Despite the widely acknowledged challenges and “headwinds” currently buffeting the broader distilled spirits industry, Lofted Spirits is not merely holding steady—it’s charging forward with an ambitious expansion plan. This decisive move underscores the company’s profound confidence in the long-term vitality of the category and its superior contract bottling and production offerings. As the powerhouse behind the critically acclaimed brands Bardstown Bourbon Company and Green River Distilling Co., and the largest distiller of Kentucky custom contract whiskey, Lofted Spirits has officially broken ground on a sprawling 4,000-square-foot expansion. This monumental project will nearly double the physical footprint of its existing bottling operation, a development that solidly cements the company’s position as the most agile and dependable independent copacker in the Commonwealth of Kentucky.
A Leap in Capacity: Scaling to Meet Global Demand
Lofted Spirits’ current bottling operation already serves a diverse and expansive customer base, spanning a wide array of distilled spirits categories. These include the flagship segment of American Whiskey, alongside Vodka, Rum, sophisticated Cream Liqueurs, and the rapidly growing category of Ready-to-Drink (RTD) beverages. While the existing facility boasts an impressive processing capacity of over 10 million bottles per year, the forthcoming addition is a game-changer. The centerpiece of this expansion is a new, high-capacity, high-speed, small-format line. This cutting-edge addition is projected to catapult the total annual bottling capacity to an astounding over 35 million bottles.
This substantial injection of capacity is specifically designed to address a critical market need, perfectly aligning with data from the International Wine and Spirits Record (IWSR). IWSR reports a significant and sustained increase in consumer demand for smaller, more convenient, and impulse-driven formats. This trend is prominent across multiple crucial channels, including travel retail, product sampling initiatives, and value-focused markets. With this expansion, Lofted Spirits’ technical capabilities will encompass all bottle sizes, ranging from the miniature 50mL up to the large-format 1.75L. Furthermore, the facility will offer virtually limitless customization options for packaging designs, closures, and premium finishes, ensuring every customer’s brand vision can be brought to life with precision.
Commitment to Customers: Investment in Flexibility and Quality
Mark Erwin, CEO of Lofted Spirits, emphasized the strategic rationale behind this significant investment. “This expansion is fundamentally about building long-term, scalable capability for our customers—meaning more capacity, significantly increased speed, and even greater flexibility—all while rigidly maintaining the highest quality standard in the industry,” Erwin stated.
He stressed the company’s foundational ethos: “Our commitment to our customers is absolutely unwavering. We were intentionally built from the ground up as a contract manufacturing facility. We continue to vividly demonstrate our dedication to supporting the ambitions of our customers as a genuine grain-to-glass one-stop-shop for every facet of their production and bottling requirements. At a time when many organizations are exhibiting caution and pulling back on capital expenditure, we are strategically investing to meet this pivotal moment and actively help our customers grow and thrive.”
This commitment is further solidified by Lofted Spirits’ industry-leading status as the only independent copacker in Kentucky to achieve and maintain the rigorous standards of international quality and food safety systems. This prestigious distinction includes both ISO 9001 (Quality Management) and FSSC 22000 (Food Safety System Certification), a level of certification held by only a select handful of operations worldwide.
Operational Excellence: Precision at Every Scale
Justin Willett, VP of Operations, highlighted the unique flexibility the expansion introduces to the company’s service offering. “With this expansion, we become one of the very few independent co-packers capable of handling large-format, large-volume orders with institutional precision, while simultaneously maintaining the meticulous care and attention to detail that allows us to also produce high-touch, premium small runs,” Willett explained. He further emphasized that the new equipment, while technologically advanced, is only one component of their success. “While the equipment is undeniably important, the integrity of our team and our deep bench of technical expertise is what truly delivers consistent excellence for our customers.”
The expansion of the bottling operation builds upon other recent, forward-thinking initiatives at Lofted Spirits. Earlier this year, the company successfully launched its Alternating Proprietorship program. This innovative offering permits brands across all spirits categories to process their products at the Bardstown facility utilizing their own Distilled Spirits Plant (DSP) license. This capability allows customers to fully capitalize on significantly reduced federal excise tax rates provided through the landmark Craft Beverage Modernization Act (CMBA), offering a distinct financial advantage in a competitive market.
A Multimillion-Dollar Commitment to the Community
Lofted Spirits’ current bottling operation is a significant employer, currently supporting 80 dedicated team members. The company anticipates adding an additional 5-6 roles as the newly expanded facility scales up its operations to full capacity. The 4,000-square-foot expansion represents a multimillion-dollar investment, a tangible reinforcement of Lofted Spirits’ long-term, unwavering commitment to the local community of Bardstown and the wider Kentucky spirits landscape.
In synergy with its continually growing portfolio of internal brands and immersive consumer experiences, this considerable investment firmly underscores Lofted Spirits’ ambitious goal: to lead the next decade of American Whiskey production and bottling.
Construction is currently progressing rapidly, with the expanded bottling operation projected to be fully operational early in the second quarter of 2026. The comprehensive design and precision engineering for the expanded facility are being executed by the highly skilled internal team at Lofted Spirits. The construction itself is being expertly carried out by industry-veterans, Buzick Construction, ensuring the project is executed to the highest standards.
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