Lofted Spirits to triple bottling output with site expansion
Kentucky-based Lofted Spirits will expand its main facility in Bardstown next year, nearly doubling its footprint while also tripling bottle capacity.
Lofted Spirits produces and owns both Bardstown Bourbon Company and Green River Distilling Co, which were united under a single name in March this year.
The company also runs a contract distilling operation, Lofted Custom Spirits, supporting clients for other distilled spirits categories such as American whiskey, vodka, rum, cream liqueur and ready-to-drink. It is the number one producer of Kentucky custom contract whiskey.
At present, its facility in Bardstown processes more than 10 million bottles a year, but with a 4,000 square-foot expansion boost, the annual amount is expected to jump to 35m.
A key part of the expansion is a new high-capacity, high-speed, small-format line, which can bottle sizes from 50ml to 1.75 litres, with ‘limitless customisation’ for packages, closures and finishes.
Beyond Bourbon, the company noted that the line’s implementation fills increasing demand for convenience and impulse formats in channels such as sampling and travel retail.
The Bardstown facility currently has 80 employees, but five or six roles are expected to be brought in for the expansion.
The project is described as a ‘multi-million dollar investment that reinforces Lofted Spirits’ long-term commitment to Bardstown and the broader Kentucky spirits community’.
Its design and engineering is led by the internal team at Lofted Spirits, while construction is handled by Buzick Construction.
Construction is already underway with it expected to be fully operational by the second quarter of 2026.
Building long-term capability
Mark Erwin, CEO of Lofted Spirits, said: “This expansion is about building long-term capability for our customers – more capacity, more speed, and even more flexibility – while maintaining the highest quality standard in the industry.
“Our commitment to our customers is unwavering. We were built as a contract manufacturing facility and we continue to demonstrate our dedication to supporting the ambitions of our customers as a grain to glass one-stop-shop for all of their production and bottling needs.
“While many organisations are pulling back, we are investing to meet the moment and help our customers grow.”
Many American distilleries have paused production this year, including Diageo’s Balcones and George Dickel sites. Kansas-based MGP Ingredients has also scaled down production.
In spite of the headwinds that the US distilled spirits industry is dealing with, Lofted Spirts noted the expansion demonstrates its confidence in the category and its contract offering.
Lofted Spirits’ Bardstown site is recognised with ISO 9001 and FSSC 22000 distinctions and claims to be the only independent co-packer in Kentucky that meets these international quality and food safety standards.
Earlier in the year, Lofted Spirits launched an Alternating Proprietorship programme that helps its partner brands get their own DSP (Designated Premises Supervisor) license at the facility, and therefore unlock ‘significantly reduced excise tax rates’ through the Craft Beverage Modernization Act (CMBA).
The company’s vice-president of operations, Justin Willett, added: “With this expansion, we are one of the few independent co-packers that handle large format, large volume orders with precision, while maintaining the care and attention to detail that also allows us to produce high-touch small runs.
“While the equipment is important, the team’s integrity and deep bench of expertise is what truly delivers for our customers.”
In other news from the company this year, Dan Callaway was named master blender for Bardstown Bourbon and Green River Distilling Co, as well as for Lofted Custom Spirits.
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