Author: April Moore

Not much to stay here. I'm just his sidekick. :-)
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Making Whiskey

Prichard's distillery utilizes two beautiful, old Vendome stills, one for stripping runs, the other for final distillation runs.

Hey, all. April here again.

In the last blog, I mentioned that we were eager to get started using Second Intention Farm’s Jimmy Red corn and springwater to make our own craft whiskey. But we haven’t built our building yet, and without a bonded premise, we can’t yet get our DSP (Distilled Spirits Permit). But there IS another option that fledgling distillery’s use all the time to get products in the queue before they have their own setup. That option is contract distilling.

Last fall, knowing we still had an abundance of corn from the previous year that was literally in the way of the critical project of building our distillery, Chip came up with an excellent way to solve both problems at once. We’d get someone else to turn the farm’s corn and springwater into whiskey and barrel it for us until we could legally store it ourselves on our own premises. It takes four years to age a bourbon and contract distilling would allow us to start that process at least two years sooner.

When it comes to contract distilling there are a whole lot of options. Some distilleries will buy a spirit outright that has already been aged and just put it in a bottle with their label on it (one distillery we know of famously won awards for their bought whiskey before they’d even put a shovel in the ground to build their own). Others will supply the contract distillery with a mash bill they want made to order. In that case, the contract distillery will usually use whatever suppliers they are accustomed to using for their own products.

There are many distilleries that offer contract distilling, since a still that isn’t running isn’t making any money. But for what we had in mind, we knew it would have to be someone local. It was our plan to not only use the mash bill we’ve been testing out for a while now, but to provide the farm’s springwater and heirloom Jimmy Red corn to make it. And we didn’t want to have to transport those materials very far, since we’d be doing it ourselves.

There are several distilleries not too far away from our farm. One of those is Prichard’s Distillery in Fayetteville. We’d met with Mr. Prichard earlier in the year to discuss buying some equipment from him he no longer needed. So we reached out to him about our contract distilling plans. After a little back and forth, a deal was struck and we signed the contract last November.

Now, we just had to finish shucking, shelling, cleaning and milling about 3 ½ tons of corn!

By early December, we had processed and milled – using the hammer mill our miller loaned us – enough corn for the first run, 1500 pounds. We were still in the midst of a severe drought, so collecting the springwater we needed took much longer than we’d anticipated. But by mid December, everything we needed was at Prichard’s, including the barley and wheat we’d purchased from Middle Tennessee’s sole malt barn, Batey Farms, near Murfreesboro. We were ready to cook.

A look down into the interior of the beer still after the first stripping run of our corn whiskey.
A look down into the interior of the beer still after the first stripping run of our corn whiskey.

We’ve covered that whole process extensively on our socials. The first day we cook the corn, add all the other grains, cook all of those, add yeast and then put the finished mash into a fermenter. After about a week, it’s a corn beer, which is siphoned off into a beer still for the stripping run, during which it goes through three stages of distillation. After that, it’s siphoned off into a “spirits” still for the final distillations, which remove any remaining compounds that could negatively impact the flavor of the whiskey.

Distillate from the stripping run is monitored constantly with a hydrometer.
Distillate from the stripping run is monitored constantly with a hydrometer.

With that first run done just before Christmas, January saw us back at the farm getting more corn processed for the second run, which we completed in mid-March. Now, we’re almost finished with the components for the third run, which we plan to send to Prichard’s in the next week or two. Going forward, we’re optimistic that we’ll be able to run another batch each month during the warmer, dryer summer months, hopefully finishing before harvest time comes around again.

The final proofs of Batch 1 and Batch 2 from our first two runs were almost identical.
The final proofs of Batch 1 and Batch 2 from our first two runs were almost identical.

We had enough distillate after that first run to fill a few barrels, but, since we are making multiple runs, Seth Kimball, Prichard’s production manager, plans to wait until all or most of those runs are finished, since we’re making the same recipe every time. Then, we can sample all of the runs and blend them accordingly before we put them into barrels to age.

We’re very happy so far with the product we have (and very eager to see it barrelled). Prichard’s has been an excellent partner to work with. And while this won’t be the bourbon we plan to produce in the future, which will be distilled by us and aged in our own white oak barrels from the farm, we think it will have a distinct and delicious flavor, thanks to the farm’s springwater and Jimmy Red corn.

In the meantime, we have a lot of work in front of us. Thank you for joining us on this journey as we move closer to opening the doors of our uniquely local, farm distillery.

