Each year, when the calendar strikes August 25, the operations of Perrault Farms kick into high gear.
For the next 35 days, the Toppenish, Wash., facilities operate around the clock to harvest, dry, bale and chill the hops that will be sold to commercial and craft brewers worldwide.
“It’s a very perishable crop,” says Steve Perrault, president of the fourth-generation family business. “Hops are kind of like a wine grape—when they’re ready, they’re ready, and we need to be very efficient at processing them.”
Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities. The buildings are designed to support maximum productivity during the crop’s brief harvesting season.
A 19,530 square-foot hop kiln building is the first stop for the green hop cones after they are stripped from the vines. In this building, propane furnaces blow hot air on the cones to remove excess moisture. The entire process takes about nine hours, 25 percent faster than at the previous facility.
“We’ve cut down our drying time, which has also reduced our propane use and electricity substantially, so it’s a much more sustainable facility,” Perrault says.
After drying, the cones are transported via conveyor to the adjacent 26,000 square-foot hop baling building, where they begin to cool. Ambient air blows through vented air trenches within the concrete floor slab, reducing cone temperature while eliminating the risk of spontaneous combustion.
A four-foot cupola extending the full length of the building allows the moist, hot air to escape out of the roof.
Next, the hop cones are compressed into 200-pound bales, stacked and transported by conveyor to the building’s refrigerated cold room where the temperature is reduced to 28 degrees Fahrenheit.
A second-story office area and conference room at the center of the building overlooks the baling operations, providing a powerful sales tool. The facility also includes a laboratory used in the business’ hop-breeding program as well as an onsite pilot brewery where new varieties of hops can be tested.
The exteriors of both buildings feature metal panels, reinforced concrete tilt-up panels with exposed aggregate finish, and a standing seam metal roof.
“The panels around the buildings contribute to the architectural design and also protect the structures from damage from forklifts and tractors as they maneuver around the site,” says Steve Young, general manager of Concord Construction, the Star builder in Wapato, Wash., that oversaw construction. “The concrete also adds structural strength to the hop baling building when the hops are cooling.”
Extensive use of metal liner wall panels contributes to the structure’s interior aesthetics, and the interior space also features hot dipped galvanized structural steel on all frames, columns and rafters so they won’t be susceptible to rusting from the excess moisture in the air.
The project also includes a 7,500 square-foot equipment cover building.
Because the new facilities process significantly more hops than the previous ones, Perrault Farms has been able to increase the acreage of crops it plants by more than 30 percent.
The new buildings also accommodate the stricter food safety guidelines required by craft brewers, which typically use fresh hops in their brewing process.
“With the craft brewing industry growing so rapidly, food safety is very important to all of us,” Perrault says.
The new complex has definitely impressed other hop farmers in the Yakima Valley, the largest hops-producing region in the U.S.
“Everybody who has gone through the buildings is amazed; it’s one of the top facilities in the industry right now,” Perrault says. “This is something I had to do for the next generations coming up.”
Project construction was completed in 10 months.
“By going with metal buildings from Star Buildings, it really decreases the construction time, which also makes it more cost-effective,” Young says.
Related Stories
| Dec 1, 2014
9 most controversial buildings ever: ArchDaily report
Inexplicable designs. Questionable functionality. Absurd budgeting. Just plain inappropriate. These are some of the characteristics that distinguish projects that ArchDaily has identified as most controversial in the annals of architecture and construction.
| Dec 1, 2014
Skanska, Foster + Partners team up on development of first commercial 3D concrete printing robot
Skanska will participate in an 18-month program with a consortium of partners to develop a robot capable of printing complex structural components with concrete.
| Dec 1, 2014
How public-private partnerships can help with public building projects
Minimizing lifecycle costs and transferring risk to the private sector are among the benefits to applying the P3 project delivery model on public building projects, according to experts from Skanska USA.
High-rise Construction | Dec 1, 2014
ThyssenKrupp develops world’s first rope-free elevator system
ThyssenKrupp's latest offering, named MULTI, will allow several cabins in the same shaft to move vertically and horizontally.
| Nov 29, 2014
20 tallest towers that were never completed
Remember the Chicago Spire? What about Russia Tower? These are two of the tallest building projects that were started, but never completed, according to the Council on Tall Buildings and Urban Habitat. The CTBUH Research team offers a roundup of the top 20 stalled skyscrapers across the globe.
| Nov 26, 2014
USITT Selects Bahrain National Theatre for Honor Award
The Bahrain National Theatre will be recognized with an Honor Award by the United States Institute for Theatre Technology (USITT) in 2015.
| Nov 26, 2014
How the 'maker culture' brings the power of design to life
Most people affiliate the maker culture with metal working, welding, ceramics, glass blowing, painting, and soldering. But it also includes coding and online content creation, writes Gensler’s Douglas Wittnebel.
| Nov 26, 2014
U.S. Steel decides to stay in Pittsburgh, plans new HQ near Penguins arena
The giant steelmaker has agreed to move into a new headquarters that is slated to be part of a major redevelopment.
Sponsored | | Nov 26, 2014
It’s time to start trusting your employees more
A recent study published in the journal Psychological Science revealed that employees were 26% more satisfied in their roles when they had positions of power. SPONSORED CONTENT
Sponsored | | Nov 26, 2014
What’s in a coating?
A beautiful coating on metal products can make a strong statement, whether used on a high-end commercial project or an industrial building. SPONSORED CONTENT