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creamery

seana and marissa's picture

Finally FINALED!

I am happy to report that our building permit is FINALED! It was Aristotle who said "patience is bitter, but its fruit is sweet." Yeah...I wonder if he endured a creamery build-out, because that pretty much sums up what it is like. Just to recap, we started the permitting process with the County of Marin back in September 2012; they finally issued a building permit to us on January 15th; we were done building the creamery and got licensed by the state of California 40 days later on Feb. 23rd; it took another 60 days after that to wrap up the septic issues in order to get the final blessing from the county; so from permit issuance to permit final, it took exactly 100 days. The County of Marin has lifted all the holds, done their last site inspection, and given their final approval, closing the book on this project once and for all....at least as far as they are concerned. We, on the other hand, still have a long to-do list!

view of the make room, with our new vat and all our cheesemaking stuff
view of the almost-complete whey removal system which is designed to be loaded into a tank for feeting to pigs & other livestock
view into the mechancial room, the door leads into the bathroom
mechanical room, with all of our new systems necessary for the creamery
a big mess of tools are still scattered all around the back of the creamery
the mechanical room window screens are a bit worse for wear after nearly 40 years. We will be repairing this soon.
front of the creamery buidling is looking good with new entry doors, and new windows and grade vents. It needs a coat of paint!
view into what will be a milk room, but we need it for aging cheese since we have nearly 3000 wheels produced this year so far
creamery bathroom is looking much better, but still needs fresh paint and some floor tile
another craigslist find: commercial dishwasher with 3 min wash cycle. We will use this to clean cheese hoops
These sneaky lambs figured out how to escape through an opening on the side of the fence
this black lamb has a very cool color pattern with a white hourglass on her head and a white tail
our complete signed and approval building permit, woohoo!
seana and marissa's picture

Creamery is almost done

Yes the creamery is almost done for real, no April Fool's joke! It’s been quite a while since I last posted about our creamery project. Valentine's Day has come and gone, the annual California Artisan Cheese Festival is behind us, and I survived another birthday last week. In between all of that, we’ve been busy trying to wrap up this creamery project once and for all so we can focus on making cheese!  I know the creamery will never really be DONE done, I’m not completely delusional. There will always be something - some new or unanticipated problem or need, always requiring more time, more energy, and more money, all of which are running pretty low for us right now. It’s been 75 days since getting our building permit, and so much has happened, I don’t know where to start. I have both good news and bad news. Which do you want first? Let’s start with the good.

the ever changing list of things we had to do up to getting our CDFA license
the day after assembling the vat, we did a test run with water (cheaper than milk!)
our new/old draining tables, courtesy of our dear cheesy friends at Cowgirl Creamery
chart recorder for our vat, in case we want to make any pasteurized products
holding tanks for whey, which will be fed back to sheep and also to pigs
getting a 100% score on our first cheese plant inspection is champagne-worthy indeed!
seana and marissa's picture

Fast & Furious Creamery

It’s been 20 days since we finally got the building permit, and there hasn’t been an idle day since. After all those months of waiting and trying to navigate through red tape and overcome bureaucracy, it’s actually happening. The creamery is really coming to life. The action has been fast and furious as we rush to bring the creamery into a functional state. We are pretty much working at a pace that pushes the limits of our budget, and especially our physical and mental stamina. Our muscles & joints have ached in new and interesting places, and we’ve only sustained minor cuts and bruises. It’s amazing though how the body can be so dead-tired, but the mind keeps racing. Well, mine does anyway. To paraphrase the lyrics of “Gin & Juice,” one of the greatest rap songs of all time: I’ve got my mind on my cheese and my cheese on my mind. Here is a recap of the big accomplishments of the past 20 days…

 

view of vents for floor drains, wood forms for the curbs that will be poured for the new milk room
another view of the drain vents as well as the rebar for the new concrete
a major bargain - we got this sink for $300 from a guy who used to have a BBQ place in Berkeley. It needs some cleaning up.
Dave is removing the worst toilet in Tomales (well, it looked like the worst to me)
here is the clean shiny new low-flow toilet, which Marin County required
The concrete truck is setting up to pour the new floor
Here is Gary, Marissa's dad, lending a helping hand to spread the new concrete around.
New business license for Marin County. I'm annoyed by the fact that they called me Seana "Dalton" -that's not my name.
Framing and doors for new milk room
Dave is boring holes for the new plubming on this "wet wall" where most of the plumbing will run
Here is the plaster crew applying a base glue type product to help seal and fill the old plaster's cracks and holes
These are some of the color options for the new plaster. I chose "Dove Gray"
The plaster crew worked 8 hours straight while Dave worked on plumbing.
Sparks were flying as Dave and I both took turns grinding off old nails and bolts from the walls
Working into the night, Dave finished up the plumbing on this wall
A view into the creamery from the area we call the "nook" which is for dry storage.
A view from the entry way, with Dave checking on his plubming work.
A fair amount of beer has gone into this creamery project. On this evening, it was brews from Deschutes in Oregon.
As you can see, it looks like a construction site!
seana and marissa's picture

The Waiting Game

Let’s just get this over with: NO, we do not have our building permit yet. We are still waiting. I’ve entered the New Year with the realization that our creamery will not be completed by my fantasy deadline of January 15th. I’ve accepted this, but here’s hoping for February 15th, which is more than the original 100 day goal (by 30 days), but we’re sticking to the $100,000 budget no matter what!

