Vale Wood Farms stays steady, but nimble, delivering ‘moo to you’ since 1933

Carissa Itle Westrick enjoys working every day with her father, Bill Itle. They see whole milk, local connections and home delivery as big trends for dairy — even before the pandemic — that are key parts of their farm and processing for decades. They also share concerns about consumer confusion with the onslaught of imitation beverages in the dairy case.
 

By Sherry Bunting (updated since originally published in Farmshine in 2018)

LORETTO, Pa. — Take a step back to a simpler time. A time when dairy farmers were looked up to, not questioned. A time when the milkman delivered fresh dairy milk to the metal ice box on the doorstep. A time when milk’s good name was upheld. When milk was milk.

A visit to Vale Wood Farms, Loretto, Cambria County, Pennsylvania, is in some ways a step back in time, but it is also a bold look into the future — one that delivers fresh, local, real milk and dairy to consumers. One that develops farm-to-consumer relationships as everything old becomes new again.

It’s not easy to corral a few of the third and fourth generations of the Itle family as they go about their work here. Getting them to drop what they’re doing for a group photo? Forget about it. Everyone’s busy with three separate businesses under one sign. And they’re not keen on drawing attention to themselves, but rather draw attention to milk and dairy.

Converging trends shape their market, and consumer connections are critical. (For example, today, two years since this article was first published, people have rediscovered whole milk and cream and since the Coronavirus pandemic, local foods and home delivery are a trend.)

But in the overall dairy industry, there is a growing number of competing beverages marketing outside the lines of real milk’s FDA standard of identity — introducing a growing surge of competing imitations into the dairy case.

In these challenging times, many dairy farmers consider on-farm processing. Carissa Itle Westrick, director of business development at Vale Wood Farms, acknowledges the risk and insecurity of this business that relies on building consumer and community relationships.

She points out that in some of their sales – wholesale and institutional – they, too, are price takers.

“My great great grandfather (C.A. Itle) was grappling with difficult economic choices in 1933 when he hitched up his horse and wagon and went to town,” Carissa relates.

Today, the Itles have a window into seeing how milk production levels in excess of demand impact profits throughout the supply-chain.

In the dairy sector, we often hear the experts and consultants drive home the point that ‘the next pound of milk is the most profitable milk on the farm.’

Is it?

“Our economics are different,” Carissa points out. “That next pound of milk is not necessarily the most profitable. If we can’t sell that next pound of milk, then making it means we just made less profit on all the milk. For us, that approach doesn’t make sense.”

What does make sense is adding processing efficiencies and capitalizing on consumer trends, while helping to shape them.

“We have to make sure what we do fits today’s families,” Carissa notes. “We are small enough to be fairly nimble, which is so important to our business model.” For example, customers can sign up and manage their home-delivery online.

Technology-driven, home-delivery — Valewood-style — still comes with a personal touch. Of their 50 employees, five are drivers. 

“Our drivers cater to our customers. They might even be asked to let the cat out or pet the dog or put the product right in the fridge,” she says with a smile. “We are hyper-local, and it’s not just a selling point for us. We shake hands with whose buying our milk.”

Meanwhile, connecting consumer dots is very much a family affair as events like the mid-July Pasture Party draw in large numbers from the community and those members of the Itle family not involved daily in the business. They bring their friends and tell their neighbors.

“When people come to an event here and go on the crazy hay wagon ride, it’s us on that wagon. It’s my uncle Dan on that wagon,” she says. “That’s our one-on-one time to tell about our cows and how they are cared for. We focus our education on how much attention we pay to the cows. They are our livelihood, and we depend on them. The effort, time, energy and emotion we put into keeping them healthy and comfortable – that’s what we want people to understand.”

The nearby schools also bring classes to connect with the farm providing their milk. In fact, Carissa’s aunt, Jan Itle, developed the “Moo to You” formal school tour program that began with five teachers and today works with nearly 75 teachers and reaches up to 5000 students annually, in addition to the other community events hosted at the farm.

Jan was recognized as 2017 Pennsylvania Dairy Innovator of the Year. Her good-natured humor is evident when she talks about working with seven brothers. And she is enthusiastic about hosting school tours.

