"jonathan m. forester" news and stories

Over the weekend Mike and I finished most of the pipe work for the brewery and distillery chilling system. All we now need is the pump and that project is done. I mentioned before, but we are using a 500 gallon wine chilling and clearing tank as the reservoir and cooling system for our chilling system. We had it already available, Mike had picked it up awhile ago very inexpensively, and it was just sitting there taking up room and unused. So being thrifty, we decided to make it useful once again. We ran PVC piping many months ago along the walls of the brewery / distillery; going to all the fermenters, the copper spirits still, and locations of future stills. Then we connected the brewery chilling plate and transfer system for the hot wort to the network. Finally we ran the pipe along the ceiling of the basement to the cooling tank, and prepped everything for installing the pump.

You can see some photos of this in the galleries to come. Also I show a few of our 500 gallon wine fermenting and storage tanks. The reason I'm show them is to focus on the PVC piping along the ceiling above the tanks. This is for venting CO2 from the tanks, to the outside. Each tank that has active fermentation still in progress has tubing that comes out of an airlock and goes into the CO2 vent pipe. This way the basement winery doesn't become filled with CO2, killing us. That just wouldn't be fun.

Early Monday morning the boiler guys came to start the boiler installation. We are usually closed Sundays and Mondays, but Mike went in to work with them; while I was off down to Rockport, near where I used to live in Rockland / Owls Head, to meet with a Steel Work company to discuss my latest project. The boiler guys spent several days working on the installation, and will come back next week to finish it.

Last Friday we took the day off from installing the steam pipes for our new brewery boiler, to bottle our first hard cider. This is the first new product to be released since I joined the team, and I had a lot of input towards its design. I have had some experience in the past creating hard ciders, both as a home brewer and wine maker, as well as commercially. Right after Mike and I shook hands to form our partnership late last November, I set off to Cornell University's Agricultural Experimental Station in Geneva, NY to take a week of workshops, primarily on advanced hard cider development and production techniques. The new information I picked up helped fine tune this cider into a great product over the past year.

We started with several different batches of sweet apple cider, fresh pressed from locally grown apples. Each batch had a different blend of apples and was fermented at cool temperatures using different yeasts. After the primary fermentation, the cider was taken off the lees (old, spent, dead and dormant yeast that settles to the bottom of the fermenting tank.) Then put into new tanks to age slowly for months and months, all at cool temperatures in our wine cellar. The cool temperature and slow, slow, slow, fermentation ensure that there will be lots of fresh apple flavor in the finished cider; as well as the tones and notes from the fermentation. Since each batch was made from different apples, and different yeasts; they had a completely different character from each other.

One of the craft secrets to creating a great hard cider is long and slow aging; and this we had done. The other is blending the cider. If you just make one, huge, batch of hard cider using all your apples, it tends to taste flat and one dimensional after fermentation. But if you make several smaller batches, with different apples in each, and later blend them carefully together; you get a final cider that is greater than the sum of its parts. Really great ciders save back some of the final blend to age even longer, and this is added to the blend the following year/s to bring in even greater complexity.

Hi Folks, well the last of the work in building the brewery, then distillery, is well under way. I mentioned that we are finally installing the steam boiler for the brewery. It's a difficult and heavy job. First we took apart all the old steam pipes attached to the brew kettle, and scavenged all the pieces that we could use. Then we cleaned them up to remove mild rust and treated them to prevent further corrosion. Many are already cut to the perfect lengths and threaded at the ends. So it will save us a lot of time and work to re-use them.

We here at Winterport Winery / Penobscot Bay Distillery & Brewery live by the New England and Maine way of thrift. As Francis H. Sisson said almost a hundred years ago, "Thrift was never more necessary in the world's history than it is today." But there are many sides to thrift. As Orison Swett Marden said, "Thrift means that you should always have the best you can possibly afford, when the thing has any reference to your physical and mental health, to your growth in efficiency and power." This holds true in business, as in personal matters. So, while we use and re-use what we can, we also make sure to use the best quality available as well. So in matters of construction, if it is good, solid, and recyclable, it's back in the game. If not, then chuck it out; and replace with the best available.

Just as a side note: the type of pipe we are working with is called "Black Pipe", the type of steel pipe used for natural gas, hot water and steam circulation in boilers, and it is made of heavy steel. It's thick, strong, but not as hard as stainless steel; and so more malleable. It expands and contracts better and is able to handle shifting; that would crack the harder, but more brittle stainless steel. You need heavy equipment to cut and tread the pipe ends. So we rented a pipe cutter/threader to do the job. This pipe is connected with even more malleable cast iron fittings. All of which are very solid and long lasting, but weigh a TON.