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The Farm’s White Oak

Stacks of white oak staves ready to be put out into the yard for aging

Hello, everyone. It’s me, April, again, with another blog to bring you all up to date on the big things that have been going on #downonthefarm over the last two years. In my last two blogs, I caught you up on the story of the corn and the springwater we’re using for our products. Now, it’s time to talk about the wood we plan to age our whiskey in.

But to do that we’re going to have to step back a little further in time, back to the fall of 2020.

We had known since before we took ownership of the farm it was long overdue for a trim. By that I mean, no timber had been taken off the property in decades. An old forest is majestic, and we love ours, but you can’t keep an oak-hickory forest healthy if young trees aren’t able to grow up to replace those that are near the end of their lives. Some of the older trees have to go in order for the new ones to have a chance. And we wanted to be able to pick and choose those trees, rather than have some natural event take down a large area of old trees en masse.

Oak and other hardwood trees growing on the northern ridge of the farm in 2021.
April 2021: Oak and other hardwood trees growing on the northern ridge of the farm.

So, in the fall or 2020, we hired The Woodlands Solution, a forestry consultant, to help us choose. That very next spring, I hiked the farm with our forester over the course of three days. He showed me what to look for when selectively cutting timber and I personally marked around 200 trees to harvest.

About 70 of those were ash trees, most of which were growing in an area behind the main house at the farm. With the green ash borer just a county away, we wanted to go ahead and take the largest of those while they still had some value as timber. And the last thing we wanted was a huge expanse of large, dead trees towering just behind the house.

The remainder of the trees I selected were a mixture of large, old, hardwood trees, such as maple, basswood, cherry, elm, hickory, poplar, chestnut oak, walnut, red oak, black oak, and white oak.

You probably know that in order to make bourbon whiskey, you have to age it in brand new, white oak barrels. But you may not know that America is consuming white oak trees much faster than they can grow. A white oak big enough to make barrels needs to be at least 15” in diameter, and those don’t just spring up overnight. That amount of growth takes decades, which creates a supply problem for distilleries.

We first learned about this problem from the White Oak Initiative, an organization made up of private landowners, industry leaders, and government agencies who are working together to advocate for sustainable white oak forest management. Engineered Spirits believes very strongly in producing our products sustainably, so we knew right away this was something we cared about and would advocate for ourselves.

Our loggers collected all the white oaks they had harvested and brought them down to the farm's front lot.
January 2022: Our loggers collected all the white oaks they had harvested and brought them down to the farm’s front lot.

Which brings us back to the trees that we selectively cut at the farm in early 2022. We harvested 15 white oaks, a couple up to 32 inches in diameter at the base. Some were just very old, others too crowded together to remain healthy. But none of those were the best white oak we had on the farm.

That honor was reserved for a single, tall, straight tree, in the prime of its life. Our forester told us it was the most valuable tree on our property, with 12 feet of trunk or more that would produce premium, veneer-quality boards.

We decided to leave that highly valuable white oak tree as our seed tree. Instead we removed the black and red oaks around it that were keeping it from getting enough sunlight. We dubbed this tree the “Queen of the Forest” and, sure enough, the next year she showered the area with acorns, which will hopefully yield the next generation of white oaks.

But we still had those 15 that we had harvested. And we really wanted those to become our distillery’s first barrels. Our loggers had even agreed to reserve those logs for us and bring them down to the front lot. But we didn’t know exactly how or even where we were going to take them. That part was up to us. And, as it turned out, it wasn’t at all simple to do.

White Oak logs from Second Intention Farm laid out in the front lot for transportation to Kentucky.
February 2022: White Oak logs from the farm laid out in the front lot for transportation to Kentucky.

This was not the first time someone told us “no one ever does that,” and it’s certainly not going to be the last. But it was one of the first times we heard so many people say it. Chip called for weeks trying to locate a stave mill that would give us our own staves back after they had aged, and a cooperage that would give us our own barrels back. At last he located a stave mill in Kentucky that said they could do it. We just had to find a commercial driver who could take the logs to them.

You wouldn’t think this would be that complicated either – at least we didn’t – but it turned out it was. Weeks passed again before he finally found someone who would do it and they demanded a very hefty fee. Finally, though, our logs made it to Kentucky.

These pallets of staves made from the farm's white oaks will age here at the stave mill for the next few years.
October 2022: These pallets of staves made from the farm’s white oaks will age here at the stave mill for the next few years.

A few months later we watched the stave mill cut them into staves. Then, they were loaded onto pallets and set aside in the stave yard to age. White oak barrel staves must age a minimum of two years. This past October they passed that mark. Hopefully, sometime in the next year or so, we can have them sent to the cooperage, where they’ll be turned into barrels for our whiskey.

