Buffalo Trace Distillery has finally completed its $1.2 billion expansion, which began in 2015. This project has significantly increased whiskey production capacity, with the addition of a new still house that doubles distillation to 120,000 gallons per day. The expansion includes new barrel warehouses, fermenters, cookers, and a state-of-the-art wastewater treatment facility. In 2025, the distillery aims to fill its 9 millionth barrel, marking a significant milestone in its growth. The expansion has also added hundreds of jobs, solidifying Buffalo Trace’s position as a major bourbon producer.
At the beginning of the year 2025, Buffalo Trace marked the filling its nine millionth barrel of whiskey, which is pretty astounding considering that there are just over 14 million barrels total ageing in Kentucky. The distillery was producing 200,000 barrels of bourbon a year with 400 employees when the project began and is now filling 500,000 with double the amount of workers. That’s thanks to a new still house that was completed in 2022, eight new 95,000-gallon fermenters, a new boiler house, 19 new rickhouses for maturing barrels, and other less sexy things like new bottling operations, distribution centre, and cookers.
This means more Buffalo Trace Bourbon whiskey, along with the likes of E.H. Taylor, Jr., George T. Stagg, and other members of the Buffalo Trace Antique Collection. Maybe some more Eagle Rare and Blanton’s. Hopefully some of this allocation will come to Malta. All of our supply over the last few years has been taken up rather (too) quickly and Bourbon lovers are unfortunately sometimes left wanting this product in Malta.
During Buffalo Trace’s $1.2 billion expansion, several advanced technologies were introduced to enhance whiskey production and sustainability. Key innovations include:
– Duplicate Still and Still-house: A new 40-foot-tall still, identical to the existing one, was installed to double production capacity to 60,000 gallons per day while maintaining consistency in whiskey quality.
– Advanced Wastewater Treatment Plant: A state-of-the-art facility processes 1.2 million gallons of water daily using a moving bed biofilm reactor, ensuring environmental compliance and water quality
– Modernised Equipment: New 93,000-gallon fermenters, 22-foot-tall cookers spanning three floors, and a dry house capable of producing 12,000 pounds of dried grain per hour were added.
These upgrades reflect a commitment to innovation and sustainability.
Since most Buffalo Trace bourbons require 8–10 years of ageing, the increased production will take time to translate into greater availability on store shelves. Despite record production levels, demand continues to outpace supply due to the bourbon boom. Buffalo Trace remains committed to quality and refuses to cut corners, ensuring that future availability matches its high standards.
Buffalo trace is owned by the Sazerac Company, who also produce Paddy Irish Whiskey and Fireball Cinnamon & Whisky Liqueur as well as a few wines.
References :
https://www.buffalotracedistillery.com/visit-us/whiskey-supply-expansion.html
https://robbreport.com/food-drink/spirits/buffalo-trace-distillery-expansion-completed-1236150444/
https://vinepair.com/booze-news/buffalo-trace-expansion-complete/
https://www.youtube.com/watch?v=mIuMtFoJ-Mc
