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Perrault commissioned new metal buildings to replace the business’ previous cramped and outdated facilities.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
University Buildings | Jan 30, 2023
How wellness is reshaping college recreation centers
Moody Nolan, a specialist in the design of college recreation centers, has participated in the evolution toward wellness on college campuses.
Mass Timber | Jan 30, 2023
Net-positive, mass timber building will promote research on planetary well-being in Barcelona
ZGF Architects, along with Barcelona-based firms MIRAG and Double Twist, have designed a net-positive, mass timber center for research on planetary well-being. Located in Barcelona, the Mercat del Peix Research Center will bring together global experts in the experimental sciences, social sciences, and humanities to address challenges related to the future of the planet.
AEC Tech | Jan 27, 2023
Epic Games' latest foray into the AEC market and real estate industry
From architecture to real estate, the realm of computer-aided design hits new heights as more and more firms utilize the power of Epic Games’ Twinmotion and Unreal Engine.
University Buildings | Jan 27, 2023
Ozarks Technical Community College's advanced manufacturing center is first-of-a-kind in region
The new Robert W. Plaster Center for Advanced Manufacturing at Ozarks Technical Community College in Springfield, Mo., is a first-of-a-kind educational asset in the region. The 125,000-sf facility will educate and train a new generation in high tech, clean manufacturing and fabrication.
Mass Timber | Jan 27, 2023
How to set up your next mass timber construction project for success
XL Construction co-founder Dave Beck shares important preconstruction steps for designing and building mass timber buildings.
Sports and Recreational Facilities | Jan 26, 2023
Miami’s motorsport ‘country club’ to build sleek events center
Designed by renowned Italian design firm Pininfarina and with Revuelta as architect, The Event Campus at The Concours Club will be the first and only motorsport-based event campus located within minutes of a major metro area.
Student Housing | Jan 26, 2023
6 ways 'choice architecture' enhances student well-being in residence halls
The environments we build and inhabit shape our lives and the choices we make. NAC Architecture's Lauren Scranton shares six strategies for enhancing well-being in residence halls.
K-12 Schools | Jan 25, 2023
As gun incidents grow, schools have beefed up security significantly in recent years
Recently released federal data shows that U.S. schools have significantly raised security measures in recent years. About two-thirds of public schools now control access to school grounds—not just the building—up from about half in the 2017-18 school year.
AEC Tech Innovation | Jan 24, 2023
ConTech investment weathered last year’s shaky economy
Investment in construction technology (ConTech) hit $5.38 billion last year (less than a 1% falloff compared to 2021) from 228 deals, according to CEMEX Ventures’ estimates. The firm announced its top 50 construction technology startups of 2023.
Sports and Recreational Facilities | Jan 24, 2023
Nashville boasts the largest soccer-specific stadium in the U.S. and Canada
At 30,105 seats and 530,000 sf, GEODIS Park, which opened in 2022, is the largest soccer-specific stadium in the U.S. and Canada. Created by design firms Populous and HASTINGS in collaboration with the Metro Nashville Sports Authority, GEODIS Park serves as the home of the Nashville Soccer Club as well as a venue for performances and events.