Back at the farm, we still have one major roadblock: we don’t yet have our building. Until that’s done, we can’t apply for our DSP (Distilled Spirits Permit). Therefore, we can’t distill our whiskey, let alone put it in a barrel. So, our next big project is salvaging and rebuilding Papa’s workshop to transform it into the Engineered Spirits Distillery. We expect that to take up this whole next year. In the meantime, it won’t hurt our staves to age a while longer at the stave mill while the distillery is getting built.

But we already have corn and springwater. We want to be making some whiskey right now, so it can be aging in a barrel over the next four years. We also want to get some more hands-on experience distilling at scale.

To address both of those things, we reached out to some folks in the next county over. But I’ll tell you the rest of that story in the next blog.

See you then!

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The Farm’s Springwater

The farm's springhouse has been completely restored, even beyond its former glory.

Hello, friends. April here again, with another blog post to catch you up on the last two years #downonthefarm. Today, I’m going to talk about the water Engineered Spirits uses. Specifically, the farm’s delicious springwater.

The farm has had a reliable springwater source at least since the mid 1800s, possibly even earlier. We don’t know who or when it was that someone first dug down a few feet and tapped into it, all those decades ago. But at some point after that, they or someone following them built the farm‘s historic springhouse out of local stone.

Those who followed after, including the Moore Family, used this same spring as their main water source until sometime in the 1980s. Over time, since the family now had water piped in from the local utility, the springhouse slowly fell into decay, while the spring itself still ran strongly beneath its crumbling walls.

A photo of the farm's springhouse as it appeared in July 2020, before any work to save it had been done.
A photo of the farm’s springhouse as it appeared in July 2020, before any work to save it had been done.

Fast forward to 2020, when we first started planning our distillery business in earnest. Chip had the farm’s springwater tested and the results showed that it was “a distiller’s dream.” But we knew it would take time to find a stonemason who would take on the project we began to refer to as our “Springhouse Revival.” We didn’t just want to repair the building, we wanted to restore it to the way it might have looked over 100 years ago, with stone walls above ground, as well as below. But our immediate concern was just preventing it from falling in completely.

On the southern side, a pecan tree in the orchard had dug its roots into the stone wall, shoving it slowly but steadily inward. On the north side, water and weather had done their worst and that wall too was sagging inward, directly over the deep sump containing the springwater we needed. The concrete block our grandfather had put on top of the original stone structure had completely separated at the base and there were broad cracks in every section. It was only a matter of time until it all toppled in completely.

The springhouse walls were in danger of collapsing entirely before we started work to stabilize them.
January 2021: The walls were badly bowed in before we started work to stabilize them.

So, in December 2020 and into February of 2021, we worked hand-in-hand with Chip’s uncles and father to stabilize it. We first brought in a steel tower and steel beams, from which we suspended two 400 lb. steel plates that were held in place up against the two most damaged walls. Then, we added oak posts and a series of six house jacks, which we put up against them at either end, bracing the walls apart. Or at least, we hoped they would.

Chip Moore hooks a chain to a steel beam as the family builds a support structure for the springhouse in January 2021.
January 2021: Chip Moore hooks a chain to a steel beam as the family builds a support structure for the springhouse.
Chip and Charles Moore stay out of the way as Thomas Moore lifts a 400 lb. steel plate with the farm's backhoe.
Chip and Charles Moore watch Uncle Tommy use the farm’s backhoe to lift a 400 lb. steel plate.
Thomas and Chip Moore tighten house jacks against 400 lb. steel plates to help brace the damaged walls apart.
Uncle Tommy and Chip tighten house jacks against the steel plates to help brace the damaged walls apart.

 

 

 

 

 

 

 

 

 

Luckily, our efforts paid off. Every few months, Chip would go down a ladder into the springhouse and tighten the jacks keeping the walls apart. Since we were going to need twice as much stone as before to rebuild it above ground, we began salvaging old cut stones from a fence that had been shoved off into our uncle’s field, just two miles away. We interviewed several stonemasons, too, but, for one reason or another, no one took up the project. 

Then in 2023, we met Sammy, who’d been helping out some contractors working on Papa and Granny’s house. He had some skill at working stone, he said, and was willing to take on the job. He had done several stone walls around town and had spent some time apprenticed under an elder stonemason. We checked out some of his work and offered him the job. 

Just before Sammy started work on the springhouse in the summer of 2023 it was overgrown with vines, but at least it was still standing.
June 2023, before work started: The springhouse was overgrown with vines, but at least it was still standing.

