Build to barrel: Inside Holladay Distillery’s ironclad plan to boost bourbon production by one-third

WESTON, Missouri — Holladay Distillery is breaking ground with Rickhouse D — its first new barrel-aging warehouse in 75 years — marking a major step in expanding bourbon production from the historic plant.

Holladay Distillery officials join representatives of St. Joseph-based Al J. Mueller for a groundbreaking event earlier this year at the site of Rickhouse D at Holladay Distillery; courtesy photo

Renowned as the only Missouri operation to age bourbon in ironclad rickhouses, Weston-based Holladay Distillery is increasing capacity to meet surging demand, said Mick Harris.

“We’re proud to continue making Missouri history by expanding our capacity to distill, age, and distribute premium bourbon to a wider audience,” the president of Holladay Distillery said.

Construction is planned to last nine months, led by St. Joseph-based construction company Al J. Mueller. Set for completion in October 2025, Rickhouse D will allow the distillery to fully utilize its distilling capacity by alleviating storage limitations, Harris added.

Holladay’s active rickhouses span roughly 9,000 square feet and offer barrel capacity between 10,000 and 12,000. Rickhouse D will feature an 11,000-barrel capacity to maintain consistency across each bourbon.

“This new addition will enable us to increase our production of Missouri bourbon by one-third,” said Harris.

Warehouse C at Holladay Distillery in Weston; courtesy photo

Honoring tradition, embracing growth

Holladay Distillery, home of McCormick Distilling Co., is the oldest distillery west of the Mississippi River on its original site, One McCormick Lane.

The distillery’s original ironclad rickhouses date back to the early 1900s. True to that heritage, Rickhouse D will replicate its predecessors, ensuring Holladay Bourbon keeps its signature character, Harris said.

“Bourbon gains its flavor during the aging process,” he explained. “Our traditional ironclad rickhouses are not climate-controlled, and the distillate in the barrels benefits from the extreme seasonal climate variations in Missouri.”

Click here to read more about the distillery’s history.

Holladay’s aging process creates variations in taste and color, shaped by temperature differences across the rickhouse’s seven floors. The top floors are warmer and drier, while the bottom floors are cooler and more humid, all of which play a key role in bourbon’s development.

A Ben Holladay Old Fashioned from Holladay Bourbon; courtesy photo

Meeting growing demand

The construction of Rickhouse D responds to increased demand for Holladay’s products, particularly Ben Holladay Bourbon and Holladay Soft Red Wheat Bourbon. The authenticity of Holladay’s bourbon has greatly contributed to its rising popularity.

Kyle Merklein, master distiller at Holladay Distillery; courtesy photo

“Modern consumers are very interested in where their food and drink are coming from, and we provide full transparency from water to whiskey when it comes to production,” said Harris.

Both Holladay Soft Red Wheat Bourbon and Ben Holladay Bourbon are bottled-in-bond, a designation that guarantees authenticity and quality. As the distillery grows, it remains committed to the high standards that have made its bourbons so popular, he said.

The distilling operation is led by Holladay’s longtime Master Distiller, Kyle Merklein, an engineer who joined the team in 2016.

Click here to learn more about Merklein’s story.

Holladay Bourbon’s Soft Red Wheat; courtesy photo

Blending history with innovation

Bottles from Holladay Distillery’s Ancient Cave Collection; courtesy photo

Holladay’s dedication to tradition doesn’t mean it avoids innovation. The distillery’s Ancient Cave Collection merges historic roots with modern experimentation.

The experimental barrels in the collection are sourced from longtime partners at Independent Stave Company in Lebanon, Missouri, adding a contemporary twist to the distillery’s legacy.

“The Ancient Cave Collection is right in line with our tradition,” Harris said. “Ben Holladay aged his first barrel of whiskey in the ancient cave, so utilizing the space for projects such as secondary aging feels like we have come full circle in a way.”

Click here to read more about the distilling process behind the Ancient Cave Collection.

With Rickhouse D on track for completion, Holladay Distillery is set for a new chapter, one that honors its 19th-century roots while meeting the growing demand for Missouri-made bourbon.

“We are thrilled to honor the traditions of the past,” Harris said, “and the latest expansion will allow us to share more Missouri bourbon with more people.”