I’m glad the holiday season is over. Don’t get me wrong, I’m not a scrooge or a grinch, but the holiday season is not very compatible with a construction project. Building a creamery requires the full focus and attention of not only the proprietors, but also the various officials, professionals and vendors associated with the project, and the holidays are both distracting and non-productive. Places and offices have limited hours, or days when they’re totally closed, and people take extra days off on top of that. It’s 2013 now, so let’s get to work!

The cover page and table of contents of our 13 page energy compliance report
The County asked us for additional detail showing the different parts of the adjacent structures and their uses
We had to write a letter stating that if we expand or open the public, we will make the required ADA modifications
This is one of the cheese draining tables we bought from Cowgirl Creamery
The other cheese draining table that will be joining our equipment lineup
Pregnant sheep awaiting the birth of their lambs. I bet they are also wondering when we'll get our building permit!
seana and marissa's picture

Giving thanks for progress

Thanksgiving has come and gone, and we have finally made some progress…not as much as I’d like, but I am thankful nonetheless! So what have we gotten done between Halloween and Thanksgiving? Quite a lot, actually. How much money has been spent so far? Also quite a lot.

We have a plan! This is a copy of our official site plan
Some of the vat parts are in these boxes. The vat itself will be arriving separately in a big crate.
Our very own documentation from the Department of Homeland Security, very official!
seana and marissa's picture

Fall is in Full Swing

It's getting cold in Tomales!

Which means it's almost Winter, which means it's almost January 31st, which means it's almost time to build the creamery if we want to stay on track!

Amazingly, Seana and Dave finished composing all the drafts for the Building Dept. to review before being officially submitted. To me, this feels like a huge step forward. Also, the cheese vat is due to arrive soon! It feels like waiting for a baby to be born...is it here yet?? Have we reached the due date?? I'm sure it's even more exciting for Seana and Dave, since it's really their vat and their creamery being developed. But ultimately I, too, will use the space (hopefully sooner rather than later), so I feel pretty elated at the progress. It doesn't actually feel real yet, as most dreams-come-true probably don't at first. But I bet once the jackhammer hits the concrete, reality will hit me, too.

Fall is in Full Swing
seana and marissa's picture

Making Progress and Cheese

Lots needs to be done to get the creamery project moving, but daily life seems to be getting in my way. Fortunately Seana and Dave are dedicating a lot of their time, and are making most of our progress!

We’re currently trying to obtain permits for plumbing, electrical, and water use. I actually thought this part of the process would go much quicker than it has, since the structure is sound and not too much needs to be done, relatively speaking. But permits take a lot of planning and negotiating. And you have to be willing to revise your plan and negotiate more. So while it’s a full-time job to get these things figured out and crossed off the to-do list, we go to our real jobs during the day, and work on permits in the hours between.

This is the cow-milk feta we made in class. It's perfectly creamy and salty and crumbly!
mollymk's picture

Patience is a Virtue

I am beginning to realize that patience may be the most important skill that I learn this year. When we were first discussing building a creamery two years ago, there was little question about hiring a contractor to do the work -- it's just not who we are (plus, our labor is much cheaper). Now, I'm beginning to see the benefit! Since my husband, the mastermind of the building part of this project, works full time, and is already kept busy by the constant flow of projects and problems that come with 150 acres and 200 year old buildings, things are progressing rather slowly. Slowly, but surely.

Three sides of the barn are stone to the roofline
Interior of the barn- thats the corner of the creamery room in the lower right
Creamery floor before I got my hands on a shop vac...
And after! Ready for new insulation and a tile floor
Bloomy rinds drying in our kitchen- my cheesemaking space until the creamery is complete (no cheese for sale, of course!)
Another exercise in patience- my new-to-me cheese vat that I can't use yet!
seana and marissa's picture

100 days and $100,000 to turn this building into a creamery?

This blog will chronicle the planning, permitting, financing (including exact dollar amounts) and building of a micro creamery on a ranch in Tomales, California. It will feature alternating posts from 2 different people, Seana Doughty and Marissa Thornton, who have joined forces to help each other achieve their cheesemaking dreams and goals. Allow us to introduce ourselves.....

Interior - before Marissa's dad cleared it out of the stuff that had accumulated since the dairy shut down in 2001
Interior - after Marissa's dad cleared out the stuff. Dave is hosing the floor to observe the drainage pattern
The milking parlor where 200 cows used to be milked everyday. This will soon be converted to milk sheep and some cows too.
Seana and Marissa- if you think these look familiar, it's because they're our Facebook profile pics!
Where in the world is Tomales? It's 55 miles north of San Francisco, and 3 miles from Tomales Bay.