Trying to predict how many barrels of bourbon and rye whiskey you are going to sell 10 years from now is like trying to predict the price of gold. You can look at historical data, market trends, consumer sentiment but at the end of the day someone must predict what the sweet spot will be for inventory 10 or even 25 years from now.
When it comes to Buffalo Trace Distillery in Frankfort, Kentucky, home to Eagle Rare, E.H. Taylor, Jr., George T. Stagg, W.L. Weller, Blanton’s, Pappy Van Winkle and other brands, they stared into their crystal ball 10 years ago and made a $1.2 billion (yes, billion with a B) bet to expand production. After a decade of non-stop construction, renovations, artic winters, a landslide, and two historic floods, this project is finally complete. And now for the first time in recent memory both retailers and consumers are starting to see the fruits of that investment. Bourbon fans that take a tour of the distillery or just visit the gift shop are starting to see brands like Eagle Rare, Blanton’s and E.H. Taylor show up on the retail shelf more and more frequently. Now if you visit on the day of a special release you’ll still see thousands (literally) of people waiting in line hoping to get their hands on a limited-edition bottle but overall availability is definitely improving.
Q: How Long Does it Take to Make a Million Barrels of Bourbon?
A: In 2008 it Took 27 Years – In 2025 it Took Less Than 3 Years
Making good bourbon and rye whiskey takes time. As the demand for bourbon and rye whiskey has ebbed and flowed over the last century, the time to make a million barrels has changed as well. When Sazerac acquired what is now known as Buffalo Trace Distillery in 1992 the number of employees had dwindled down to 50. According to Jake Wenz, Sazerac Company, President and CEO when production began on the 7 millionth barrel, about 11 years ago, the distillery had grown to 350 employees. Today that number has more than doubled to over 800 people.
So, how long does it take to fill a million barrels of bourbon and rye whiskey? Back in 2008, Buffalo Trace Distillery celebrated their 6 millionth barrel since Prohibition. At that time, it took 27 years to make a million barrels of bourbon. This year, when Buffalo Trace Distillery celebrated filling their 9 millionth barrel it took less than three years. That is quite a testament the success of their massive investment that now allows them to run two 84” wide by 40’ tall Vendome Copper & Brass Works column stills 24×7 since February 2023.
Related Story – The Complete Buffalo Trace Distillery Timeline – 1773 to Today
Buffalo Trace Master Distiller Harlen Wheatley Celebrates Filling 9 Million Barrels
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“The filling of our nine millionth barrel represents a historic chapter in the Distillery’s story, which began more than two centuries ago and is still being written today,” said Harlen Wheatley, Buffalo Trace Distillery Master Distiller. “This milestone is exciting not just because we are producing more whiskey than ever before, but because every barrel filled ensures that generations to come will be able to enjoy the same quality and craftsmanship that has defined the Distillery since the 1850’s.”
Bourbon distilling at the site now known as Buffalo Trace Distillery dates back to the 1770s, with formal operations beginning in the 1850s. During Prohibition, the George T. Stagg Distillery (as it was then known) remained one of the few allowed to produce whiskey for medicinal purposes, but official barrel counting began in 1933. Since then, the Distillery has celebrated multiple millionth barrel milestones. Take a look at the chart below and you can see the amount of time it took for each millionth barrel.
| No. Barrels | Fill Date | Years Between Million | Distillery Name |
|---|---|---|---|
| 1,000,000* | July 2, 1942 | 9 | Ancient Age Distilling Co. |
| 2,000,000 | June 20, 1953 | 11 | Ancient Age Distilling Co. |
| 3,000,000 | May 29, 1961 | 8 | Ancient Age Distilling Co. |
| 4,000,000 | October 21, 1971 | 10 | Ancient Age Distilling Co. |
| 5,000,000 | March 4, 1981 | 10 | Ancient Age Distilling Co. |
| 6,000,000 | May 14, 2008 | 27 | Buffalo Trace Distillery |
| 7,000,000 | April 11, 2018 | 10 | Buffalo Trace Distillery |
| 8,000,000 | November 29, 2022 | 4 | Buffalo Trace Distillery |
| 9,000,000 | August 13, 2025 | 3 | Buffalo Trace Distillery |
| 10,000,000** | September 1, 2027 | 2 Yrs, 1 Month | Buffalo Trace Distillery |
“Since official barrel counting began in 1933, each millionth barrel milestone has marked more than just a number: they stand as symbols of heritage, resilience and the timeless pursuit of excellence in bourbon,” said Wheatley. “The Distillery’s resilience was proven once again during the historic flood this past April which touched 90% of the campus. I’m proud of the team for their hard work to ensure Buffalo Trace recovered quickly – after just a few short months we’re 100% back open, operational and welcoming visitors.”
