Each year, when the calendar strikes August 25, the operations of Perrault Farms kick into high gear.Â
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. Â Â
“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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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.  Â
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. Â Â
“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.Â
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.Â
Â
Â
A four-foot cupola extending the full length of the building allows the moist, hot air to escape out of the roof.Â
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.Â
The exteriors of both buildings feature metal panels, reinforced concrete tilt-up panels with exposed aggregate finish, and a standing seam metal roof. Â
“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.”Â
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.Â
The project also includes a 7,500 square-foot equipment cover building.Â
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.Â
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.Â
“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.”Â
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
| Aug 26, 2014
Ranked: Top industrial sector AEC firms [2014 Giants 300 Report]
Stantec, Jacobs, and Turner top BD+C's rankings of the nation's largest industrial sector design and construction firms, as reported in the 2014 Giants 300 Report.
| Aug 26, 2014
High-rise concept uses 'sky street' to link towers [slideshow]
The design for a new complex in Shenzhen’s bay area consists of highly reflective glass towers, expansive garden space, and a horizontal glass structure that connects the buildings.
| Aug 25, 2014
Restoration of quake-ravaged Atascadero City Hall affirms city’s strength [2014 Reconstruction Awards]
The landmark city hall was severely damaged by the San Simeon earthquake in 2003. Reconstruction renewed the building’s stability, restored its exterior, and improved the functionality of the interior.Â
| Aug 25, 2014
Ranked: Top cultural facility sector AEC firms [2014 Giants 300 Report]
Arup, Gensler, and Turner head BD+C's rankings of design and construction firms with the most revenue from cultural facility projects, as reported in the 2014 Giants 300 Report.
| Aug 25, 2014
Tall wood buildings: Surveying the early innovators
Timber has been largely abandoned as a structural solution in taller buildings during the last century, in favor of concrete and steel. Perkins+Will's Rebecca Holt writes about the firm's work in surveying the burgeoning tall wood buildings sector.
| Aug 25, 2014
'Vanity space' makes up large percentage of world's tallest buildings [infographic]
Large portions of some skyscrapers are useless space used to artificially enhance their height, according to the Council on Tall Buildings and Urban Habitat.
| Aug 25, 2014
Photographer creates time-lapse video of 1 WTC using 30,000 photos
Choosing from 30,000 photos he took from the day construction began in 2006 to the day when construction was finished in 2012, Brooklyn-based photographer Benjamin Rosamund compressed 1,100 photos to create the two-minute video.
| Aug 25, 2014
Glazing plays key role in reinventing stairway design
Within the architectural community, a movement called "active design" seeks to convert barren and unappealing stairwells originally conceived as emergency contingencies into well-designed architectural focal points. SPONSORED CONTENT
| Aug 25, 2014
An easy trick for minimizing construction delays
About one out of every three construction projects is behind schedule or over budget, according to the Construction Industry Institute's Assessment of Owner Project Management Practices and Performance survey. SPONSORED CONTENT
| Aug 22, 2014
Before & After: Hospital upgrade shows shifting needs in healthcare construction
Community Hospice of Northeast Florida took an outdated 10-bed inpatient hospice unit and created a space that would meet the needs of patients receiving end of life care by creating a place that felt like home.