This past week has brought new economic expenses to the forefront and left us scrambling to make sure that everything falls into place right. I guess this entry might be called “Focus On The Structure”. It can be used as a lesson to anyone of you that might consider opening a brewery in the future. The main thing that anyone who might want to accomplish this must consider are permits. Permits are the main hindrance to any startup business whether it be a restaurant or a brewery. The structure of the building holds the locks to obtaining these permits and the city officials that release these permits hold the keys to unlock the structure. That is why I can’t possibly emphasize enough how important prepping and obtaining permits for the structure is.

 That being said, if you aren’t interested in mechanical and technical issues regarding how the equipment works then you might be bored to death by this entry. These are the ropes. It is not my first time on them this time around either. I am starting to learn and get comfortable with the ropes. They provide the solace of anger, frustration and are bundled together by anticipation.

 Buying a brand new system is not the end of putting together a brewery. Remember those toys your parents bought you for Christmas? You were so happy and then you realized that in fine print on the box it says “batteries not included”. This is the place that we have come to linger in as of late. It isn’t an entertaining place to be. When it comes down to the line, everything becomes accelerated to a rate that you might find your head spinning and trying to hold it all together for the last second of focus before everything comes apart at the seams. If you can hold that focus long enough then the pieces fall into place appropriately. If not then it is wasted weeks and wasted dollars. No income and more expenses begin to wear away at you until you get to the golden moment of the first day of production. That is where I am headed but I have made several wayside stops on this journey that don’t have the best atmosphere to hang out in.

 First hang up, I thought that the electrical schematic would be covered by the mechanical blueprint. My worst enemy might be my assumptions because this was not true. I had to scramble to find an electrical engineer to handle the project at breakneck speed so that as the mechanical permit was falling into place, the work on the floors, the cooler and tank placement could be conducted. This is my hope. The electrical engineer has the majority of the information but I received an email from him today saying he needs a few more details to continue the plan. I know that I must provide those soon (preferably yesterday).

 The next thing that I realized was that the boiler did not come with a condensate return tank. The first quote that we received was 1.7K. I have another quote coming that should put it at around 1.1K. That makes me feel a little better but still an unforeseen expense.

 Then there is the fact that the solenoid valves for hot and cold side applications are not included in the package by Premier Stainless. They are working on getting a Grainger order together for us to solve this problem. We are probably looking at an additional 1.5K for this.

 We did not budget for bulk CO2, O2, an LPM gauge, CO2 regulators, a pump for the cold liquor tank, an air compressor for the bottling line/keg washer. Nor a flow meter for our bottle conditioned beer program and to initially mark volumes for kettle yield, a sprinkler system for the cold room(we have to have this to meet code), a CO2 stone for artificial carbonation and any additional parts that we might need for gas applications on the fermenters that are not included on the tank.

 We have also had to bring in an HVAC team to cover the install of the cooling units for the cold room and to pull the permits for the install of the chiller (it’s a monster at 10 tons and 10 horses with dual pumps). The HVAC team most likely won’t even have to touch the chiller but just oversee its install. We have to have the permits though so there is no choice.

 I could have easily gone into detail and made this a much longer entry but when I see it in writing it makes matter worse in my head. I know that there will most likely be more unexpected expenses and we will have to do everything that we can to make intelligent decisions as to how we proceed with the project. Like Jimmi Hendrix said “it’s a frustrated mess” and no it isn’t depression but most likely manic.

 I have been dealing with a stuck fermentation on the 34 degree plato barley wine that we brewed. I made a starter with the White Labs High Gravity yeast this evening and I am hoping that this will do the trick. We moved it into a secondary vessel today to avoid any potential autolytic off flavors.

 I pray that we are finally getting close to a working proof for the IPA label but we shall see. We are using a different marketing team as of yesterday and are awaiting their first proofs. Usually the first proofs tell you a great deal about the team that is working for you and whether there is a connection or if the team misunderstands what the intent of the business is. I can only hope for the best.

 I will be meeting with several plumbing contractors between tomorrow and Monday to obtain a second quote. We received out first one today and it looks astronomical to us. All the details (mechanical blueprints and pipe/drain/exhaust specs) are in place so may the best proposal win. 

 My apologies for a rather droll/technical entry but if you wonder how I feel at this point in the operation and can sense the emotion and mood of this entry then you will understand where we are. This project will have to kill me to make me stop but it definitely is at a stressful point as of now. Since these are the last finishing touches before we go into production it brings to mind a saying that I have heard over and over in movies and television, “Watch out for that last step…it’s a doozy”.

 Hope you are all well and enjoying your favorite beery libation as you contemplate the nearing arrival of winter. I know it is still hot but I can already sense it coming on and it makes me want to drink an Oktoberfest. Then there is the good old mainstay…quality pale ale or IPA.

Hang in there…we are going to put beer on the shelf if it kills us,

Wayne Wambles

Head Brewer

Cigar City Brewing