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boning room

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Why and How to Do On-Farm Butchery

As I’ve already detailed here on The Hedonist Life, last year we crowdfunded and built our own butcher’s shop here on the farm. Once again, can I just thank the wonderful community of ethical omnivores (& vegetarians!) who supported our efforts, and who have been duly rewarded with uncommonly delicious pork & Jonai Farms calendars. ☺

In the interest of supporting Australia’s fair food movement and the other small livestock farmers who would like to move to on-farm processing, it’s time we gave you some more details about our budget and actuals on the project, and on how we went with our local council and the state regulator PrimeSafe.

Rationale & Profitability Before I give you the nitty gritty I’d love to share the rationale and real financial benefit to our farm.

Based on the final four months of having our meat butchered (Sept-Dec) and the first four of doing our own butchering on farm (Jan-Apr), our butchering direct costs went from 43% to 30% of total direct costs. More dramatically, it went from 22% to 11% of our total costs (including overheads).

While running a coolroom & other associated infrastructure took our energy costs up some, it was in truth only a 3% increase (from 2-5%) in overheads, or a 2% (from 1-3%) in total costs.

This change in costs came at the time we increased our supply from 5-7 pigs per month to 8-12 pigs per month (which would have increased our butchering costs a great deal), and introduced our CSA model (we now have 28 members!).

We went immediately from making a loss on the farm (subsidised by my off-farm income, which I gave up in December with some trepidation…) to turning a profit. Huzzah!

Now onto the details of building the boning room…

Construction In my earlier post on the meatsmith, I recounted the process we went through to build it from a 40-foot refrigerated container, so have a look at that for timelines, materials and construction challenges.

Council We were initially informed we would need a planning permit, but due to changes to the planning scheme in Victoria 1 September 2014, that proved not to be the case for us. The new scheme allows for primary produce sales & rural industry without permits. Clearly if you have overlays on your property they could trigger the need for a planning permit, so you'd need to check those.

So that just left us with PrimeSafe.

Regulation We were really uncertain about how we’d go with our regulator as we’d heard stories that they could be difficult to deal with. Also, many said we were crazy and they’d never approve a butcher’s shop on a farm. As there are other butcher’s shops on farms, that’s clearly not true… and now we’re here as another example!

Understanding the Victorian Standard for Hygienic Production of Meat at Retail Premises is slightly daunting when you’ve come from outside the industry, and working out how to operationalize standards is tricky without advice. Now that I’m a butcher I have to say they make perfect sense…

I won’t go into great detail here though except to say that the Standards are for the most part quite reasonable and relatively common sense (eg non-porous materials for benches & floors for obvious reasons of hygiene). I will also note that there is an entire sub-clause for wooden butcher’s blocks under section 4.1.3:

(d) wooden chopping blocks (“Butchers Blocks”) shall be free of splits, cracks and holes; and shall be maintained in a hygienic condition;

That is, wooden blocks are legal, and simply must be kept in good condition.

If you want more insight into how to build something legal, we found it very worthwhile to join the Australian Meat Industry Council (AMIC). They not only have been great at providing advice and making visits to check out our facility before the inspectors came, your membership fee pays your year’s audit fees, so is a great value proposition.

Butchering qualifications There is no legal requirement to have a certificate to be a butcher. But there is very good reason to ensure you are trained by one! Butchering is hard, skilled work, and should be approached seriously as such. I apprenticed informally with our butcher for six months, butchering between two and four pigs per fortnight over that period. It was invaluable, and I’d strongly recommend you do similarly if you can find someone as accommodating as Sal was.

Budget & Actuals I’ll finish with our budget, target and actuals. As with most things at Jonai Farms & Meatsmiths, we buy secondhand materials as often as possible. Virtually everything in the butcher’s shop is secondhand (excepting the bandsaw, MGO & expoxy flooring, and my beautiful red gum butcher’s block made by our mate Turk). So while we budgeted for possibly having to pay the price of new equipment, we typically found secondhand due to Stuart’s excellent commitment to spend time trawling the internet & back laneways for others’ disused or discarded items. That’s why the ‘target’ column is lower than the ‘budget’.

