Sometimes, I REALLY Love My Job

I experience a “magic moment” in the course of doing my summer job.

A little backstory…

Cherry drying (or blowing) is one of those things most folks don’t know about. The short version is this: in the two to three weeks before the cherries are ready to harvest, if they get rained on they can split or rot, making them unmarketable. If a grower loses 50% or more of his crop to splits or other water damage, he won’t bother picking at all and the entire crop is lost.

So to protect the crop from this kind of damage, growers hire helicopter pilots with helicopters to stand by during the period before harvest. When it rains, they call us out to hover low over the trees. Our downwash blows the tree branches and shakes the water off the fruit, “drying” it. It’s tedious work that requires a good bit of concentration to deal with wind and obstructions. And it can be dangerous — in fact, there were three crashes in the area last year, one of which took a young guy’s life.

This is my fifth season doing this kind of work.

It was late afternoon on a day with drifting storm clouds. I was on call for cherry drying and had already gone out once, earlier in the day.

When I wasn’t flying or prepping the helicopter, I’d spent a good part of the day watching the weather radar on my iPad. Various colored blobs were drifting across from the west, after a gradual shift from their southwest to northeast direction earlier in the day. Rain varied in intensity from a light drizzle to torrential downpour. Every time a storm hit or missed an area, there would be another one right behind it to possibly do the same. Sometimes the rain was so intense that the storm would drain itself and the colored blob would fade as it tracked across the screen.

I was only on contract with one orchard: a 30-acre block of mostly very mature trees near the Columbia River. The grower was very careful about his orchard and, during the vital period, normally spent all day just about every day among his trees. Sometimes he’d mow the long strips of grass in the aisles between them. Other times he’d tinker with the tractors and other equipment he needed to care for his crop. Still other times, he worked on his shop, patching insulation, repairing a roof, adding a wall. Smart phones and good cell service — not to mention a good pair of eyes — had made it relatively easy for him to track the weather throughout the day. But he occasionally called or texted me at my base seven air miles away, where I had a better look at the sky and a bigger screen to watch the radar blobs.

I saw the storm coming on radar and confirmed it with a look outside. It was across the river to the west, heading right for the orchard. While there was a chance it might rain itself out before it arrived, I suspected it might not. Already still suited up from my flight a few hours before, I headed back to the helicopter to pull off the blade tie downs and prepare to fly.

Low CloudsThe sky was intensely dark out toward the river and the storm was definitely heading in my direction. But what was even scarier was the low hanging cloud near me that seemed to be swirling gently like something from a Weather Channel tornado special. I watched it for a while, wondering whether the storm was really intense enough to get a tornado going. It didn’t seem to be.

My phone rang. It was my client. “Work your magic,” he said.

It took me a second to comprehend his words. “It didn’t even start raining here,” I said.

“It poured like hell on the orchard,” he told me. “It’s stopped now. Come on out and dry.”

I hung up and moved my truck out of the way. By the time I was hurrying back to the helicopter, big raindrops were falling on me. The swirling cloud was gone.

I started up and began the warm up process. It wasn’t until I was pulling on my helmet that I realized I’d forgotten to take my door off. This could be a problem if the sun came out and it warmed up; the helicopter would become like an oven every time I faced the sun. But the sky was dark and that didn’t seem likely. Ah, little did I know…

By the time I lifted off the pad, the rain was dumping on me. The cockpit bubble was wet with a million drops. I pushed the cyclic forward and accelerated into my climb. The drops ran off the sides, clearing the window enough to see. I turned to the west and flew right into a wall of hard rain.

When I flew at the Grand Canyon back in 2004, we had a sort of mantra for dealing with heavy rain: if you can see through it, you can fly through it. This rain was so intense that I could barely see brightness in the sky beyond it. I was flying at about 200 feet off the ground — just high enough to clear the local power lines but probably not high enough to clear the high-tension power lines I knew were up ahead. The air was remarkably calm, so at least I didn’t have to deal with turbulence. I climbed cautiously, heading west, flying at 110 knots, focused on reaching the orchard quickly.

The sky brightened. The rain lessened. Then I was through the storm, on the other side, flying into what looked like a beautiful day.

A really beautiful day.

