A new venture in Fordsville is transforming excess wood byproducts into a growing line of fuel and grilling products, while creating jobs and expanding the reach of a long-standing local industry.
Fordsville Pellet Company, co-owned by Gavin Christ, began production in August 2025 and is approaching its first full year in operation. The company operates independently but shares ownership with Dunaway Timber Company, a business that has been based in the region for more than 70 years.
Christ said the idea for the pellet operation emerged from a need to better utilize leftover materials from timber production.
“We seemed to be having a harder time getting rid of what we call residuals — sawdust and chips,” Christ said. “We’ve looked at different opportunities that we could use to move that product, and we started looking into pellets a few years back and started this process of building this facility.”
The company broke ground on a new production facility in 2023, completed construction in 2024, and launched operations the following year. The site features specialized equipment designed to process wood waste into uniform pellets and compressed fuel products.
The process begins by breaking down raw wood material through a series of hammer mills — first while the material is still wet, then again after it is dried to create a consistent particle size. That material is then compressed into pellets using high-pressure mills inside the facility.
“We take that pile of chips and sawdust and break it down to a smaller particle to dry, and then we’ll break it down again where it’s a more uniform particle to be able to squeeze into a pellet,” Christ said.
Fordsville Pellet Company currently produces two primary products: home heating pellets and barbecue pellets. The heating pellets are designed for residential pellet stoves, offering an alternative to traditional firewood.
“We’ve got customers that started using us this last winter, and they’ll come pick up a pallet at a time, pick up a ton, and they heat their house with it,” Christ said. “A bag will last about a week for them or a few days, and that’s what they’ll run their heat on.”
The company also produces barbecue pellets for use in grills and smokers, with a hickory-oak blend currently available. Christ said future plans include expanding into single-species options such as maple or cherry.
“The grilling side of it is still expected to grow within the next handful of years,” Christ said. “They don’t see that slowing down anytime soon.”
In addition to pellets, the company produces compressed “fuel bricks” made from sawdust, which burn hotter and more efficiently than traditional firewood.
The facility currently employs about 10 people, contributing to the local workforce in Fordsville, where the broader timber operation employs around 60 people. Across all locations in Western Kentucky, the affiliated timber business supports roughly 125 employees.
Christ said launching the pellet company also provides a way to connect more directly with customers and promote the Fordsville community.
“We started Fordsville Pellet Company as a way to sell to the public and get our name out there and promote Fordsville on a bigger stage,” he said.
The company’s products are currently available at several regional retailers, including Royal-Lampkin Feed & Farm Supply, Hill View Farms Meats, Owensboro RV, Pool Medic on Kentucky 54, Burley’s Market, and Triple B Archery. Customers can also purchase directly from the facility.
Fordsville Pellet Company is also a vendor at local farmers markets and is working to launch a website that will provide updated retail locations and product information.
As the operation continues to ramp up production, Christ said the focus remains on growth and efficiency.
“We’re just trying to get our feet wet, figure out everything, how we want to do everything,” he said. “We’re ready to start moving more pellets.”