This was probably one of the best decisions we’d made so far, although, given the amount of backbreaking work required, we’re not entirely sure Sammy would agree!

He began work the week of July 4, 2023. Within two weeks he’d removed all the concrete block and had begun taking the original stone walls down to be rebuilt. The third week, Chip and Sammy met to discuss the next stage of work. By then, he and his team had already remortared the lower part of the western wall, re-laid and re-mortared the lower section of the southern wall, and begun excavating the northern wall. His plan was to bring all four walls back up together.

Two weeks in, the damaged concrete block walls were all gone.
July 16. 2023: The damaged concrete block walls were all gone and work had started below.
July 22: Sammy discusses the next stage of work with Chip as he digs out the northern wall of the springhouse.
July 22. 2023: Here, you can also see the pipe Sammy put in for a future pumping system that will connect directly to the distillery.
August 2023: Barriers were laid over the sump during this time to protect it from falling mortar.
August 2023: Barriers were laid over the sump during this time to protect it from falling mortar.
October 2023: Sammy discusses how we wants to finish the exterior walls with one of his crew members.
October 2023: Sammy discusses how we wants to finish the exterior walls with one of his crew members.
November 2023: The roof was going on, using materials Sammy salvaged from the farm's damaged trench silo.
November 2023: The roof was going on, using materials Sammy salvaged from the farm’s damaged trench silo.

Nonetheless, by December 2023, he and his crew of helpers had not only revived our springhouse; they had made it even more beautiful than we could have imagined. Our very own Christmas miracle. Sammy hadn’t just given us what we asked for; he had improved upon it in so many ways. If you’ve been following our social channels, you’ve probably heard about that.

December 2023: There was clean-up yet to do and it still needed a door, but the springhouse was all but finished.
December 2023: There was clean-up yet to do and it still needed a door, but the springhouse was all but finished.

Earlier this year, Sammy completed his last few tasks at the farm’s springhouse: black slates around the sump, a rustic door, and a screen for the window, so visitors can look in from the outside. It is truly a feat of craftsmanship and we look forward to the day when you can see it for yourself.

The farm's springhouse has been completely restored, even beyond its former glory.
The farm’s springhouse has been completely restored, even beyond its former glory.

And, of course, best of all, now we have both our corn and our springwater. It’s another huge step toward getting all the main ingredients for making our own whiskey directly from the farm.  Our corn, our water, our wood. 100% our whiskey. 

Guess what I’m going to tell you about next. 

Until then.

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Jimmy Red Corn

Ears of dark red Jimmy Red heirloom corn

Hello, friends. April here. It’s been a long time since we wrote one of these and we apologize for that. But there’s a whole lot to update you on regarding Engineered Spirits, too much to cover in one post, so we hope you’ll be patient with us just a little bit longer as we tackle the main updates a topic at a time over the next few weeks.

About six years ago now, we started talking about finding a new purpose for the family farm after our family stopped raising beef cattle and “retired” from farming. But when you have a green belt farm with over 100 acres, you can’t just wake up one day and stop farming it. It was a couple of years before James Moore (better known as Chip to his friends and family) came up with the idea of building a farm distillery on the land and talked me (his wife) into it. That’s how we arrived at the name “Second Intention Farm.” Most folks would buy a farm to build a distillery, but in our case, we were building the distillery to save the farm.  

Even then, we knew we wanted to be in control of the ingredients that went into our products as much as possible. All during the lockdowns of 2020, we brainstormed, planned, and did research on the types of grains and botanicals we might grow to use in our products. We decided to start by growing heirloom corn and eventually I found an NPR article discussing a famous moonshiner corn that had been brought back from the edge of extinction, Jimmy Red. It was an interesting story and we like those.

We were able to get the seed of this unique, open-pollinated variety from a co-op in Alabama and then we spent that year and the following, really, just learning how to grow it. I won’t go into all that – our learning curve has been pretty well documented over the last four years on our social media channels, as well as on the farm’s – but ever since, we’ve been saving our own seed and planting and harvesting it with the vintage farm equipment our family owns. 

Jimmy Red produces dark, dark red ears that, when milled, make delicious pink grits, as well as pink cornmeal. Used as cornmeal, it makes anything you’d use that for even more delicious. Most distilleries use cornmeal to make their whiskeys and indeed there are a few using Jimmy Red now. But Chip didn’t want to use cornmeal. He wanted to do what those old moonshiners did and crack it. 