“Give back to the community at all times,” is something Jan says they learned from their parents.

For her generation growing up, the Itle house was the gathering place, Jan recalls. “Our house was like a train station, and we still extend that invitation to the community today — to come and see what we do and share our passion.”

As the public becomes more generations removed from farm life, and the dairy disconnect grows, the Itles are doing all they can to reconnect. That helps their business model and the dairy industry as a whole.

The Itle family has seen it all in their farm-to-consumer business at Vale Wood Farms. The land on which the farm and processing plant sit today has been in the family since 1841, and while they’ve been processing and home-delivering milk and dairy products since 1933, “we are still addicted to our cow habit,” says Carissa.

Carissa is one of six fourth-generation family members working full-time here. Her father Bill is one of eight third-generation siblings involved full-time, plus another involved to some degree with a career as a veterinarian.

As company president, Bill manages the processing side. His brother Pat manages the 500 acres of crops. His sister Jan is the herd manager with her nephew Zach as assistant herd manager.

Being one of the oldest of the 18 members of her generation, ranging from adults to infants, Carissa describes the overlap. It’s easy to see how her role serves as a bridge between generations.

All told, Vale Wood Farms employs 55 people, including family members. In fact, Carissa confirms that some of their employees are also multi-generational. In fact, even the many family members with careers outside of Vale Wood Farms, come back to help with events and such. “We were all raised to jump in and do, when we see something needing done,” says Carissa.

When Bill Itle looks at the future, he notes the confusion about what is real dairy is an issue.

“We feel the pain when farmers feel the pain, because we’re part of that, and it’s not always the processor making the money,” he says. While he has seen an increase in whole milk consumption, the overall drag on total fluid sales, says Bill, is confusion in the dairy case.

“It’s tough to get our name back and away from imitation products. They’ve been doing it a long time. They aren’t hiding in the woodwork,” Bill relates.

Carissa agrees, noting that some consumers don’t really know that almond milk isn’t milk.

“I have friends who ask why we don’t make it,” she says. “They think it’s a milk flavor.”

For all of its challenges and opportunities, this is a family that loves what they do.

“We appreciate how lucky we are to have this tradition here, and we also have a responsibility to keep it alive,” says Carissa, noting that for multiple generations to run three separate businesses together takes flexibility.

She recalls her grandmother often saying, “you can disagree without being disagreeable.”

“Balancing the generation with one foot out the door with the generation gaining life experience can be tricky,” says Carissa, admitting sometimes her role is more “cat herder” and interpreter. 

“In a family business, we learn that there will be differing opinions, but at the end of the day, we make decisions and everyone supports the decisions. In a family business, you learn to have good healthy debate and to strongly support your point of view, but then to compromise and accept a decision once it’s made, and that’s how you thrive.”

As the industry changes around them, the Itle family jumps in to make key consumer connections. As a result, they maintain a steady market for their steady milk supply, growing home-delivery sales in the face of increased competition and consolidation being the new reality in supermarket dairy case sales.

They have an on-site dairy store, but it is off the beaten track and represents just 2% of their sales. As we sit in the pavilion that Carissa’s sister Jen has decorated for the following week’s Pasture Party, Carissa explains the evolution of dairy trends coming full-circle.

She gives four examples: The resurgence of fresh, real and local foods; the ‘new’ idea of home delivery; how ‘old’ products like whole milk, butter, and cottage cheese, are making a comeback; and how those old paper cartons are making a comeback too.

(In fact, take a look at the dairy case the next time you go to the supermarket. Most ‘new’ plant-based non-dairy beverages and ‘new’ dairy case items like iced coffees are packaged in paper cartons.)

“Consumers are gravitating back to the carton,” says Carissa. While Vale Wood bottles a variety of sizes in plastic bottles, paper half-gallon cartons are also available “because our customers see this as a great thing, from an environmental standpoint, and we like it because it protects the milk from light.”

We talk about the growing number of consumers seeking food delivery services and how the meal kit companies have really taken off. In fact, the three biggest food retailers – Walmart, Kroger and Amazon/Whole Foods — have either bought or created meal kit or food box delivery services.

