ABOUT THIS PROJECT
Brown-Forman Corporation needed a state-of-the-art cooperage facility to support its growing whiskey production while optimizing efficiency, sustainability, and worker safety.
Luckett & Farley designed a new cooperage plant for Brown-Forman Corporation in Decatur, AL, featuring a 156,000 SF manufacturing space and an 11,400 SF modern office area. The facility includes an environmentally controlled toasting room, boiler room, shipping docks, and a dedicated shipping office to support operations. The plant processes white oak staves, which are raised into barrels before undergoing a specialized toasting and charring process to enhance the whiskey’s flavor and color. Once prepared, steel hoops are fitted, and lids—manufactured on a separate line—are secured to complete the barrels. Luckett & Farley designed the structural and utilities infrastructure to support these critical processes, along with an extensive sawdust collection and disposal system and several wood drying kilns to optimize production efficiency.
The office area features executive offices, conference rooms, a training room, an employee cafeteria, a security office, restrooms, a touring room, and locker rooms. Luckett & Farley also provided interior design and furniture selections, ensuring a modern and functional workspace. The building envelope consists of structural steel framing with open web joists and trusses, exterior insulated steel wall panels with interior liner panels, and a roof system featuring metal decking, rigid insulation, and a white PVC membrane to enhance energy efficiency by increasing reflectivity and reducing energy loads.
The mechanical and HVAC systems include rooftop air handling units and a boiler plant that generates steam for the on-site wood drying kilns. While air conditioning was not included, sufficient air exchanges ensure proper ventilation and worker comfort. A steel trestle system supports piping and conduits between the boiler plant and kilns. The electrical system required coordination with utility providers to bring power and telecommunication services to the site. Power distribution included main switchgear, multiple distribution panels, motor control centers, and lighting systems, along with an arc flash study to ensure electrical safety.
The 60-acre greenfield site was developed to accommodate the facility, including the extension of utilities from the entrance road, a carefully planned site layout, and traffic circulation strategies to separate truck and passenger vehicle movement. Additional site improvements included paving, drainage systems, stave storage areas, and kilns, requiring extensive coordination with local utility companies and regulatory authorities.
Luckett & Farley provided full architecture and engineering (A/E) services with an in-house team, allowing for seamless coordination between disciplines and minimizing field conflicts. By utilizing BIM technologies, potential system interferences were resolved during the design phase, ensuring a smooth construction process and on-time project delivery.