Ahead of me, the sun was shining brightly, sending patches of light through broken clouds onto the yellow-green hillsides beyond the Columbia River. Some low-level clouds were floating at my altitude over the river and beyond. Wisps of clouds were wrapping themselves around hilltops like winter scarves around thick necks. The sky had a kind of three-dimensionality I rarely get to see.

And over my right shoulder, back in the dark storm I was passing, was a double rainbow.

There are times that I can only classify as magical — times I wish I could bottle up and save, just so I can open them up to re-experience them when I need a little magic in my life. This was one of those times.

I realized, in a flash of clarity, that I really loved doing what I do.

I call myself a writer, but in all honesty, there’s no way I can express, in words, the feeling I get when I experience one of these moments. I can try to describe what I see. I can try to paint a picture for my reader to see something similar in his own mind as he reads my words. But in truth, there’s no way to share this kind of experience after the fact. It’s a moment in time and space — something that becomes part of me. It’s like a happy little secret I’m forced to bear, unable to share it with anyone else.

It’s moments like these that make my life worth living.

I cleared the big wires, reached the edge of the plateau, and lowered the collective almost to the floor to start a steep descent down to the river. The water was smooth, reflecting the clouds in a magnificent sky. Everything below me looked fresh and clean and wet. I descended at 1200 feet per minute over the river, then pulled the cyclic back gently to slow my airspeed and descent rate. Coming in over the orchardI came in over the orchard in a grand, swooping arc, settling in at the southeast corner in a hover over trees nearly as old as I am.

And then I got down to work, hovering back and forth, up and down the rows of trees, performing the tedious task I was paid to do.

From my seat only a few feet above the treetops, I could clearly see the bright red fruit and the droplets of water clinging to them. I could see my downwash shaking the tree branches all around me. Everything was very wet, but with only one pass, most of that water was shaken and blown down to the ground.

Sunset Cherry Dry

Golden Light

I stole glimpses of the river and sky and cliffs. It was early evening on a Washington day when the sun would set well after 8:30 PM. The sun played peek-a-book with thin strips of clouds. The sunlight illuminated the cliff faces in a golden light.

On the ground out on the road in front of the orchard, my client stood outside his truck, snapping photos with his camera. Inside the front passenger seat, I saw his mom. She waved once but, with both hands fully occupied, I couldn’t wave back. Later, the truck was in the orchard, near the shop building. The photos started arriving on my cell phone, which was docked in a cradle within reach, a while later. I wouldn’t be able to see them until much later.

It took over an hour to do the whole orchard. It always does. It’s a tough dry, with trees of varying ages and heights, a gentle slope, a deep gully, and some nasty wires right at rotor height along one side of the orchard. I spend a lot of time flying sideways so I can keep low on a downhill stretch without getting my tail rotor in the trees behind me. But finally I was done. I did what I think of as my “victory lap,” a fast, low-level flight diagonally across the orchard, gaining speed before pulling the cyclic back to start a steep climb up the cliff face.

At the top of the cliff, thin clouds were thickening, forming a fog layer that would soon be too thick to pass through. I squeezed through a gap in the clouds and pointed the helicopter east, toward my home base.


Note: Many thanks to Patrick, my client, for providing the in-flight photos that appear in this post and on Facebook.

Adventures in Boating

The truth can now be told.

My Boat
Here’s Pete and Linda helping me do a pre-purchase inspection last fall.

For a while, I was doing a lot of tweeting and Facebook updating about my little boat. It’s a 1995 Sea Ray Sea Rayder F-16. Sounds hot, huh? Well, it’s just a little old 16-foot jet boat that can take up to 750 pounds of payload spread among five seats — about the same capacity as my helicopter, with one extra seat.

The Mobile Mansion in Tow
The mobile mansion at one of two overnight stops on the way back to Arizona last October.

I’d bought it in Washington State last autumn, just before going back to Arizona for the season. Because I had to tow my “mobile mansion” back to Arizona, I had to leave the boat behind. The folks I bought it from kindly agreed to store it form me. I regretted not taking it home; I didn’t use the mobile mansion in Arizona over the winter, but I sure could have used that boat.

Taking Possession

In the spring, I returned to Washington for cherry drying season. I came back early, mostly because I like it up here so much better than Arizona. In fact, I’m seriously considering relocating.