Even as total consumption of dairy milk continues to erode, the large chain supermarkets and big-box stores are getting into the game because their checkout scanners confirm that milk — real dairy milk — is still the most frequently found item in grocery baskets.

So the future will either be a competition for shrinking market share – or an all-out effort to expand the fluid market. Vale Wood pays attention to those trends to steady their market while opening eyes of consumers expand it.

The upheaval in the industry reveals the trend toward the nation’s larger retail chains wanting a bigger piece of the shrinking fluid market. Small processors, like Vale Wood, on the other hand, seek to appeal to consumers and increase product demand.

The direct competition for supermarket shelf space is becoming intense because milk, though consumption is down, is still a store’s gateway to win customer loyalty.

As all processors navigate the competitive pressures, it is the home delivery service that is steadying the ship for Vale Wood. That part of their business brings them back to that key: connecting with consumers. A big part of that connection is the cows at the farm.

“It’s unique that we still milk cows,” says Carissa. “The cows are central to our farm history and heritage and our sense of identity.”

The Itle family milks 200 cows. Their processing covers 400 cows, as they purchase milk from three neighboring dairy farms instead of expanding their own.

In addition to bottling milk and flavored milk and making ice cream, they do soft products like dips and cottage cheese, and are now doing flavored butters. They do “a little bit of everything” to capitalize on trends. This helps them deal with increased competition for fewer milk drinkers.

“We can never underestimate the effort required to get into (or keep) a market,” Carissa says. And those barriers to entry are becoming more challenging as store brand private label market share increases at the same time that non-dairy beverage alternatives compete for space in the dairy case.

Still, 95% of Vale Wood’s milk utilization is Class I, thanks in large part to their consumer connections and education that lead to product awareness and loyalty.

Milestone reached by Shenandoah Family Farms

BlogShenFamFarms085BlogShenFamFarms-011

By Sherry Bunting, reprinted from Farmshine March 21, 2014

HAGERSTOWN, Md. – “Every day we reach new milestones, and today is one of them,” said Tom Francis, production manager and VIP / media tour-guide Tuesday, March 18 at the dairy plant where Shenandoah Family Farms Brand milk and cream products are made.

The 142,000 square foot facility in Hagerstown, Maryland was idled by Unilever in 2012, then purchased in August 2013 by Valley Pride LLC, a dairy business owned by 21 dairy farmers from the Shenandoah Valley region of Virginia. This purchase, and the separate formation of Shenandoah Family Farms Cooperative, grew from seeds planted during a 2012 meeting of the five original board members at the Thomas House restaurant in Harrisonburg, Virginia.

“We are excited to be here and look forward to moving forward,” said Randy Inman during Tuesday’s pre-tour press conference. Inman, a Harrisonburg, Virginia dairy producer, serves as vice president of Valley Pride LLC and Shenandoah Family Farms Cooperative.BlogShenFamFarms104

Over the past 18 months, they have developed a media and social media presence as they prepared for the startup of milk and cream bottling operations at the renovated plant February 24. Soft-serve ice cream mix production began last week, and hard ice cream production will begin after new equipment arrives in April.

To this point, Shenandoah Family Farms has used social media to bring farm families, farm life, farm children — even farm calves, cows, cats and dogs — right to the computers and smart-phones of thousands of customers. Brilliant photography of life on the farm and scenes of the beautiful Shenandoah Valley bring a nostalgic feel to the marketing of natural dairy products prized for their quality, flavor and wholesomeness.

“Our web presence will grow in the next three weeks with the launch of a new website with store locators and profiles of our farmers and staff,” said Shenandoah Family Farms marketing director Jennifer Churchman.

The plant is currently just scratching the surface of the demand and production capacity. The equipment has the capability of bottling 32 gallons of milk per minute, and the largest single-day of production they had since Feb. 24 was 6000 gallons. But Francis said this can be doubled with more shifts, workers and equipment as the demand grows.

