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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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
| Jan 19, 2011
Biomedical research center in Texas to foster scientific collaboration
The new Health and Biomedical Sciences Center at the University of Houston will facilitate interaction between scientists in a 167,000-sf, six-story research facility. The center will bring together researchers from many of the school’s departments to collaborate on interdisciplinary projects. The facility also will feature an ambulatory surgery center for the College of Optometry, the first of its kind for an optometry school. Boston-based firms Shepley Bulfinch and Bailey Architects designed the project.
| Jan 19, 2011
San Diego casino renovations upgrade gaming and entertainment
The Sycuan Casino in San Diego will get an update with a $27 million, 245,000-sf renovation. Hnedak Bobo Group, Memphis, Tenn., and Cleo Design, Las Vegas, drew design inspiration from the historic culture of the Sycuan tribe and the desert landscape, creating a more open space with better circulation. Renovation highlights include a new “waterless” water entry feature and new sports bar and grill, plus updates to gaming, poker, off-track-betting, retail, and bingo areas. The local office of San Francisco-based Swinerton Builders will provide construction services.
| Jan 19, 2011
Extended stay hotel aims to provide comfort of home
Housing development company Campus Apartments broke ground on a new extended stay hotel that will serve the medical and academic facilities in Philadelphia’s University City, including the University of Pennsylvania and the Children’s Hospital of Philadelphia. The 11,000-sf hotel will operate under Hilton’s Homewood Suites brand, with 136 suites with full kitchens and dining and work areas. A part of the city’s EnergyWorks loan program, the project aims for LEED with a green roof, low-flow fixtures, and onsite stormwater management. Local firms Alesker & Dundon Architects and GC L.F. Driscoll Co. complete the Building Team.
| Jan 19, 2011
New Fort Hood hospital will replace aging medical center
The Army Corps of Engineers selected London-based Balfour Beatty and St. Louis-based McCarthy to provide design-build services for the Fort Hood Replacement Hospital in Texas, a $503 million, 944,000-sf complex partially funded by the American Recovery and Reinvestment Act. The firm plans to use BIM for the project, which will include outpatient clinics, an ambulance garage, a central utility plant, and three parking structures. Texas firms HKS Architects and Wingler & Sharp will participate as design partners. The project seeks LEED Gold.
| Jan 19, 2011
Museum design integrates Greek history and architecture
Construction is under way in Chicago on the National Hellenic Museum, the nation’s first museum devoted to Greek history and culture. RTKL designed the 40,000-sf limestone and glass building to include such historic references as the covered walkway of classical architecture and the natural wood accents of Byzantine monasteries. The museum will include a research library and oral history center, plus a 3,600-sf rooftop terrace featuring three gardens. The project seeks LEED Silver.
| Jan 19, 2011
Architecture Billings Index jumped more than 2 points in December
On the heels of its highest mark since 2007, the Architecture Billings Index jumped more than two points in December. The American Institute of Architects reported the December ABI score was 54.2, up from a reading of 52.0 the previous month.
| Jan 19, 2011
Large-Scale Concrete Reconstruction Solid Thinking
Driven by both current economic conditions and sustainable building trends, Building Teams are looking more and more to retrofits and reconstruction as the most viable alternative to new construction. In that context, large-scale concrete restoration projects are playing an important role within this growing specialty.
| Jan 10, 2011
Architect Jean Nouvel designs an island near Paris
Abandoned by carmaker Renault almost 20 years ago, Seguin Island in Boulogne-Billancourt, France, is being renewed by architect Jean Nouvel. Plans for the 300,000-square-meter project includes a mix of culture, commerce, urban parks, and gardens, which officials hope will attract both Parisians and tourists.
| Jan 10, 2011
Michael J. Alter, president of The Alter Group: ‘There’s a significant pent-up demand for projects’
Michael J. Alter, president of The Alter Group, a national corporate real estate development firm headquartered in Skokie, Ill., on the growth of urban centers, project financing, and what clients are saying about sustainability.