Creamery Construction Update

Creamery Construction Update

Creamery Construction Update

The creamery construction is coming along nicely.

creamery construction

The top concrete block rows are finished up to the floor heights . . . finally. To be clear, I mean the floor level for both floor heights. There is a 28″ difference. The barn floor is higher (green lines) while the parlor (yellow lines) & main floor is lower.

I would like to explain what you see here. I’ll fill you in on our milking dairy design.

The dairy working space (the parlor) can be flat, or have a ‘pit’ or be entirely raised off the floor. The more common, least expensive and easiest to work is a ‘pit’ design; the pit is simply a long trench or hole below floor level to make the cow’s udder available at a good working height. That milking pit can be up to 3’ deep. You walk down steps into it, the cows are standing at an angle on the common floor level with udders towards you and the work with the cows begins at a good height for the farmer.

The Parlor

Our milking parlor will be a one sided ‘milking pit’ (yellow lines). The shape of the land slopes and was the deciding factor in our parlor plan.

Let’s look at the one-sided pit idea: The picture shows from left to right – Barn, Parlor, and Main floor areas. The tops of each block wall are the floor heights (look for the thick green and  yellow lines in the picture). The milking parlor space is in the middle: It has a left-hand, taller wall or the high side of the pit a right-hand lower wall. While the cows will stay up on the higher barn floor level (to the visual left, green lines), we will walk on and work from the lower parlor floor (to the visual right, yellow lines). There will be lots of cow traffic on and along the taller floor edge — that left-hand barn-parlor wall. This is my version of a one sided ‘milking pit’ or parlor

The long left-hand barn-parlor wall will be poured solid & have a formed concrete lip extending 6″ past the wall to support the cow milking stalls metal support system.

The retaining wall is closest to the driveway. It is designed to hold back mud, water and vehicles.

Structural Integrity

Let’s talk structural building strength: For the barn floor (higher), the top row of blocks will have the inside pieces knocked out. These top blocks reinforced with steel rebar will become part of the poured floor, locking the floor edge to the wall and down to the footer. The retaining wall is setup the same way for the same purpose. creamery construction 3


creamery construction 4

As it is today, I still have two footer lengths to dig out; look closely to see where dirt and steel bars are showing between those lower floor corners. These footers and walls define the shorter building ends. This is where the cheese make room, the aging coolers and the commercial kitchen all reside.

I temporarily filled in the footers with dirt. There was a need to be able to drive heavy equipment across the floor areas carrying in all those blocks. I will rough grade the dirt with my tractor before I dig out those footers and complete the lay up of those shorter walls.

The dirt rough grading will include making the floor area of the walk-in coolers lower by 4″. That’s extra depth is needed for the cooler floor insulation.

Animal Movement Logistics

The animals get to the creamery building by walking the natural ground path along a fenced highway or travel lane. The animal travel lane is nearest that higher barn end of the building. They will find the entry and exit to be comfortable as it will fit the shape of the land. The cows will stay up on that left-hand ‘barn’ floor; they will come in the building corner on that floor then leave the building corner from that same floor level.

Dirt moved and graded, the last footer blocks in place, then layout with strings all the pipe trenches. It’s like a little 3D puzzle.  It will be time for digging trenches for the pipes! That will take a good effort in the cold hard ground. All of those floor drains, bathroom and kitchen drains, supply line conduits for water, electrical and gas need to cut across the floor at various angles and depths.

After setting all those pipes in place and back-filling those trenches it will be time for digging the footers for the internal block walls! All the inside room walls will be regular common blocks as you see here. Many of those walls are weight bearing, carrying the roof and attic storage.




My oldest brother is coming to the farm from Florida to help walk through all the plumbing details so his knowledge will give me great feedback.

Like I mentioned, I have a lot of trenches to dig so I’ll get back to sharing more after all the snow melts and when the next step is visible.

Cheesemaking in Pictures

Cheesemaking in Pictures

Cheesemaking – an Introduction

I wanted to share a few cheesemaking ideas and pictures. I hope this is interesting for you. This won’t be too detailed yet should help make understanding what happens clearer. I hope to stimulate your appreciation of the cooking process, recipe differences, equipment involved, skills developed and the amount of time invested. You can make cheese in nearly any quantity from a kitchen sink cook pot to a large stainless steel vat.

Ararat Legend BabyWe make farmstead and artisan cheeses. So what’s the difference? Farmstead cheese is hand-made in small batches using our own cows’ milk. We milk our cows daily and use the raw milk for making our farmstead cheeses. That is what makes us unique and special.