I finally took possession of my little boat early in May. I towed it back to the campground where I was living.

Boat in Tow

My Boat at the Campground
Here’s my little boat, parked at the campground where I’m living right now. That’s my mobile mansion in the background, with the windsock.

The boat needed some work, but not much. The bumper around the edge of the boat was cracked in front and I wanted to replace it. The grip stickers on the engine lid were half peeled off and I wanted to replace them, too. The wires for the trailer lights were frayed and patched and needed to be fixed up. The trailer wheel bearings likely needed repacking with grease for the long drive back to Arizona. And the bimini top had two broken parts that had to be replaced before I could use it. I set about taking care of these things, making an appointment at a boat dealer for some and ordering parts for others.

I also bought a river anchor and some line for it, just in case the engine decided it didn’t want to run when I was out on the water. I didn’t want to end up at the next dam.

The Planned Test Run Doesn’t Go as Planned

The weather warmed and the winds calmed. In mid-month, we had two consecutive days forecasted with unusually warm weather and light winds. It would be a perfect opportunity to take the boat out for a test run.

I admit that I was nervous about taking the boat out by myself. I had plenty of confidence in the boat’s seaworthiness — its previous owners had taken good care of it. But it had been a long time since I’d ever launched a watercraft — jet skis at least 5 years ago — and I’d never done it alone. I asked my friend Pete to accompany me to the boat ramp and advise me while I launched the boat.

Pete’s schedule was tight, with just an hour-long gap between appointments, so my goal was to prep the boat and get it all ready to launch before we met. I hooked it up to the truck and stripped off the boat cover. I got all my gear together, including a bag of goodies to snack on. Then I hopped in the truck and started the 15-mile drive to Crescent Bar, stopping to fill the boat’s gas tank with gas along the way.

Crescent Bar from the Air
Crescent Bar from the air. You can see (and buy) a larger version of this image here.

Crescent Bar is a resort area near Quincy, WA. It’s right on the Columbia River — a narrow strip of land stretching downriver. Half it it is an island, connected to the mainland with a little bridge. There’s a boat ramp and a handful of slips near the bridge. This is just one of a few access points for Wanapum Lake, the stretch of Columbia River between the Wanapum and Rock Island dams.

It’s an interesting body of water. I’ve seen it as smooth as glass on a windless day. But I’ve also seen it whipped up to whitecaps when the wind howls down the river between the cliff faces.

This is where I’d do most of my area boating.

To reach Crescent Bar from Quincy, you have to drive down two hills. The first, on Route 28 is a steep 60 mph road with one lane downhill and two uphill. It’s relatively straight and very smooth. The second is the side road that winds down the cliffs to Crescent bar.

I was doing about 55 miles per hour down that first hill when I caught a flash of white in my rear view mirror. I didn’t see anything when I looked — at least at first. Then I noticed the car behind me, which was about 10 car lengths back, was taking evasive maneuvers. And then I saw something white skidding across the road.

I knew immediately what it was: the engine lid from my boat.

You see, the engine lid opens from front to back (consult first photo on this post) so you can access the engine compartment while you’re on the water. It was held down with two latches. I thought they’d been latched. The boat cover, which snaps over the front part of the engine lid, also helps to hold the lid down by preventing air from getting under the lid. But I’d removed it to speed up the launch process.

I stopped the truck on the side of the road, shut down the engine, and put on the emergency flashers. I looked back and could see the engine lid in the left uphill lane about 1000 feet away, just lying there. I could imagine a semi truck running it over and shattering it into a million pieces. So I ran.

I didn’t know I could still run. I didn’t do it very well. I certainly won’t be signing up for any races soon. But I got up there before any uphill traffic. Then I grabbed the engine lid and carried it to the side of the road.

It was awkward and heavy. But it was also in one piece. I examined it when I reached the safety of the roadside. It had hit the pavement in one corner and slid on its top. The fiberglass was slightly smashed in the corner and scratched like hell on the top. The big hinge had been ripped off the back; I assumed (correctly) that it remained on the boat.

I began the long walk back to the truck, glad it was all downhill. I was winded. I was able to carry my burden by grasping it from two round cutouts in the bottom side. Still, I could only take about 50 steps before I had to rest. The damn thing was heavy.

