Efficient Plant April 2018 - 23
feature | plant profile
something that just happens overnight. It's a stepby-step-by-step process."
Four Roses is currently in the final stages of the expansion, scheduled to be completed in September
2018. The first phase involved adding a new maintenance shop, boiler, and grain-milling system.
Phase 2 began with installation of a new grain
unloading area, updated foundation and structure
for the fermentation room, a fermenting addition,
then relocating the current beer still and installing
a new still. It also included installing a new doubler
and byproducts system. In this phase, the company
additionally installed a new water-treatment system, cooker, chilled-water plant, and a byproducts
Phase 3, which will be completed in the first half
of 2018, includes installation of the fermenters and
getting them operational. Three new yeast tubs
will be installed, along with the piping for the new
cooker, still, and doubler. Since doubling capacity
is the goal, another new cooker and beer still with
doublers are part of the phase, along with more
yeast tubs. An advanced-design separation centrifuge system will also be installed. The number
of fermenters has been doubled and new cooling
plant and byproduct processing area installed.
Phase 4 is the expansion of the Cox's Creek
warehouse, on a separate site, to provide additional
storage capacity. That phase will be completed in
the second half of 2018.
To accomplish all of this, careful planning was
crucial, Goodlett said. One key element is an
annual summer shutdown that usually lasts six to
"We have scheduled downtime every summer
for a couple months," he said. "It's obviously going
to be challenging, but we will use this scheduled
downtime wisely. This year, we added an extra
month, so this will help us get all the preventive
maintenance accomplished so we can have smooth
operations when we move to doubled capacity."
Four Roses worked with Louisville, KY, firms
Vitok Engineering Inc. (vitok.com), and Joseph
& Joseph Architects (josephandjoseph.net), to
help plan the expansion. The space planning was
accomplished using CAD designs that helped
simplify piping modifications required to fit all the
new equipment into the existing distillery. "We are
moving things around in order to make it work,"
Reorganizing the existing plant, along with
making the most of the space, made sense for the
company, according to chief operating officer Ryan
In addition to implementing several
electrical improvements, the distillery's automation level is increasing.
When finished, the operation will be
80% to 90% automated.