How Did Buffalo Trace Distillery Make a Million Barrels So Fast?
While each millionth barrel reflects centuries of dedication to quality and tradition, the nine millionth marks a particularly significant chapter in Buffalo Trace Distillery’s history. Since the $1.2 billion expansion project began in 2015 it touched nearly every facet of operations – from a new distribution center, bottling operation, upgraded cistern room and new boiler, dry, mill and still houses to 20 new fermentation tanks, three steam boilers and 19 new aging warehouses. Completed in January 2025, the project has increased the distillery’s production capacity by 150%.
“We are proud to be the birthplace of bourbon, and celebrations like this one remind us that our signature industry is as strong as ever,” said Kentucky Lieutenant Governor Jacqueline Coleman. “Buffalo Trace Distillery not only preserves centuries of craftsmanship, but also drives jobs, tourism, and opportunity for families here in Franklin County and across the Commonwealth. Thank you to the leaders at Buffalo Trace for their continued commitment to the Commonwealth and our people.”
What Happens to Each Millionth Barrel?
The 9 millionth barrel is now aging in Buffalo Trace Distillery’s Warehouse V, the world’s only bonded single barrel warehouse, where it will age until the filling of the ten millionth barrel. At that time, the 9 millionth barrel will be moved to another rickhouse until it reaches full maturity in eight and 10 years. Distillery visitors are welcome to view the barrel inside Warehouse V during regular business hours and capture photos of this piece of bourbon history.
Buffalo Trace Distillery has a deep commitment to supporting charitable initiatives. Bottles of bourbon from the 6 millionth barrel were made available to nonprofit organizations for fundraising. At last count proceeds from the 6 millionth barrel have raised over one million dollars.
A ceremony celebrating this historic milestone was held on Monday, September 29. On hand to mark the occasion was Kentucky Lieutenant Governor Jacqueline Coleman, Franklin County Judge Executive Michael Mueller, Frankfort Mayor Layne Wilkerson and Buffalo Trace Distillery officials, including third generation team member Freddie Johnson whose family has been involved in every millionth barrel since 1942.
Buffalo Trace Distillery is an American family-owned company based in Frankfort, Kentucky. The distillery’s rich tradition dates back to 1775 and it is a National Historic Landmark, as well as listed on the National Register of Historic Places. Its history includes such legends as E.H. Taylor, Jr., George T. Stagg, Albert B. Blanton, Orville Schupp, and Elmer T. Lee.
Related Stories
- The Complete Buffalo Trace Distillery Timeline – 1773 to Today
- Buffalo Trace Rolls Out 8 Millionth Barrel – Freddie Johnson’s Family Has Touched Every Millionth Since Prohibition [Infographic]
- Buffalo Trace Distillery Celebrates the Filling of its 7 Millionth Barrel – Honors Family Tradition [Video]
- Sazerac Co. Announces $600 Million Expansion – Largest Distilled Spirits-Related Investment in Kentucky’s History
- Buffalo Trace Distillery Production up 50% as $1.2 Billion Expansion Continues – Capacity to Double to 2,000+ Barrels/Day by Year End
Learn more about Buffalo Trace Distillery.
View all Frankfort Distilleries.
View all Kentucky Distilleries.
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Buffalo Trace Distillery Millionth Barrel Timeline [Infographic]
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