A car stopped just past my truck and a guy got out. He walked up the hill and met me when I was halfway back.

“Looks like you can use a hand,” he said.

Who says there aren’t any Good Samaritans anymore?

It was easier with each of us grasping the lid by one of the round holes. He helped me lift it into the bed of the pickup. We looked back at the boat and the gaping opening over the engine. The hinge, which was attached to a piece of wood, was still there. So were the two hydraulic lift arms. But the damage was extensive — not something that could be fixed easily, like with duct tape.

I thanked my helper and watched him go back to his car and continue down the hill. I made a U-turn and headed back to Quincy. I stopped at my friend Pete’s house, where he was just finishing up with one of his appointments. We fitted the lid back on the engine. It fit nicely, but wouldn’t stay on its own. Pete gave me a strap to hold it down. I went home, feeling very stupid.

Repairs

I worked the phones. The local boat shops weren’t interested in helping me, but one of them recommended an auto body shop that does fiberglas work.

A few days later, I got an estimate at Earhart’s Collision Repair. The initial estimate, which would make the engine lid “good as new,” was $1,500. Ouch. I asked if there was a way to make it less. He redid the estimate without painting and managed to cut it in half. I considered that my “stupidity tax.” I left the boat with them.

It was a week before the boat was done. In the meantime, I’d gotten the bimini top parts I needed to repair the top. The boat dealer got the parts they needed to do the rubber bumper.

I picked up the boat at Earhart’s. It looked great. The repair was very well done and the lid was fully functional. Well, except for one of the latches, which had broken and was on order with a Sea Ray dealer in Arizona.

I took the boat across the river to the boat shop and left it with them for the rubber bumper and trailer repairs. I told them that since the lid was scratched up, I wasn’t interested in the no-slip stickers. I offered to pay for them — since they’d been a special order — but they said they’d put them on the shelf for others to buy.

The next day, I picked up the boat and brought it back to the campground. I was back to square one.

Boat with Top Up
Still on dry land, but at least the top works.

I spent a few hours repairing the bimini top’s frame and installing new hardware on the boat for it. I put the top up. It looked and worked great.

Second Try

I watched the weather carefully. Memorial Day weekend was pretty good, but Crescent Bar gets crazy on weekends and I wasn’t interested in making my first outing an ordeal. And then I had to wait until Pete or Linda (who had sold me the boat) was available to supervise. Schedules were tough.

I almost went out on Thursday afternoon by myself. But I chickened out.

On Friday, Pete and Linda were both busy, but Pete could pull away if he had to. I decided to give it a go by myself and call him only if I needed help.

So once again, I made the trip down to Crescent Bar. This time, with the lid firmly strapped on, I had no mishaps. It was about 3 PM when I got there and there weren’t many people around. I prepped the boat by stripping off the straps and cover. I loaded a canvas bag with a bit of extra gear — towel, long-sleeved shirt, bottled water, phone in a zip-lock bag, etc. I took my time.

Because I was by myself and the launch area was very small, I’d have to cast off from the dock while sitting at the wheel. I’d fastened a length of line to the steering wheel — the boat doesn’t have any cleats! — and secured the long end of the rope to a cleat on the dock. I didn’t want the boat floating off without me once it was off the trailer. Then I backed the boat trailer into the water on the right side of the wooden dock. I did it slowly and stopped gently just as the trucks back wheels touched the water. The boat floated slowly off the trailer.

I got out of the truck, walked out onto the dock, and used the rope to pull the boat to the dock. Then I used the short end of the rope on the steering wheel to secure the boat tightly to the end of the dock.

So far, so good.

I pulled the trailer out of the water and parked it. I locked the truck and went back to the boat.

By this time, another couple had arrived with their boat and were launching it. They had some trouble getting it started. But not as much trouble as I had. The reason: I had forgotten how.

I’d only been out in the boat once and I admit that I hadn’t been paying close attention to the starting process. I knew I had to stick in the key and I knew I had to attach a safety clip designed to shut down the engine if the driver falls out. (Jet skis have these, too.) But what else?

