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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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
| May 30, 2013
5 tips for running a successful BIM coordination meeting
BIM modeling tools are great, but if you can't run efficient, productive coordination meetings, the Building Team will never realize the benefits of true BIM coordination. Here are some helpful tips for making the most of coordination meetings.
| May 29, 2013
Realtors report positive trends in commercial real estate market
Realtors who practice commercial real estate have reported an increase in annual gross income for the third year in a row, signaling the market is on the road to recovery.
| May 29, 2013
6 award-winning library projects
The Anacostia Neighborhood Library in Washington, D.C., and the renovation of Cass Gilbert’s grand Beaux-Arts library in St. Louis are among six projects to be named 2013 AIA/ALA Library Building Award winners.
| May 28, 2013
LED lighting's risks and rewards
LED lighting technology provides unique advantages, but it’s also important to understand its limitations for optimized application.
| May 28, 2013
Minneapolis transit hub will double as cultural center [slideshow]
The Building Team for the Interchange project in downtown Minneapolis is employing the principles of "open transit" design to create a station that is one part transit, one part cultural icon.
| May 24, 2013
James Turrell's art installation turns Guggenheim Museum into 'skyspace'
James Turrell, an artist whose projects are more properly defined as "light sculptures," will have a major installation at the Guggenheim Museum this summer, turning Frank Lloyd Wright's famed serpentine atrium into a show of shifting colors and textures. The site-specific project, Aten Reign, will run from June 21 to September 25.
| May 24, 2013
First look: Revised plan for Amazon's Seattle HQ and 'biodome'
NBBJ has released renderings of a revised plan for Amazon's new three-block headquarters in Seattle. The proposal would replace a previously approved six-story office building with a three-unit "biodome."
| May 23, 2013
Supertall 'Sky City' will house 4,400 families in Changsha, China
Broad Sustainable Building has completed a long and arduous approval process, and is starting excavation and construction on Sky City in June, 2013. The proposed "world's tallest building" will be a mixed-use project that could accommodate life and work needs of up to 30,000 people.
| May 23, 2013
Are design-build contracts killing small architecture firms?
Are federal design-build contract laws unfair to small firms? AIA thinks so, citing an interesting fact: an architecture firm spends a median of $260,000 to compete for a design-build project.