Bardstown Bourbon Company, based in Bardstown, Kentucky, known as the "Bourbon Capital of the World," has recently completed its largest distillery expansion to date. The project, valued at $28 million, significantly increases the distillery’s production capacity and incorporates a number of sustainable initiatives. This major expansion is part of the company’s ongoing commitment to environmental stewardship, product quality, and operational growth.
Image credit: Bardstown Bourbon Company
Massive Capacity Increase
Since its inception in 2016, Bardstown Bourbon Company has been steadily expanding. Initially, the company was producing 25,000 barrels of bourbon annually. With the recent expansion, the distillery now has the ability to roll out 289,000 barrels each year—an impressive leap that cements Bardstown Bourbon’s position as a major player in the bourbon industry.
The distillery's property, originally situated on 100 acres of farmland, has now expanded to 400 acres. A second distillery has been added, which includes state-of-the-art facilities such as three column stills, 48 fermentation tanks, aging warehouses, and a cutting-edge bottling and logistics center. The warehouses alone are capable of holding nearly two million barrels of bourbon.
The expansion is not just for the production of Bardstown Bourbon’s own brand. It also accommodates over 300 custom distillation and bottling partners, making Bardstown Bourbon Company a key collaborator in the broader whiskey market.
Sustainability and Environmental Commitment
Image credit: Bardstown Bourbon Company
One of the key aspects of the expansion is Bardstown Bourbon Company’s focus on sustainability. The company has implemented several eco-friendly measures that aim to reduce its environmental impact while supporting its growth.
In recent years, the company has successfully cut energy consumption by 30%, even as production has nearly doubled. This reduction in energy use is largely due to an innovative system that captures and redeploys heat generated during distillation, reducing the need for additional energy input. In recognition of these efforts, Bardstown Bourbon Company was one of just eight distilleries nationwide to receive the inaugural Energy Star certification for distilleries from the U.S. Environmental Protection Agency (EPA) in 2023.
Water conservation is another area where Bardstown Bourbon is making strides. The distillery purifies and recycles 90% of the water used in its operations, which is then reused for processes like cleaning, cooling, and irrigation. This has allowed the company to expand production without putting strain on Bardstown’s local water resources.
Looking ahead, Bardstown Bourbon Company plans to further its sustainability efforts over the next three years. These initiatives include exploring alternative solutions for managing spent grain, optimizing fertilization processes, and investing in solar energy to reduce its carbon footprint even more.
The Bardstown Approach to Bourbon Making
Since its inception, Bardstown Bourbon Company has been a disruptor in the industry. The company prides itself on combining cutting-edge technology with traditional bourbon-making techniques to produce consistently high-quality whiskey. According to CEO Mark Erwin, Bardstown Bourbon’s success is driven by its commitment to innovation, excellence, and the customer experience.
The distillery’s production process is meticulously controlled, with over 500 checkpoints throughout production, allowing for unparalleled customization and quality management. This proprietary distillery management system gives Bardstown Bourbon a competitive edge, as it can precisely control every aspect of the bourbon-making process, ensuring that each batch meets the highest standards.
With certifications like Energy Star, ISO 9001 (which recognizes quality management systems), and FSSC 22000 (for food safety standards), Bardstown Bourbon has set a new benchmark for the bourbon industry. The distillery's focus on both quality and sustainability is a model for other bourbon producers, as it highlights how environmental responsibility and business growth can go hand in hand.
Economic Impact and Job Creation
In addition to increasing its production capacity and implementing sustainability initiatives, Bardstown Bourbon Company’s expansion has a positive economic impact. The project has brought 29 new jobs to the distillery, contributing to the local economy and providing new opportunities for the community. The new hires will help support the expanded operations, which include not only increased production but also enhanced logistics, bottling, and warehouse management.
Looking to the Future
As Bardstown Bourbon Company continues to grow, the company’s leadership remains committed to pushing the boundaries of what is possible in the spirits industry. CEO Mark Erwin stated, “We revolutionized the bourbon industry when we started operations in 2016 and we haven’t stopped growing since." He emphasized that the company is dedicated to delivering the highest-quality whiskey to its customers, both through its own brand and its custom distilling services.
With further expansion and sustainability initiatives on the horizon, Bardstown Bourbon Company shows no signs of slowing down. The distillery’s motto, "Never Stand Still," reflects its ambition to continue innovating and growing while maintaining a strong commitment to environmental stewardship and product excellence.
In conclusion, Bardstown Bourbon Company’s recent expansion marks a major milestone in the company’s history. With increased production capacity, cutting-edge technology, a deep commitment to sustainability, and a focus on delivering the best customer experience, Bardstown Bourbon is positioned to remain a leader in the bourbon industry for years to come.
About Bardstown Bourbon Company
Bardstown Bourbon Company is a dynamic and innovative distillery located in the heart of Kentucky’s bourbon country. Founded in 2014 in Bardstown, Kentucky—the “Bourbon Capital of the World”—the distillery has quickly gained a reputation for its modern approach to whiskey-making while honoring the rich traditions of the region. Bardstown Bourbon Company is known for its blend of classic craftsmanship and forward-thinking innovation, offering a unique experience in the world of American whiskey.
One of the key features that sets Bardstown Bourbon Company apart is its focus on transparency and collaboration. The distillery has a custom distillation program, producing whiskey for a wide array of brands in addition to its own labels. Through this program, they partner with both established and emerging brands, offering custom mash bills, aging processes, and even blending services. This collaborative approach has helped Bardstown Bourbon Company become a significant player in the industry, blending tradition with new ideas.
The distillery’s own portfolio includes several well-regarded expressions, with a focus on small-batch, high-quality products. The Bardstown Fusion Series blends sourced aged bourbon with younger bourbon distilled in-house, creating a layered and balanced whiskey that showcases the company’s blending expertise. The Discovery Series, on the other hand, features premium blends of older sourced bourbons, highlighting complex and sophisticated flavor profiles. Additionally, Bardstown Bourbon Company offers limited releases that often experiment with cask finishes, blending techniques, and unique flavor combinations.
Bardstown Bourbon Company is also renowned for its state-of-the-art facility, which combines the elegance of a modern distillery with an open, visitor-friendly atmosphere. The campus includes a large, visually striking distillery, rickhouses for aging whiskey, and an award-winning restaurant and bar. The restaurant, known as “The Kitchen & Bar at Bardstown Bourbon Company,” has become a destination in itself, offering farm-to-table cuisine paired with bourbon experiences.
In addition to producing high-quality whiskey, Bardstown Bourbon Company is a leader in bourbon tourism and education. They offer comprehensive tours, tastings, and interactive experiences that allow visitors to learn about the bourbon-making process from start to finish. This focus on transparency and engagement with visitors has helped the company build a loyal following among whiskey enthusiasts.
Overall, Bardstown Bourbon Company is a standout in the modern bourbon landscape. With its innovative collaborations, commitment to quality, and inviting visitor experience, the distillery represents a blend of tradition and contemporary vision, making it a key player in the ongoing evolution of Kentucky bourbon.