Diageo Lebanon Distillery
Carbon Neutral Distillery.
Diageo is among the world’s largest spirits producers, and when the company decided to build a new distillery in Kentucky, it turned to Gray as its design-build partner for the project.
Leveraging its deep industry experience and resources, Gray integrated complete turnkey solutions for the customer’s bourbon distillery, dried grain facility, and barrel-aging warehouses within the state-of-the-art operation. The complex features an automated distillery process—including granary, mash cooking, fermentation distillation, and barrel filling processes—and an annual production capacity of 10 million proof gallons.
Gray scope included full architectural and MEP design as well as construction for the distillery and seven barrel-aging warehouses. Gray’s onsite technical team handled coordination of all building trades with mechanical, electrical, and equipment installation subcontractors.
Gray provided automation & controls for the project, including I/O panels and PLC coding for the distillery process. As the process integrator for the Diageo Lebanon Distillery project, Gray was responsible for the development of the mass and energy balances, PFD and P&ID, equipment general arrangements and stack-ups, process equipment procurement, and vendor management. Rounding out its robust service offering, Gray provided manufacturing network architecture design, installation, and integration with the business LAN.
The new facility will bring more than 30 full-time jobs to the area. Even more impressive, the facility is completely carbon neutral, powered by 100% renewable electricity throughout the cooking, distillation, and dry house processes.
“Gray is proud to play a role in the carbon neutral efforts happening at the Diageo Lebanon facility,” said Stephen Gray, president and CEO of Gray. “Diageo’s commitment to sustainability will no doubt impact and challenge the industry toward advancement.”
Process & Packaging Systems Engineering
Automation & Controls
Custom equipment Ovens & cookers Process skids Batching equipment Clean-in-place systems Bioreactors Extruders Distributed products Mixers & blenders
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.
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.
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.