Note that the actuals column includes items we hadn’t foreseen, and yet we still came in under budget (*high fives to Stuart*).

At the bottom we’ve costed in how much we think labour would have cost if Stuart hadn’t done it all himself – based on paying a qualified builder full time for one month to do the full conversion. Happy to take feedback on whether we’ve got that right or not.

Budget Jonai Farms Boning Room

Component

Est Unit $

Target $

Actual $

Difference

HACCP QA Manual

$700

$700

0

-$700

Design/spec consult

$500

$0

0

-$500

First inspection

$300

$300

340

$40

Aust Meat Indust Council

$1,000

$1,000

1200

$200

40' Reefer

$6,000

$4,000

4500

-$1,500

Delivery

$1,500

$1,500

700

-$800

Footings

$160

$50

40

-$120

Rust treat

$100

$50

50

-$50

Floor level - MGO

$1,000

$1,000

300

-$700

Floor epoxy

$1,000

$1,000

1050

$50

Drains + grease trap

$800

$600

200

-$600

Window

$600

$400

70

-$530

Door

$2,000

$400

110

-$1,890

Frame

70

$70

Rework frame

185

$185

Plumbing

$1,500

$1,200

700

-$800

Hot Water

$4,500

$500

1200

-$3,300

UV filter

$1,300

$1,300

600

-$700

Water pump

$300

$50

100

-$200

Electrical + Lighting

$1,500

$1,300

3706

$2,206

AC Unit

$3,000

$400

600

-$2,400

Cool rm chiller

$2,000

$2,000

3000

$1,000

Hand sink

$500

$100

100

-$400

Equip sink

$1,000

$500

355

-$645

Chop boards

$600

$300

120

-$480

Mincer

$250

$250

150

-$100

Benches

$2,000

$1,400

1800

-$200

Slicer

$300

$150

1500

$1,200

Band saw

$2,000

$400

2164

$164

Shelves

$1,000

$500

390

-$610

Rail

600

$600

Smoker

3250

$3,250

Display fridge

2500

$2,500

Freezer

300

$300

Consumable set up

1500

$1,500

Butcher block

$0

$0

Incidentals

$2,000

$1,000

1600

-$400

$0

TOTAL

$39,410

$22,350

$35,050

-$4,360

Labour

 $6,400.00

The work and cost involved in taking control of our supply chain has had enormous benefits to us, which we sum up as an ‘ethically viable no-growth model’.

Most importantly, we can provide total transparency to our customers (e.g. there’s really no gluten in any of our sausages, just meat, fat, salt, pepper, spices & herbs from the garden!), and can respond flexibly to their orders just like a regular butcher’s shop, instead of being locked into particular sized cuts, number of chops per package, etc.

We also have control of the reliability of our butchering – only we can let ourselves down if we can’t cut for some reason. This is an enormous relief as most small producers will attest.

We don’t need to grow our herd to make ends meet – we’re fully viable at a size that respects what Salatin calls the ‘ecological umbilical’. We have no need (let alone desire, but who does?) to tax our land beyond its capacity.

We hope this information is all useful to lots of other passionate fair food farmers out there! We take Joel Salatin’s advice to ‘hold your innovations lightly’ very seriously, and intend to keep sharing what works (and what doesn’t!).

Viva la revolucion!

* * *

If you’re keen for more information, we now offer producers’ workshops on our ethically viable no-growth model, which we’re keeping intentionally affordable as we are here to help grow this movement, not just our own wallets. The next one is on 16 August 2014 and right now has plenty of room, but the last one filled up so don’t leave it too late to book.