Fortunately, I had downloaded the boat’s Operator’s Manual from the Sea Ray website. It was a PDF created from a scan, but it was perfectly legible on my iPad. I zipped to the instructions and followed them. After running the blower for a few minutes, I turned the key and pushed the starter rocker button. The engine cranked. It took five tries before it caught. Then it idled noisily like most boat engines do.

And that’s when I realized that “idle” on my little boat didn’t really mean idle. Even though the boat’s throttle was in neutral, the boat was trying to move, pulling hard on the rope that attached it to the dock’s cleat. I was able to get some slack in the rope and disconnect it. Then the boat motored slowly toward the bridge.

Driving a boat isn’t like driving a car. You must have motion — forward or backward — to steer it. On a jet boat, motion isn’t enough. Because there’s no rudder, you must have powered motion. It’s the thrust of the engine that steers the boat. So the slower you go, the harder the boat is to steer.

The steering wheel on my boat doesn’t have much movement. It only goes about 30° in each direction. When I didn’t get an immediate response, I assumed the steering wasn’t working right. But that wasn’t the case. It just was very slow to react. So I just kept overreacting.

One of my Facebook friends compared it to trying to hover a helicopter for the first time. He’s right, but backwards. In a helicopter, you over control because the controls are just so damn sensitive. In this boat, you over control because nothing seems to be happening.

I nearly hit the rocks on the opposite side of the channel. I used reverse throttle to get myself out of there. Then forward a bit faster than I should have to get away from the dock area.

Out and About

I headed out toward the river. The wind had kicked up and there were waves 1-2 feet high. I puttered out, trying to drive at the No Wake speed I was supposed to be at. Then I cleared the No Wake area and gunned it. The boat bounced along in the waves.

I was still having trouble with steering — and that’s because of the way jet boats steer. They fool you into thinking that they’re just like any other boat, but, in realty, they steer like jet skis. When you steer a boat, boat turns kind of like a car, leaning into the curve as it moves. When you steer this jet boat, however, it kind of slips into the curve with very little body roll. It’s extremely disconcerting — at least at first. With the bumpy water, it wasn’t a very good feeling.

I decided to head across the river to calmer water near West Bar, an undeveloped piece of land on the inside curve of the river. I got there quickly, slowed down, and then idled down, pointing upriver.

My phone rang. It was Pete. I got it out of its zip-lock bag and answered. He was down at the dock; he’d come down to see if I needed help. I asked him if I needed to run the blower while the boat was running. He told me I could shut it off. He also told me that the wind was kicking up and the water was rough upriver. He suggested that I go on the other side of the island where the water was calmer.

Good idea. I thanked him, hung up, and stowed my phone. Then I headed back across the river again. It seemed even rougher. The boat jumped on the waves. The water came up and splashed me in the face. I was glad it was a warm day.

I slowed to No Wake speed, passed under the bridge again, and continued to the narrow strip of water between the island and the cliffs. The water was dead calm. I experimented with different power settings. At first, I thought the slowest I could go while remaining in control was with the engine at 1600 RPM. But I played around some more and soon got good controlling the boat at “idle” speed: 1000 RPM.

I went all the way out to the end of the island, past the leased homesites and golf course. I shut off the engine and drifted in the still water, enjoying the sudden silence and hearing, for the first time, the birds and frogs in the cliffs and water around me. I also spotted a family of Canada geese, feeding along the island’s shore. I could imagine spending hours drifting like this, maybe with the stereo on low, the top up, and a book in my hand. There’s something about being out on the water…

But I was thinking about what would come next: docking the boat and getting it out of the water — by myself. I realized that to pull it off, I’d have to come in slowly and be able to put the dock’s cleat right next to my seat at the steering wheel. With the wind blowing, I wasn’t sure whether I could do it.

So I decided to practice before going back. I restarted the engine — it came to life immediately. Then I picked various points along the shore and pretended that they were my docking spot. I’d aim for them, compensating for the wind. Just before I reached them, I’d put the boat into reverse and bring it to a stop. Then I’d back away and do it again at another point. I did this four times and got better with every try.

It was time to go back.

Docking

Before heading in, I fastened a long line to a round tow point at the front of the boat and secured the line, neatly wrapped, in one of the grab handles up front. Then I fastened a much shorter line to the steering wheel.

I motored in slowly. Several times, I was tempted to pick up the pace, but somehow I knew that patience was the key.