While Artisan cheese is still hand made in small batches, the milk comes from another source. We can and have used milk from another local dairy to make an artisan cheese: A different quality of milk makes a different cheese. Melanie also makes butter and ice cream for our own use from our cows’ milk.

It all starts with milk, of course, but a wide variety of tastes are achieved via heating, cutting, cooking, pressing, and aging methods. Bacterial cultures also contribute to making bland curds into awesome aged cheese by breaking down the fat and protein over time. For our raw milk cheeses, we engage in months of aging time with lots of handling according to the kind of cheese.  This is called affinage.

cheesemakingBut you can do the same using a couple gallons of milk bought at your local grocery. It will make make a couple pound cheese. You might try using a SS stock pot in your kitchen sink, surrounding the pot with hot water to control the temperature. Just follow the recipe.

We made farmstead cheddar today.  We started with a tried and true recipe for making cheese, followed it as closely as possible. That’s very important for consistency in the final product. We are refining the various recipes as we progress with one cheese after another. In the end each becomes our very own recipe. Between the use of our grassfed cows’ milk and recipe tweeks, we are creating something unique in the cheese world.

Is your mouth watering yet?

Heating the milk

After the vat and other tools have been sanitized, the refrigerated milk is poured into the 100 gallon vat.

The milk in the vat is heated by very hot water circulating in the “jacketed” vat walls. This piece of equipment was custom made for our purposes.

We use a long plastic paddle to gently stir the milk so it heats evenly. A temperature probe is also used throughout the heating and cooking process.

The milk is heated up to the target temp. This can be 86-92F depending on the type of cheese to be made. The temp will be raised higher as needed during the cooking process, according to the type of cheese. We need to maintain the target temperature during the stages.

The control of temperature is learned by practice (trial & ‘what now’ testing) and soon becomes a method. We are still learning a lot about how to control the temperature. This aspect of the cheesemaking process is vital to actually creating the cheese you desire.

At one point we were making Havarti and the temperature got way too hot — like 7 degrees above the target. We decided to let it go and see what would result. So, we didn’t really make Havarti that time. Sometimes this kind of mistake can make a unique great cheese that you want to make over and over again. That was not the case with this one, however. We just wished we had pigs or chickens. They would have loved it.

Starting The Culturing Process

Once the milk has reached it’s starting temp goal, bacterial ‘starter’ cultures are added, stirred in. This is then left to ‘culture’ for a period of time. The time allotted here for the bacteria to run wild in the milk and work its magic again depends on the cheese.

Then maybe another ‘ripening’ culture along with a little liquid calcium can be added.

The number and combinations of starter and ripening cultures available are mind boggling. But for home cheesemaking there are simple choices to get you started.

The curdling agent, in this case Rennet, is added by gently mixing it in briefly. But then it must be left to rest and work its magic.  In a short time the whole volume of milk becomes a solid custard! This still amazes me every time.

From Custard to Curds and Whey

After the milk becomes a solid custard, we cut it all into hazelnut sized pieces with tools called curd knives or harps. They are basically stainless steel wires in racks. These were also custom made for our operation.

When using smaller pots we simply use a long thin knife purchased for the single purpose of cutting cheese curd.

The curds need to be as uniform in size as possible. They will shrink in size as they cook and various textures will become evident. You guessed it the texture depends on the cheese cultures, the temp, the size of the curd, how long they are cooked and so on.

making cheddar cheeseOnce “cooking” is complete, the curds are allowed to settle to the bottom of the vat or cook pot. In the vat, we push the curds to one end of the vat. We had custom made food grade plastic boards made for this purpose. They have holes drilled in them to allow the whey to flow past as the curd is pushed to the back of the vat.

There are a couple of things that can happen here. Either we drain off all the whey leaving a curd mass as shown here or we “press under the whey”. That involves only draining the whey to the top of the curds. We then apply weight to cause the curds to knit together to form a solid curd mass.

As a side note, the whey has nutritional value and is what you are drinking in your protein shakes. We can use it for feeding livestock or it can be spread on the fields for fertilizer.  It can also be used to make Ricotta cheese.

We made cheddar today. That is a process all of its own.

The Cheddaring process

This shows a cheddar curd mass cut in half as a starting step of the special ‘cheddaring’ process. This process is what makes cheddar cheese a reality.

The whey continues to leak out slowly and the curds are stretched and pressed as we follow the dance steps to cut and stack, flip and restack, then flip and restack higher. The increasing weight of the stack is its own weight to press out the whey.