At Moonshine University – the training course for the Kentucky Distiller’s Association – Chip had learned how to cook the corn. But he’d never done it by himself on his own equipment. So, last year, he started practicing, using the farm’s cracked corn, turning it into beer, just going through the process he had learned. This year, he repeated the same process, but with cornmeal instead. Construction has been moving very slowly at the farm, so he figured he might as well practice. That way, once the distillery’s doors are open, we can hit the ground running.

All of this work just to learn the best way to make whiskey and to have a product we can be proud of. We could have bought Jimmy Red from a local farm. We know the farmer well. He has a combine and plants several acres. He uses modern techniques. But he also uses herbicides and pesticides so he can sell his corn on the market at a cheaper price.

We’re just not going to do that. Our corn is grown the way those old moonshiners grew it, with nothing but sun, rain, and a lot of hard work. It’s the farm’s crop, of course, but we know the history of how it was planted, grown, harvested, processed, milled, cooked and fermented. Eventually, we’ll also be able to tell you how it was distilled and barreled, all the way from the seed until you pour it in your glass.

Our goal is nothing less than this: Our corn, our water, our wood. 100% our whiskey. 

Now, we can check that first one off our list.

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A Year on the Farm

Engineered Spirits - Red Buckeyes on the Ridge

Down on the Farm

Work never stops down on the farm, but even in the depths of winter, there’s always something to see, learn and experience.

In earliest January, we’re out in the woods, identifying trees, checking on the health of the forest, repairing trails and access roads, and addressing any problems that may harm our beautiful forests. Then, in a slowly drifting wave of color, the first native wildflowers appear on the forest floor – rue anemone, trilliums, toothworts, the first mayapples. In March and April, the forest  accelerates with the season, and now we see firepinks, Jack-in-the-Pulpit, wild hyacinths, dwarf larkspur, wild blue phlox, false garlic, bluebells, foamflower, and a host of other beautiful ephemerals, crescendoing in a great burst of color as the buckeyes light up the ridge in a blaze of red. But the show’s not over yet, and won’t be for months, as more native shrubs, trees, fruits, and wildflowers break into bloom. Hearing the hum of the first bees and hummingbirds all around as they visit these plants is something everyone should experience.

In April and May, as soon as the weather dries up a bit, we’re preparing our fields for planting crops, especially the heirloom Jimmy Red corn that the distillery plans to use for its products. In May the burgundy corn seeds go in, and then we’re weeding, fertilizing, and trying to keep the deer and raccoons away from the crop while it grows (we have a few innovative ways of doing that you may find amusing).

In the meantime, our summer vegetables for the kitchen have been planted in the vegetable beds, and new annual herbs, started from seed in our greenhouse, have been planted alongside the perennial herbs that have grown here all winter. All summer we’re harvesting fruit we’ve grown and foraging for wild ones, first strawberries and raspberries, then cherries, blackberries, mulberries, currants, elderberries, pears…. If we don’t eat them outright or serve them in the kitchen, they’ll be sold to the distillery to make the small batch, artisanal spirits for which it’s becoming known. And you’ll be able to be part of that forest-to-bottle story.

In August or September, of course,  it’s time to harvest the corn, so we’ll be out in the fields collecting firm ears of corn and putting them on the screens to dry, before sending to the mill. But we’re also collecting ripe pawpaws and persimmons as they come in, to round out the botanical flavors for our customers to enjoy, either in seasonal dishes served fresh from the farm’s kitchens or in an Engineered Spirits bottle. Learning how to identify and forage these unique fruits is an experience you’re sure to enjoy, just as we have.

Later in Autumn, we’ll mow or burn the wildflower meadow, collect seeds for next year,  and lime and fertilize the fields we’ll grow our corn in next spring.  As the holidays approach, we’ll collect nuts for the table and for use in new recipes. The Christmas Market will come and go in a splash of bright colors, carols, cool crafts and the smell of hot cocoa.

Then, once more, it will be time to reflect on what we’ve accomplished, plan our new endeavors and products for the coming year, and sit and dream with a nice glass of something by the fire as another beautiful year on the farm draws to a close. And then begins again.

It will take time for some of these plans to reach fruition, but each day, step-by-step, they come closer to reality. A week passes, or a month, and another piece of the puzzle slides into place.

In the coming months, we’ll be posting a calendar here and on the farm’s website, which will be launching later this month. From that calendar, you’ll be able to plan your visit to the distillery and to the farm and experience everything throughout the year we have to enjoy, whether that’s booking a tour of the distillery and a tasting, enjoying a farm fresh picnic lunch, or taking a tour of the botanical beds. We’ll hope you’ll consider joining us there.

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