Understand that I’ve been on various boats and water craft many times in my life. My parents had a series of small motor boats for Hudson River excursions starting when I was about 10. When my mother remarried, she talked my stepdad into getting a boat; their last boat was a 28-foot Bayliner with a cabin. I’ve driven all of these boats. I’ve also driven various watercraft from dinghies to houseboats.

During that time, I’ve seen plenty of bad docking. I remember one trip across the Long Island Sound from Kings Park to someplace in Connecticut when my stepdad came in way too fast and gunned it in reverse just in time to prevent damage to either the dock or our boat. Spectators really enjoyed that. Another time, one of my companions nosed a houseboat into a dock at Lake Powell’s Dangling Rope Marina so hard that I thought the dock might break loose. In each case of bad docking I could remember, the problem had been speed: too much of it.

So I was going to take it slowly.

I was glad — at least at first — that there was no one around to witness my approach and docking. I floated forward, right on target the entire time. I pulled back on the throttle until I was at idle speed. Then the cleat was within reach of my hand. I nudged the throttle to reverse to stop the boat, grabbed the cleat, and secured the line around it.

It had been a perfect approach and docking. The best I’d ever seen. Certain the best I’d ever done.

Where were the witnesses when you wanted them?

I stepped out onto the dock, took the rope fastened to the bow, and tied it to a cleat halfway up the dock. The boat was now secured in two places. Time to get the trailer.

I think the hardest thing I did that day was back the empty trailer down the ramp. Trouble was, because it was so low, I simply couldn’t see it. It took about 10 tries to get it in position.

Then I walked back down the dock, unfastened the rope at my seat, and then unfastened the long rope. I walked around the dock to the front of the trailer and pulled the boat in. I got it close enough to attach the hook for the crank and cranked it the rest of the way. Easy.

I pulled the boat out of the water and away from the ramp so I wouldn’t block others. Then I took my time fastening the boat back down to the trailer and putting the cover back on.

Mission Accomplished

My main purpose in going out on the boat yesterday was to develop some kind of procedure for launching and later docking the boat by myself. I knew there would be special challenges that crews of two or more don’t have to deal with. I wanted to make sure I knew what needed to be done and come up with a way to do it all alone.

I honestly didn’t expect it to go as well as it did. The launching and docking went better than I could have imagined. Starting the boat and driving it out had been the big challenges — but by taking my time and working hard to do it right I’d been able to rise to those challenges. I now knew exactly what to expect — and how to deal with it.

Pete nailed it when he pointed out, later in the day, that it had been a confidence builder. The next time I go out, I’ll likely go farther and enjoy myself even more.

Malaga Springs to Martin Scott by Helicopter

Another nosecam video.

On Saturday, I spent a good portion of the day flying between Martin Scott Winery in East Wenatchee, WA and Malaga Springs Winery in Malaga, WA. I use my helicopter to offer wine-tasting tours for part of the summer season. These are just two of the four (so far) wineries that have suitable landing zones for me and encourage me to bring people there.

As shown in the map below, the two wineries are on opposite sides of the Columbia River. To drive from one to the other, it’s 12.5 miles and will take (according to Google Maps) about 31 minutes. Malaga Springs is a bit tough to find and the last 1.4 miles is on a gravel road. I drove to it just the other day and was convinced I was going the wrong way when I spotted a winery sign that said “Keep the Faith” and encouraged me to continue on my way.

Martin Scott to Malaga Springs

By helicopter, however, it takes less than 2.5 minutes on a direct flight across the river.

Yesterday, I flew nine people from Martin Scott to Malaga Springs and back. For some of those flights, I had my GoPro “nosecam” set up and turned on. Since it’s been so long since I shared a “nosecam” video, I threw one together Saturday night and uploaded it Sunday morning. Here it is:

Interested in a wine-tasting tour by helicopter? Learn more on Flying M Air’s Web site.

A Visit from the Bee Man

Removing a swarm of bees is easy — if you know what you’re doing and aren’t afraid to get stung.

BeesThe text message from my friend Pete arrived just as I was trying to think of another way to procrastinate:

Bees swarming on the shop. Bee man is going to come get them.

A cell phone image accompanied the text. It showed a roof eaves absolutely littered with bees.