The curd slabs get stacked over and over again until they are dry enough and have reached the desired texture. The test for the proper texture is to tear a piece of the curd in two. It should look similar to cooked chicken breast.

Cut and stack. Repeat. And repeat every 15 minutes for a couple of hours.

The time to complete a cheese from start to finish varies from cheese to cheese. With cheddar there is a great deal of time spent on cheesemaking day just to get it to the stage of pressing. More on that later.

Once the cheddaring process is complete, the curd slabs are weighed. This is used to calculate the correct amount of salt to get that perfect cheese. There is one more step – adding that salt.

Milling and Salting Cheddar Curd

All curd slabs are torn into small ragged pieces before the salt is added. We bought another unique piece of equipment. It’s a curd mill. We use this device like a hand grinder with little stainless steel fingers that tear the solid cheese mass into small pieces.

For small, home batches you would simply cut them into small pieces with a knife.

We use a large stainless steel pot to catch the pieces. They still need to be salted. Every cheese we make gets salted in some way. With cheddar the salt is mixed directly onto the broken up  curds. We use flaked sea salt. There is pressing still to be done: We don’t want it to just drain away with the whey. We want it to dissolve quickly and be absorbed into the curds.

BTW, when you see curds for sale, this is what you are buying. They are salted cheddar curds. We enjoy these ourselves but cannot sell them to you (sorry, government regulations). You’ll just have to settle for those that are made from pasteurized (boiled) milk.

Most of the other cheeses we make are floated in brine for anywhere from 6 to 24 or more hours depending on the size of the cheese. But I’m getting ahead of myself. That happens after pressing.

Cheese Molds and the Cheese Presses

The curds are placed into a strong plastic molds which provide a finished shape for the cheese. Some types of cheese require specific molds. Camembert, for instance, needs to be a particular diameter and height in order to age properly.

We use dutch cadova molds, standard tome molds and truckle molds. We have molds for baby Gouda and are experimenting by using them for Gruyere, Havarti and Raclette. The jury is still out on whether this will work or not. They are really designed for “young” cheeses that are not aged for long periods of time. We’ll keep you updated on that experiment.

In general, the curd ‘pressing’ begins with lighter weight to settle those curds closer together, then flip the whole mass and use more weight to ‘close’ the cheese. The rind needs to be smooth so that no unwanted bacteria and molds get inside and there are no air spaces or gaps.

Pressing is repeated at intervals adding weight up to a point so that the air and whey are pushed out. Sometimes the ‘pressing’ takes several hours at room temperature and sometimes it lasts 24 hours: Cheddar can take 24 hours. It is all according to the recipe and the desired goal. Pictured above are small molds used to make Gouda. Again, we use molds of various sizes and proportions appropriate to the type of cheese being made.

pneumatic pressPictured here are larger ‘truckle’ molds used for cheddar (pronounced like buckle) in our fancy cheese press.  Cheddar requires a lot of weight; more weight than most any other cheese we make!  We now have a pneumatic press that can handle this. We ordered this from a supplier in Canada who imports them from the Netherlands. It took a long time to get this jewel (and lots of dollars) but it is so worth it.

We wanted to make a really great cheddar. Having this press was essential to reach that goal.

Salting Cheese

Cheese needs salt! Just the right amount makes all the difference. And there are several methods of getting that salt in there. Camembert has it sprinkled on each side. It’s not even mixed in at all but makes its way into the cheese just the same.

As shown above, Cheddar gets salt added amongst the milled curds.

Most of the cheeses we make float in a saturated brine for hours and hours as the method to get salt into the curds that have been pressed together. Gouda, Parmesan, Raclette, and Gruyere are soaked in that heavy brine solution. The time varies according to the size of the cheese. And Havarti gets salt added during the cooking process and is also brined afterwards.

After salt and pressing or pressing and salt, the wheels of cheese come out of the molds and are air dried. Then they receive various treatments designed to create a most awesome cheese.

Begin the Aging Process

Aging in the cheese cave is called affinage. After the cheese is allowed to dry at room temperature or inside the cheese cooler / cave, various methods of helping the cultures continued their magic are employed.  These include: a clear coating to keep out unwanted molds and such, cheese wax to maintain moisture, cheese cloth ‘bandaging’ with lard as a barrier.  Various techniques are used to develop a natural rind – so many that it’s creative indeed.

Each method provides a different and unique end result. There is a lot of time spent in the cheese cooler / cave as the cheese goes through various stages of aging. There is also turning and turning and more turning: That will be daily during the first week or so and then usually once per week after that.