* * *

Our next step in taking control of that chain and making more delicious things for our wonderful community is to build a curing room and commercial kitchen, where we’ll be able to cure salami, prosciutto, coppa, and pancetta, and cook a range of charcuterie such as rillettes, pate de tete, and other things that make the most of the rich potential of the pig.

You can check out our latest crowdfunding campaign to do just that over on Pozible, where we’re asking people to let us feed you instead of the banks!

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Gratitude & Progress!

Like an old world barn-raising (2.0), you came and helped us build a dream. When the clock ticked over past the 40 days and 40 nights of seeking funding for our on-farm boning room, we’d just hit $27,570 - $6,120 over target (which we reached on Day 19!)! It’s a testament to how much people do want to know about where their food comes from that we’ve had such a success, and we’re grateful to all of our wonderful supporters and to Pozible for providing the platform that connected us. Last week the Weekly Times ran a feature on Jonai Farms (p.65-66), as well as a news piece about our success. And then we were on ABC Statewide Drive to talk about our plans and the benefits of crowdfunding. Apparently we’re the first farmers in Australia to crowdfund on Pozible!

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We've already been able to deliver over 70kg of ethical pork rewards to the wonderful people who have supported us, and look forward to delivering another 450kg over the second half of this year. We've also got the shed ready for a day of fun, feasting and learning for Salami Day, at which we look forward to meeting many of the people who've so generously contributed to our project.

Well supporters, once again we thank you. The 40-foot refrigerated container arrived last Monday after a week’s delay due to very wet weather and a boggy driveway, and one of our lovely neighbours came around to help us drag it into position with his tractor. Stuart has commenced the fitout, and the knives are ready and sharpened. ;-)

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We’ll keep you posted on progress, but we hope to be doing the butchering here on the farm by the end of August… wish us luck!

Thank you so much to all of the people who supported us, all of whom are part of the real food revolution in Australia!

Jonai Farms Supporters

Adrian Wong
Al O'Toole
Amie Batalibasi
Angela Ashley Chiew
Angelina Ng
Anne Shea
Antonina Lewis
Benjamin McCarthy
Bronte Lance
Clancy Whittle
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Firstdog Onthemoon
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Goldie Pergl
jane canaway
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maia sauren
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Mosey
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Ben Dutton - The Stock Merchant
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J L
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Liz Rowe
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David Barlow
Earl Canteen
Fooi-Ling Khoo
Kate kilsby
Kim Jenkins
Laura Binks
Neil Moody
Neil Moody
Norma Foster
Phil Lees
RedBeard Bakery
Sally Syme
Stephen Weber
Tosh
John Nolan
Kelli Garrison
Leslie Swearingin
Mich Zeitoun
noel bayley
Scott Anderson
The Wolf Taskers
Wayne Jonas
Daniel BondFrank KeanyJulia Morris

Melissa McEwen

Meryl McKerrow

Mindy Johnson

scott & penina

Tommy Hoschke

Zoe Bowman

max king

Yu-ching Lee

Zara Pearson

Jim Collings

at Glebe2037

Celia Maslen

Dylan Copeland

Geoff Tolchard

Jo Scard

john

Kirsty Leishman

Matthew Smith

Melissa Brooks

Monica Sharma

Naomi Ingleton

Reem Abdelaty

If you want to keep up with our progress and delivery days, you can now subscribe to our regular newsletter!

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Jonai Farms in Epicure!

Today we got a short write up of our Pozible project to build a boning room on the farm and do all our own butchering. If you haven't seen it already, check out the video 13-year-old Oscar produced for us, and spread the word about re-localising and bringing greater transparency to our food systems! And if you'd like some of our uncommonly delicious ethical pork, the rewards we're offering through the campaign are primarily pre-orders of pork! Screen Shot 2013-05-14 at 4.06.12 PM

 

For those interested in more background on why we're farming the way we are and why we want to do our own butchering and curing, Amanda at Lambs Ears & Honey did a great interview with me last week that answers a lot of those questions. :-)

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