A while later, I was at my friend’s farm, watching the bee man set up. He was an older man who’d likely been doing his job for quite some time. He was dressed in a loose-fitting, white coverall that was tight at his wrists and ankles. An attached hood with mesh mask hung at his back. He’d arrived in a flatbed truck towing a forklift on a trailer.

BeesWhen I arrived, he was placing a wooden door atop a fruit crate on a forklift, forming an elevated table. He placed a white box atop that and raised the apparatus about four feet off the ground, right beneath the bee swarm. The bees looked even more impressive live. Pete, three of his sons, and two of his older son’s friends stood a good fifty feet away, watching.

The bee man explained that the bees were swarmed around a queen and that they’d likely decided to settle there. It was pretty obvious that they needed to be removed.

While folks in cities might call an exterminator, here in farm country, bees have real value. The “bee man” was a beekeeper who not only made honey but rented his bees out to farmers for pollination. In fact, Pete had a few dozen of his hives out by his apple trees. The bee man would take the bees home and set them up with their own bee hive boxes. Pete might see them again next year in more controlled conditions.

The Bee ManWhen Pete made it clear that he wasn’t interested in sitting on the forklift to lift the bee man and his box up to the swarm, the bee man fetched his forklift off the trailer and parked it beside Pete’s. He then raised the two sets of forks and climbed up beside the box.

And then, as we watched, he used his bare hand to scrape the bees off the eaves and into the box.

“These bees are very calm,” he said.

Bee Man in Action

Bees CloseupHe wasn’t kidding. He continued to sweep them down toward the box with his hand and, later, a stick. Although everyone else kept their distance, I got closer and closer with my camera. Soon I was standing on a third forklift parked inside the shop, not eight feet from the swarm and box, snapping photos.

Bee Man with iPhoneI wasn’t the only one taking photos. The bee man climbed down, went to his truck, and came back with his iPhone. He then climbed back up the forklift and used the phone to take a closeup photo of the bees. I’m wondering if his shot ended up on Facebook.

Lighting the Smoker

Smoking the Bees

It took quite a while — at least 30 minutes. The bee man was very patient. One by one, most of his other spectators wandered off. He was sure he’d gotten the queen in the box, but the rest of the bees were taking their time joining her.

After a while, he got out his smoker, torched the burlap piece inside, and used smoke to coax the bees into the box. He explained that the smoke makes the bees think there’s a fire so they go into the hive to eat honey in case its lost. They then get sleepy from eating so much. Didn’t sound quite right to me, but what do I know?

Bees on a TruckWhen he had most of the bees in the box, he covered it up, carried it back to his truck, and strapped it down on the flat bed. He pulled his forklift back onto its trailer and got ready to leave — but not before he gave Pete a plastic gallon jug of honey in exchange for two of Pete’s bottles of wine.

I’d enjoyed the show and was glad I’d gotten that text message.

Bottling Wine, Day 2: Bottling

A look inside a mobile wine bottling facility.

I’m one of those people who likes to see and do as many things as I possibly can. Life, to me, is a quest to learn and experience as much as possible. Each day I get to do or see or learn something interesting is another day worth living.

Yesterday was one of those days. I got an opportunity to photograph, video, and help out in a mobile wine bottling facility.

The Truck

Big wineries — like the ones everyone has heard of — have their own wine bottling facilities. These are likely big rooms filled with very expensive, highly specialized equipment. Big wineries can afford to buy and maintain these machines. After all, they’re producing thousands of cases of wine every year and may run the bottling line dozens of times a year.

Smaller wineries can’t afford such luxuries. Not only is the cost of the equipment usually beyond their means, but they also lack the space to house it and the funds to maintain it. Besides, they’re producing much smaller quantities of wine and only need to bottle once or twice a year. It just doesn’t make sense to make such a huge investment when there is another alternative.

That other alternative is a mobile bottling truck. This is a big rig truck with a trailer on the back. The trailer is completely outfitted with all the equipment needed to fill, cork, cap, and label bottles of wine.

The truck is driven and operated by a single technician who travels from one small winery to another. He knows exactly how to operate the equipment — which is both mechanical and computerized — and how to fix it if something goes wrong. He sets it up for the bottles, wine, corks, foil caps, and labels the winemaker provides. He then gets the line running while a handful of laborers the winemaker provides do the few manual tasks required to complete the process.