Whew! Keeping up with which cheese needs what treatment, and when, is a brain strain and maybe a spreadsheet as well.

We have experimented with a ‘clothbound’ cheddar and its surface mold.

We also use cheese coating and / or cheese wax, depending on the cheese. Those lovely green ones are Gruyeres. The red ones are Goudas. There are a couple of yellow-waxed Parmesans and some have a clear coating.

Packaging and Labels

Cutting and sealing the aged cheese, adding labels and getting ready to ship or get picked up is another set of choices, supplies and skills.

Each cheese is labeled on the ‘make day’ with a lot number. We use this for tracking and inventory.

There are labels for each cheese identifying the type of cheese, the approximate weight and price. But first the cheese must be cut to size, placed in the package and vacuum sealed. This happens just prior to sale.

The baby wheels don’t need cutting per se: They are w hole little wheel at about one pound. Though we are making 1/2 and 1/4 pound ‘babies’ available and those need to be cut and packaged.

The real work with cutting and packaging comes with those 12 pound wheels.

Let me finish up here with some other miscellaneous tools we use from time to time. You wouldn’t need all of these for making cheese at home, but we have collected all sorts of equipment over the years.

I mentioned the stainless steel jacketed vat where we heat up the milk and some food grade plastic boards to help collect the curds, separating them from the whey.

These are essential to our operation but not for the home cheesemaker.

Then there was the curd knives, the curd mill, cheese molds and the cheese press. A lot of these were necessary for making cheddar. Other cheeses can be made with some simple long knives and standard cheese molds.

We also use weights for pressing that are the same as those found at any fitness center. You can see them in the picture above under the Cheese Molds and Cheese Presses heading. They are chrome plated and range from 2.5 lbs to 10 pounds each in weight.

There are several hand tools that may also be used such as other long knives, scoops, buckets, and colanders.

We even have a couple of paint strainers that we use to catch curd. We use pitchers and quart-sized glass measuring cups. And one day we are going to get that pH meter mastered.

You might have guessed by now that cleaning all those things is nearly a full time job. Making the cheese is only half the time involved. The rest is spent cleaning all that stuff and getting ready for the next cheesemaking.


So, this was a pictorial review of the cheesemaking processes and equipment.  There are so many variations and details not included.

We are and have been making these types of cheeses: Our Ararat Legend is made in the Gouda-style, Pinnacle is made similar to Gruyere or other Alpine cheeses you may had tried, Peaceful Heart Havarti is a favorite, Patrick Parma takes a long time to age but is worth the wait, Blue Ridge Raclette will be great for your family gatherings and Clau d’ville Cheddar speaks for itself.

We have gradually ramped up in skills, recipes, experience and equipment.  We still need to increase our work space.  That next project is pretty big with a combined building for milking cows, storing milk, cheese making plus aging and packaging stages.

Please note that we are offering cheese samples in recognition of donations made to building that creamery. Go here to make a donation and receive your cheese sample.  Thank you for your support.

Happy cheesemaking and eating!

Garden Design, hugelcultur raised beds

Garden Design, hugelcultur raised beds

Gardening in this old way is new to many.  The older ideas of using nature’s way to self-feed plant  roots with wood decomposing under your soil.hugelcultur example has a raised bed effectCombine that example with raised beds which reduce back strain from leaning over, lessen weed problems when the walkways are covered, and improves watering issues.

It does take time to learn & grow plants but it does not have to be expensive or elaborate to start. Develop the garden soil that supports your belly! Nourish your soul by getting your hands in the dirt. Work with Nature.

Hugelkultur or similar raised bed methods give several advantages to us. Wood (& other yard / woods carbon material) that would become waste or scrap, compost & aged manure in there, topsoil over that – together provide nutrients to roots and microbes in the soil.mounds of soil over layers of wood planting over the raised surface

We are building this 4th or maybe 5th version of a annual vegetable garden: we have adjusted size, methods and varieties of plants by combining these new and old methods.  Two foot high bed surface, drip irrigation, decaying wood underneath, heavy tarp with hardwood mulch covering the walkways and a more gentle draining slope are built together in our space.


Keep in mind, we are really grass farmers (the animals eat the grass or we eat a crop). But the microbes make the plants thrive, not merely the dirt. Feed the microbes, they feed the plants, plants feed your animals & you.!  cows, sheep, goats, donkeys graze together rotating paddocksOur new garden is shown in the pictures and videos on Facebook:

dry stack blocks as bed walls do not rot

Creating gardens is an evolution to answer the need to eat well: We develop skill, apply resources and enjoy time spent in Nature.  We will reap Nature’s abundance as nutritious plant food of a wide variety.  Crop rotation of plant types for extra benefit is easy and can be planned ahead.