Wow, the twentieth chapter of my journal, and still no distillery! Whodda thunkit? Well, it won't be much longer now. (Fingers Crossed, as well as toes, eyes, lips, legs... I must look like I have to pee REAL bad.) Anyway, I always loved to climb, as a kid, and then a teen, I would scale the highest trees in the neighborhood, always trying to get my head above the canopy. I only fell twice when branches broke. The first time was on a young willow tree when I was in 4th grade. I slightly twisted my ankle and learned that willows have weak branches for their size. I promptly went to the library and read up on trees and learned to identify them and which were strong or weak. I also moved on to climbing the sides of buildings, radio antennas, and anything else that was possibly climbable, and a few things that probably weren't. There were no rock-climbing areas near me, so I really got into tree-climbing, sometimes even using safety ropes, and what later became known as "Buildering," climbing buildings and other structures. The neighborhood cops got to know me by name, since they found me on roof-tops, telephone poles, flagpoles, light poles, street signs, tall fences, etc. on a regular basis.

The second time I had a tree branch break on me was when I was nineteen and I messed up my right knee real bad for the first time and was on crutches for awhile. (Note: Do not have keg parties in trees without safety harnesses. I learned the hard way.) As soon as I was healed I fell off the roof of a house during a thunderstorm. It had been real fun running along the long, low, slanted roof in the pouring rain and sliding down it; and then to bring yourself to a stop before you got to the edge. One time I tried to do a stunt from a cowboy movie and grab the gutter as I slid off, and do a drop kick onto a friend. Oops! There went my other knee. That was a great summer! As I got older I started working for Outward Bound and was always up in trees on challenge/ropes courses and got so comfortable I could make it through these airborne obstacle courses 30-60 feet in the air, blindfolded.

Every now and then over the years I would put in a stint in contracting and construction, thereby ending up on ladders and rooftops. Well, unsecured ladders started to scare the hell out of me real quick. I had a best friends father fall and break his neck when a ladder slipped. A fellow worker had a ladder slip and he broke both his wrists. I started getting really conservative when it came to ladder safety. Even when setting up access to a ropes course I always made sure the ladder was secured at the top so it couldn't slip. Even after all my years going up and down ladders I am still fearful. But I also stubborn and refuse to be intimidated or controlled by anything other than myself.

Wow, it's the first weekend of Autumn and in marshy areas and along ponds and rivers the leaves are starting to turn red. It's only the first hint of color in most places, but it's that time of year again. My favorite time of year. The nights have already gotten cool enough that I have had the heat on for more than a week and that wonderful smell of woodsmoke from my neighbors' fireplaces drifts by every now and then. Time sure flies. It's been almost ten months since I first met Michael, Joan, and Jody; my partners here in Winterport; and eight to nine months since we first started building the brewery & distillery. A Loooong nine months! I had hoped for a small distillery that would be up and running by Memorial Day. Then I hoped for a small brewery and distillery and hoped it would be up and running after nine months of gestation, but alas, that was not meant to be. Now we are ten times the size we originally planned and will grow even more.

As you may have noticed as I write my journal, things are speeding up here at our facility. I am starting to feel like an expectant papa once again. The feeling is almost indescribable; exciting and scary, filled with impatience and frustration, and every now and then a sense of wonder. We are now finishing the construction that had been put on hold way too many times, until we got certain parts and pieces of equipment. When we first got the brewery equipment we knew it was a good deal. What we didn't realize at first was how badly the equipment had been misused. It came to us third-hand. The first owners knew what they were doing, but the second owners were clueless. Everything that could be broken, was. Fixing it all has cost almost as much as the original price. You wouldn't believe how many hours have been spent on it as well. We have been building, rebuilding, cleaning, polishing, taking things apart, repairing them, and putting them back together. Manuals were ordered, read, studied, and memorized. I see the disaster of equipment in all stages of use and misuse, then partly dismantled and in a state of repair; littering what was once the beautiful and clean home of my future brewery/distillery. Finally it is all slowly coming together.

Do you remember the 70's TV Show "The Six Million Dollar Man"? At the start of each episode they say "Steve Austin, astronaut. A man barely alive. Gentlemen, we can rebuild him. We have the technology. We have the capability to build the world's first bionic man. Steve Austin will be that man. Better than he was before. Better, stronger, faster." Well that's what's going on here. I feel like we are team of surgeons, or maybe mad scientists... re-building a living being from the horribly injured wreck of what once was great. Sometimes the surgery is detailed. Piecing together tiny wires, resistors, connections. Other times you reach for the biggest hammer or wrench you can find. We are discarding old and outdated parts of the brewery and replace them with the best, cutting edge, adding new technology. Computers, sensors, probes, you name it. We will rebuild it. Better than it was before. Better, Stronger, Faster. It will be The Bionic Brewery! (And hopefully not cost six million dollars!)

Here and after the jump are photos of the first part of installing the steel vent pipe. It was heavy as hell, and I had to lift it into place by hand as the brew kettle was jockeyed into position, that had to be exact to within a 1/2 inch so it could connect to the pre-cut and fitted pipes that attach to other pieces of equipment.