Over the past few weeks we’ve been hard at work making some much needed improvements at the malt house. The main focus (as always) has been the kiln. This little room has caused many a sleepless night for us, as there is no “textbook” method of designing, building, and operating these things at our scale. Our first design/build worked well, but didn’t give us the capacity we need to meet demand (or turn a profit!).

As the orders started to stack up in early March, we knew it was time to take to the next step forward. We enlisted the help of our friends Andrea and Christian at Valley Malt.  After speaking with numerous engineers across the country who just didn’t “get it”, it was a welcome change to have an in-depth discussion with Christian.  These discussions generated several upgrades to system…better ventilation, more air flow, etc.  All of which will translate into larger, more consistent batches of locally grown malt!

Game plan in hand, we purchased a new fan/motor and scheduled our subcontractors to install the new duct work.  Installation of all of this new equipment halted malt production for several weeks, but we are back online and moving fast!

The next phase of improvement will involve the installation of process controls.  These gadgets will allow us to program temperature and fan speed settings for each style of malt we produce.  We’ll even be able to adjust humidity and temperature from our smartphones…pretty cool, huh?

 

Last week we gave a tour to a group of students from Warren Wilson College.  The students were part of an ethnobotany class taught by Jay Bost.  This was a new audience for us, but it gave us a great opportunity to focus on some of the sustainability aspects of our work that are often omitted during a typical tour.  We started with a brief overview of the commodity markets that control the price of grain and transitioned into the “day in the life” of a maltster routine that Brian and I have been perfecting over the past several months.  We also covered some of the basics of brewing beer, just to get them in the mood for spring break!

The student were engaged in our discussions regarding fossil fuel consumption, development of local food systems, and brewing quality craft beer from 6-row barley.  We also got a chance to learn about several of their class projects, like growing mushrooms on compost material and brewing beer from moss!  Needless to say, this was much different than my college experience….they’ve got a great thing going out there in Swannanoa.

A few weeks ago, I headed down to the Organic Commodity Conference held in Rocky Mount, NC, that was arranged by our friends at the Carolina Farm Stewardship Association (CFSA).  This event offers a chance for farmers, scientists, policy makers, and end users to get to know one another.  It also provides a great opportunity for someone with little to no farming background (like myself) to really get a feel for the market pitfalls, certification headaches, and soil fertility issues that our growers face every year.

Many of this year’s presenters focused on a common problem encountered by organic farmers: matching nutrient availability with plant growth cycles.  Simply put, many of the organic fertilizers available do not provide nutrients that are immediately available to plants.  These amendments, such as chicken litter or compost, must be chemically altered by microbes in the soil ecosystem before they can be utilized by plants.  Researchers presented new guidance on testing procedures, scheduling, and economic analyses which were designed to help growers maximize yield without breaking the bank.  Most of the sessions were followed by a great “Q&A” period where growers and scientists exchanged information on the latest pricing, shipping rates, and individual experiences; all of which facilitated an exchange of information that I found greatly beneficial.

After filling our heads with the latest in organic farming data, it was time to fill our bellies at the local Mexican restaurant, “El Tap” as it’s known Down East.  I can say that, as I grew up about 20 miles from the conference site.  By the time dinner arrived, our crew had pretty much taken over the place….several farmers (Kenny Haynes and Herb Winslow), NC State’s research team (Chris Reberg-Horton and staff), Carolina Ground (Jennifer Lapidus), and Nick Williams (Head Brewer at Weeping Radish all sat down to salsa, guac, and burritos.  The conversation covered everything from compost tea to the explosion in craft beer production throughout North Carolina.

During the long drive back, I got a chance to think about all the aspects of the beer economy, and how these types of conferences are essential to supporting the development of this market for farmers and processors like Riverbend.  As Sierra Nevada and New Belgium make plans to expand into our state, it only makes sense to foster the research and development necessary to produce the barley, wheat, and rye that will ultimately fill their mash tuns.  Both companies have a proven track record of environmental stewardship and will no doubt look to our researchers and farmers for a high-quality locally-grown product that reflects our southern heritage.

Last week I got a phone call from the good folks at the Blue Ridge Distilling Company based in Golden Valley, North Carolina.  We started talking about local grain production, craft distilling, and the challenges of running a small business.  By the time the conversation was over, we were both excited about the idea of producing local spirits, and I made plans to visit their facility the following day.  I also realized that I had a fair bit of googling to do!

While the differences between bourbon, whiskey, and rye might be “old hat” to most folks in this part of the country….there is a new wave of craft distillers that are exploring new recipes, ingredients, and production methods.  For example, Blue Ridge is planning to produce a “single malt” vodka, crafted with 100% malted barley (as opposed to a blend of corn, wheat, or potatoes).

I arrived late the following afternoon to discover a newly constructed barn with close to 100 acres of prime farmland wrapped around it.  While I’ve seen plenty of high-end brewing equipment, I must say this was my first glance at a modern distillery, and it was pretty impressive!  The picture below shows a “hybrid” system that allows for traditional pot stilling techniques in the center vessel or multi-chambered distillation through the column on the left.  The bulbous feature on the pot still is referred to as the whiskey helmet.  This design element provides more surface area during the distillation process, resulting in a smoother tasting finished product.

Tim at Blue Ridge and his team brought me up to speed on their plans to produce vodka, gin, whiskey, and an array of brandies.  Turns out, they have been developing this business for almost two years and are eager to begin distilling and packaging in early 2012!

Following our meeting, we sent them home with 100 lb. of our heritage malt to conduct some testing.  Who knows, local vodka could be just around the corner!

As for the whiskey, we will have to be patient….extremely patient….it has to age a minimum of 3 years.  Call Blue Ridge to reserve your own barrel now!