Bio-intensive plant spacing will be used also to maximize production without taxing the soil.

Learning how to grow your own food is & will be very important. This should be obvious to many by now. Buy common variety open pollinated seeds and grow the food in your space – small, medium or large space – just do it to become then good at it  so you can depend on the produce.

Old Tree Piles

Old Tree Piles

Tree piles – large piles where you cannot burn them yet are in the way now.  I had been waiting for over a year to get to this little farm chore – clearing piles of old large trees. I cannot burn them where they are & they are definitely in the road or in the ‘lane’ I should say.

Old trees crowding the lane

Old trees are crowding the Travel Lane now.

used to be a good place to dump old trees

This used to be a good place to dump old trees.

The ‘Travel Lane’ is the sheep-way or herd-pathway where we walk animals from paddock to paddock. It really is a good management tool – we make a fenced 10-20’ wide pathway between / through the pastures / woods.  Well, the lane had a long gap in its fence barrier along the creek bed, 250′ of a gap.  The tree piles are right at this gap and in the way of putting up the barrier fence. The tree piles kinda’ made a barrier but animals were not fooled for long. If they can find a way to go somewhere, they will!  They can walk around or over many things.

This need to put up a fence is all about making it easier for us to handle our boys-n-girls peacefully.  No aggravation or injuries for daily chores, thank you very much.  How do you move the milk cows twice daily for milking them?  – Answer – follow the travel lane between field & barn.  Herding animals is a common need on a farm.  From my observation, “Herding Livestock” can be like snack times in the kindergarten except the kids are way bigger.  And they have a serious pecking order attitude, brambles, rocks, flies, poop & grass to nibble.  This herding can quickly NOT be smooth & straightforward BUT it can be easy if setup properly.  Bringing in the flock or herd can be enjoyable.

Travel Lane passing between orchard & paddock

Travel Lane passing between orchard & paddock

The Sheep-way is for easy movement of the flock / herd.

The Sheep-way is for movement of the flock & herd.

So, this travel lane gap has to be closed. For a couple weeks, the girl cows have been ignoring my rotational grazing plan: They should know better!  And I truly think they do know the routines yet are like willful children getting away with what they can.  They are just being themselves, not actually trying to cause trouble.  So into the gap or breach they go:  The donkeys, sheep & cows walk around / through the tree piles then simply scramble down-n-up  the steep ravine banks crossing the creek and like-magic escape into somewhere special  – in this case the beautiful, shaded creek bed with many green delights.  They actually don’t go that far; they are just not where you want them to be.  To round them up, it takes a lot of time & sweat:  You can picture me jogging back-n-forth, panting, waving my arms, clapping my hands as they shift and dodge around me.  They are perfectly happy eating that fresh greenery, merely being.  Did you know they love being first to get to it and race to get there!

Wished I had a better use for them..

Wished I had a better use for them..

Cut & carried to roll them roll them into the creek ravine

Cut & carried & rolled them into the ravine.

All together there were over 100 whole tree trunks (6-20” diameter, 15-40’ long), collected over 8 years. I had drug & stacked them at the bottom of the garden field next to the creek ravine – it was out of the way back then!  It is right in the way now.  The chainsaw, log chain & tractor front end bucket helped make these piles over the years. Various farm needs and bad weather required clearing trees (I try to not cut trees down, actually hate having to do it – I really love trees).  Yet, there they are nicely stacked laying parallel at 4-5′ high & 10-20′ wide in 5 piles all along the gap.  These wet, half rotten trees do NOT move as a ‘pile’ because of my little tractor.

It took two weekends, lots of sweat/beer/water/ ibuprofen & my trustee chainsaw.  Most of this tree mass had to be removed by hand.  I cut them into 3′ pieces and carried / tossed / rolled 3/4 of these piles into the ravine and creek.  Only after cutting them into little pieces and digging down to the bottom of the piles could I shave off a cluster of pieces with the front end bucket to push them over the edge. Yeah, the tractor helped push them into the creek bed / ravine late yesterday afternoon but only at that point. Only that last hour could I use the tractor.  I finally cleared those large piles of old trees from the travel lane.  Happily I did find a few locust trees – cut / hauled them off to use for fence posts later.


I was glad to work in the shade!

I was glad to work in the shade!

This will work better.

This will work better.

Then I put up the fence – Almost finished that part before dark.


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