Bardstown Bourbon doubles capacity with distillery expansion

Expanded capacity and resource conservation positions the organization for next phase of growth

In 2014, Bardstown Bourbon Co. began construction on 100 acres of farmland in the Bourbon Capital of the World. Today, ten years later, Bardstown Bourbon announces the completion of its most significant expansion to date, which pushes the organization’s capacity to more than 18 million proof gallons while focusing on conserving natural resources.

The expansion brings online a complete second distillery to the now 400-acre property. The campus boasts three column stills and 48 fermentation tanks, a state-of-the-art bottling and logistics facility and aging warehouses accommodating nearly 2 million barrels. In addition to growing capacity for the Bardstown Bourbon Co.’s award-winning owned brand, the growth supports the needs of more than 300 custom distillation and bottling partners. 

Initially producing just 25,000 barrels a year, today the company can roll out 289,000 barrels annually. 

“Bardstown Bourbon Co. revolutionized the bourbon industry when we started operations in 2016 and we haven’t stopped growing since,” said CEO Mark Erwin. “This most recent expansion is the latest proof point in our commitment to deliver the highest quality, most consistent whiskey available to custom distilling customers in Kentucky. We have the track record, the team and the ability to continue investing in our business to provide the best customer experience available anywhere.”

The company’s proprietary distillery management system allows control and customization of more than 500 points of production, giving insight into every part of the process from grain to glass. With decades of technical expertise combined with Energy Star certification, ISO 9001 certification in quality management standards and FSSC 22000 certification in food safety, Bardstown Bourbon has created a new standard for whiskey production.

Sustainability initiatives to reduce water, energy key part of growth plan

The distillery expansion also included significant investment in equipment, processes and people that materially reduce waste and environmental impact.

Though capacity has nearly doubled over the same period, Bardstown Bourbon today uses 30 percent less energy than it did in 2018 by capturing and redeploying the heat produced by distillation. In November 2023, it was one of just eight distilleries nationally to earn the EPA’s first-ever ENERGY STAR certified distilleries award for meeting strict energy performance standards.  

Simultaneously, Bardstown Bourbon has focused on water conservation, purifying and recycling 90 percent of the distillery’s operational water for reuse throughout the property for cleaning, cooling and irrigation. The efforts have allowed Bardstown Bourbon Company to complete expansion without taxing the city’s water supply.

Over the next three years, Bardstown Bourbon Company will implement additional energy and resource conserving initiatives including non-traditional solutions to spent grain, fertilization, and solar that will expand the organizations commitment to thoughtful growth while continuing to provide unmatched customer outcomes. 

“We truly have the best team in the spirits industry – committed to pushing the category forward through thoughtful innovation, technical prowess and sustainable growth,” said Erwin. “With even more expansion and growth on the horizon, Bardstown Bourbon Co. remains true to our promise to Never Stand Still.”