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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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
Roofing | Jan 8, 2024
Researchers devise adaptive roof tile concept that adjusts to ambient temperatures
Scientists at the University of California Santa Barbara published a paper that proposes adaptive roof tile technology that can adjust to ambient temperatures. Using a wax motor, tiles could switch from a heating or cooling state enabling savings on heating and cooling costs.
MFPRO+ News | Jan 4, 2024
Bjarke Ingels's curved residential high-rise will anchor a massive urban regeneration project in Greece
In Athens, Greece, Lamda Development has launched Little Athens, the newest residential neighborhood at the Ellinikon, a multiuse development billed as a smart city. Bjarke Ingels Group's 50-meter Park Rise building will serve as Little Athens’ centerpiece.
MFPRO+ Special Reports | Jan 4, 2024
Top 10 trends in multifamily rental housing
Demographic and economic shifts, along with work and lifestyle changes, have made apartment living preferable for a wider range of buyers and renters. These top 10 trends in multifamily housing come from BD+C's 2023 Multifamily Annual Report.
Giants 400 | Jan 3, 2024
Top 200 Reconstruction Architecture Firms for 2023
Gensler, Stantec, HDR, Corgan, and PBK Architects top BD+C's ranking of the nation's largest building reconstruction/renovation architecture and architecture engineering (AE) firms for 2023, as reported in the 2023 Giants 400 Report.
Designers | Jan 3, 2024
Designing better built environments for a neurodiverse world
For most of human history, design has mostly considered “typical users” who are fully able-bodied without clinical or emotional disabilities. The problem with this approach is that it offers a limited perspective on how space can positively or negatively influence someone based on their physical, mental, and sensory abilities.
Giants 400 | Jan 2, 2024
Top 120 Hotel Architecture Firms for 2023
Gensler, WATG, HKS, DLR Group, and HBG Design top BD+C's ranking of the nation's largest hotel and resort architecture and architecture/engineering (AE) firms for 2023, as reported in Building Design+Construction's 2023 Giants 400 Report.
Resiliency | Jan 2, 2024
Americans are migrating from areas of high flood risk
Americans are abandoning areas of high flood risk in significant numbers, according to research by the First Street Foundation. Climate Abandonment Areas account for more than 818,000 Census Blocks and lost a total of 3.2 million-plus residents due to flooding from 2000 to 2020, the study found.
MFPRO+ News | Jan 2, 2024
New York City will slash regulations on housing projects
New York City Mayor Eric Adams is expected to cut red tape to make it easier and less costly to build housing projects in the city. Adams would exempt projects with fewer than 175 units in low-density residential areas and those with fewer than 250 units in commercial, manufacturing, and medium- and high-density residential areas from environmental review.
Contractors | Dec 22, 2023
DBIA releases two free DEI resources for AEC firms
The Design-Build Institute of America (DBIA) has released two new resources offering guidance and provisions on diversity, equity, and inclusion (DEI) on design-build projects.
MFPRO+ News | Dec 22, 2023
Document offers guidance on heat pump deployment for multifamily housing
ICAST (International Center for Appropriate and Sustainable Technology) has released a resource guide to help multifamily owners and managers, policymakers, utilities, energy efficiency program implementers, and others advance the deployment of VHE heat pump HVAC and water heaters in multifamily housing.