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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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
| Aug 11, 2010
PCA partners with MIT on concrete research center
MIT today announced the creation of the Concrete Sustainability Hub, a research center established at MIT in collaboration with the Portland Cement Association (PCA) and Ready Mixed Concrete (RMC) Research & Education Foundation.
| Aug 11, 2010
Study explains the financial value of green commercial buildings
Green building may be booming, especially in the Northwest, but the claims made for high-performance buildings have been slow to gain traction in the financial community. Appraisers, lenders, investors and brokers have found it difficult to confirm the value of high-performance green features and related savings. A new study of office buildings identifies how high-performance green features and systems can increase the value of commercial buildings.
| Aug 11, 2010
Architecture Billings Index flat in May, according to AIA
After a slight decline in April, the Architecture Billings Index was up a tenth of a point to 42.9 in May. As a leading economic indicator of construction activity, the ABI reflects the approximate nine to twelve month lag time between architecture billings and construction spending. Any score above 50 indicates an increase in billings.
| Aug 11, 2010
Architecture Billings Index drops to lowest level since June
Another stall in the recovery for the construction industry as the Architecture Billings Index (ABI) dropped to its lowest level since June. The American Institute of Architects (AIA) reported the August ABI rating was 41.7, down slightly from 43.1 in July. This score indicates a decline in demand for design services (any score above 50 indicates an increase in billings).
| Aug 11, 2010
RTKL names Lance Josal president and CEO
Lance K. Josal FAIA has been named President and CEO of RTKL Associates Inc., the international planning, design and engineering firm. Josal succeeds RTKL’s current President and CEO, David C. Hudson AIA, who is retiring from the firm. The changes will take effect on 1 September 2009.
| Aug 11, 2010
Balfour Beatty agrees to acquire Parsons Brinckerhoff for $626 million
Balfour Beatty, the international engineering, construction, investment and services group, has agreed to acquire Parsons Brinckerhoff for $626 million. Balfour Beatty executives believe the merger will be a major step forward in accomplishing a number of Balfour Beatty’s objectives, including establishing a global professional services business of scale, creating a leading position in U.S. civil infrastructure, particularly in the transportation sector, and enhancing its global reach.
| Aug 11, 2010
Construction unemployment rises to 17.1% as another 64,000 construction workers are laid off in September
The national unemployment rate for the construction industry rose to 17.1 percent as another 64,000 construction workers lost their jobs in September, according to an analysis of new employment data released today. With 80 percent of layoffs occurring in nonresidential construction, Ken Simonson, chief economist for the Associated General Contractors of America, said the decline in nonresidential construction has eclipsed housing’s problems.
| Aug 11, 2010
Billings at U.S. architecture firms exceeds $40 billion annually
In the three-year period leading up to the current recession, gross billings at U.S. architecture firms increased nearly $16 billion from 2005 and totaled $44.3 billion in 2008. This equates to 54 percent growth over the three-year period with annual growth of about 16 percent. These findings are from the American Institute of Architects (AIA) Business of Architecture: AIA Survey Report on Firm Characteristics.