To say it was amazing is an understatement. Watching this thing in action was awesome.

The Bottling Process

Pumping Wine
Wine is pumped from a vat into the trailer.

Arranging Bottles
This machine sterilizes the bottles and places them on the line in single file.

Filling Bottles
The bottles are filled with wine as they move.

Corking machine
Bottles move into the corking equipment where they are corked.

Adding Foil Caps
Two workers add foil caps to each bottle.

Sealing Foil
This machine presses the foil caps onto the bottle tops.

Applying Labels
The bottles move past the labeler, which applies front and back labels with one pass.

Production Line
This look from the front of the trailer’s inside shows the bottles on the right heading back toward the door.

Boxing Wine
Two people load the bottles into cases. They’re loaded neck down to keep the cork wet during storage.

Case of Wine
Cases of wine slide down a track from the back of the trailer.

It all starts outside the trailer, where wine is pumped from its storage vat into the trailer itself though sterile hoses. From there, it goes into the filling equipment where it waits for the bottles.

Meanwhile, at the back end of the trailer, a forklift brings palettes of empty bottles to the open door. The bottom of each case of 12 bottles is unsealed. A man standing just inside the door takes a case, being careful to hold the bottom of the box closed, places it on a wide conveyor belt, and lifts the box, depositing the bottles, neck end up. He’ll do this four to six times a minute as long as the line is running.

The bottles then move, jiggling and clinking, into a rotating mechanism that sterilizes the bottles and places them on another belt where they enter the equipment in single file.

From there, the bottles are placed on tiny elevators that lift each bottle to a filling machine that moves the bottles along the line. The machine senses when the bottles are filled and stops adding wine.

The bottles then go into a corking machine that puts a cork into each bottle. Then the bottles move past two workers who place foil caps on top of each bottle. At the line’s speed, it would be nearly impossible for just one person to handle this task.

From there, the bottles move into a machine that pressed the foil caps down onto the top of the bottle, providing a secondary seal over the cork. Both the corks and the foil seals are customized with the winery’s logo.

Next, the bottles move past the labeler. The labels come on rolls that alternate front and back labels. The machine uses a vacuum to pull the labels off their backing, exposing the sticky side. As the bottles move past the vacuum pad, the sticky side of the label is pressed onto each bottle. The spacing of the labels is finely tuned for each bottle size.

At this point, the bottles of wine are complete. But they’re at the front of the trailer and need to be in the back. So they make the long trip all the way down the side of the trailer, in single file, to where two people wait. Stationed right beside the man who puts the empty bottles on the line, they have the empty boxes he discards in piles at their feet. The first person places a box on a workspace and fills it with six bottles as they file past. She then moves the box to her companion who places another six bottles in, closes the box, and pushes it through a machine that tapes it shut. Both workers are performing their tasks nonstop to keep up with the flow of incoming bottles.

After being taped shut, the box rolls down a ramp where other workers apply a label to the box and stamp the date on it. The boxes are then stacked on palettes. When all cases of a variety are bottled and stacked, the palette is wrapped with shrink wrap. It’s then transported into a temperature controlled storage area by forklift and an empty palette is prepared for the next variety.

The Results

At full speed, the equipment can process about 60 bottles per minute. The bottling tech told me we were running a little slower, maybe about 55 bottles per minute. That’s still pretty damn fast.

We bottled seven varieties of red wine yesterday, including one rosé. We used three different bottles, each of which required the machinery to be recalibrated for proper movement, corking, and label positioning. We started at about 8 AM and were finished by 2 PM. We took about an hour for a lunch break.

We bottled a total of 818 cases of wine.

Afterward, the six volunteers (including me) got to sample some of the wine that wound up in partially filled cases. Despite its bottle shock, it was pretty darn good. I think the Petit Verdot was the best of the bunch and really look forward to its release. And yes, I grabbed a bottle of that and a bottle of Zinfandel as my reward for a day’s work in the truck. I’ll wait until Pete officially releases them before I open them.

The Photos

I took a lot of photos during this process — the ones you see here are only a sampling that illustrate the main part of the process. The photos include shots taken on Sunday during the filtering, which I cover in a separate blog post.