalo Trace Distillery Mash House

Heart of the Bourbon Business.

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.

In Numbers

  • Frankfort, KY
  • 12000 s.f.
    Square Footage
  • 17 months
Buffalo Trace Distillery Mash House
Frankfort, KY
12000 s.f.
17 months

Innovative Technology Upgrades


Continuing a partnership of more than five years, Gray and Buffalo Trace teamed-up to renovate the mash house and construct a 4-story process building attached to the existing facility. The mash house project doubles Buffalo Trace Distillery’s capacity by focusing on a complete technology upgrade, including new process controls and automation.


The new facility includes state-of-the-art corn meal dust collection system to reduce debris and danger. The new system contains spark detection in the dust collection ducts and fast-acting gate valves that close instantly to isolate the bins and fire suppression cannons that activate in the duct. A new screw auger distribution system was integrated to move the meal to the cookers.


With the facility located directly on the Kentucky River, Gray utilized both a river barge operation to expand the structure and a tower crane to remove existing equipment through the roof before installing new process equipment and piping. Gray installed 216, 52’ deep micropiles on the bank of the Kentucky River as a part of this project.


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