Buffalo Trace Distillery Increased Production 50% in 5 Years

Buffalo Trace Distillery says it is on track to double its bourbon production as progress on its $1.2 billion expansion project continues. Nine years ago, expansion at Buffalo Trace Distillery began to meet growing consumer demand for its products, and to date those efforts have resulted in a 50% increase in whiskey making.  In the coming years that number is projected to double with the completion of Buffalo Trace Distillery's additional still house.

The $1.2 billion expansion encompasses all operations at Buffalo Trace Distillery, starting with a new distribution center and bottling operation in 2015 and 2019. More recently, the Distillery added 14 new barrel warehouses, 12 additional fermenters, additional cookers, a new cooling system and tripled the size of its visitor center. In 2022, Buffalo Trace’s additional dry house, hammer mill, additional still house and wastewater treatment plant have been constructed and will be operational by the end of this year.

The newly constructed still house will begin operating in December 2022 and allows Buffalo Trace to double its production. The second still house is located adjacent to Buffalo Trace’s existing 1930s still house and contains a duplicate still of Buffalo Trace’s existing still, standing 40 feet tall and having the capacity of 60,000 gallons a day.

“We’re finishing the electrical work in the new still house now, and then will move into commissioning it for test runs in the next few weeks. If all goes as planned, we will start production before the end of this year. We are excited to double our distillation capacity so we can bring more bourbons to our fans,” said Harlen Wheatley, master distiller.

Wastewater Treatment:  The wastewater treatment plant will process 1.2 million gallons of water per day. “It’s rare to see this much money invested in a standalone, sophisticated wastewater treatment plant.  I am excited to see its start up because it truly demonstrates Buffalo Trace Distillery’s commitment to protecting the Commonwealth’s water,” said Steve Tolliver, president of Aqua Utility Services, Buffalo Trace Distillery’s regional wastewater operator. The treatment plant will be comprised of a moving bed biofilm reactor, allowing wastewater to be treated efficiently and maintain water quality standards. Wastewater will be treated and disinfected so it’s clean enough to release into the Penitentiary Branch, which leads to the Kentucky River.

Doubling  Production:  When the new still starts next year, it will double the distillery's capacity, says Sara Saunders, vp.  The expansion has already added 200 production-focused jobs and will add 50 more in coming years.