BlogShenFamFarms063cropped

To-date, Shenandoah Family Farms milk goes to 170 retail and restaurant establishments along the Route 81 corridor from Shenandoah Family Farm Cooperative’s home base in Harrisonburg, Virginia, through the plant location in Hagerstown, Maryland, and north and west into West Virginia and the Waynesboro and Greencastle areas of Pennsylvania.

“We’re adding 5 to 10 new customers per day,” Churchman confirmed, explaining how end-consumers can fill out product request forms at shenandoahfamilyfarms.com and take them to the stores and restaurants they patronize. The product-request forms have also been the key in developing initial leads for the sales team.BlogShenFamFarms110

“The more requests that are submitted, the easier it is to get our product on the shelves,” aaid Inman. He noted they are close to getting their products into the local Walmarts.

“We are beginning to reach out to the Washington, D.C., area, and getting a lot of interest there,” said plant manager Fred Rodes, who has 25 years of experience working for three creameries after jumping the fence from dairy farming to dairy manufacturing in 1988 for health reasons. Rodes also said they would be open to doing private label work, but are focused right now on working directly with customers and through distributors to build their brand.

Hagerstown Mayor David Gysberts and other local city and county officials were on-hand Tuesday showing their enthusiasm for the plant’s re-start. “We are happy to see the Virginia farmers bring jobs back to our region,” said Gysberts. One-third of the 44 full time and 4 part time employees worked at the Hagerstown plant under its previous owner, Unilever, which employeed 400 at its peak before idling the plant in 2012.

“The more the community supports Shenandoah Family Farms products, the more products we can make, and the more jobs we can create here,” said Inman. “It’s a snowball effect.”

He explained that Shenandoah Family Farms products come from a small group of farms. Right now that is 21 farms average 130 milk cows per farm.

“The close proximity of our dairy farmers to our market will give customers assurance of fresh dairy products,” added Inman. “We are focused on high quality milk production and the assurance of best management practices for environmental sustainability, heritage farming practices, humane animal care, involvement in our community and involving our customers in our decisions as we grow.”

Inman said the primary goal of this enterprise is to preserve small family farms for generations to come. “We saw this as a way to take some control of our product by building a relationship with our end-consumers and taking our milk from the farm to the consumer, and to see our farmers rewarded for their high quality production with a steady milk price.”

The investment runs deep here – beyond dollars. Inman explained that the farmers and staff “worked hands-on and side-by-side” to upgrade and renovate the facility over the past six months. USDA loan-guarantees helped the group of farmers get the financing to not only purchase but also upgrade the plant and build awareness for their brand.

The facility’s milk silos, large conveyors, pasteurizer, existing ice cream equipment, coolers, and in-wall freezers were all part of the plant purchase. The owners purchased a separator, homogenizer, bottling equipment and new ice cream manufacturing equipment as well as upgrading computers, software and the ability to track milk from farm-to-store. They also upgraded the coolers and chillers and adding other conveyor capabilities throughout the plant.

BlogShenFamFarms121

“We’ve had some delays with equipment arriving and the challenges you would expect with a project like this, but we’re ready. The word is getting out about our products, and the support from the local communities has been quite encouraging,” Inman said, adding that he’s impressed with how his fellow farmers and the plant staff have worked together.

“I’m amazed by the super commitment of the farmers, and their families, to get this up and going, and by our staff as we’ve worked together,” he said.

To be bottling the Shenandoah Family Farms milk and on the verge of beginning ice cream production was described as “overwhelming” by board member and producer Dennis Trissel. “In any business like this, you always hope to put in place what’s necessary to get the product marketed,” he said. “Our farmers know how to make high quality milk and our plant managers know how to make quality products…”

Now the ball rolls into the consumer domain through product purchases and requests where they shop.

“Our store customers need to see that we are capable of being here five years and forward,” said Rodes. “We have good staff and a lot of experience. I grew up on a dairy farm and I enjoy the challenges of running a creamery. I’m willing to work hard for these guys (the farmers) because I know they care about putting out a quality product. Now the rubber meets the road in sales.”BlogShenFamFarms067

For the sales force Lyndon Jonson and Rich Muldoon, that’s a challenge they are meeting daily – “hitting the road and knocking on doors.”

“The most rewarding thing for me is getting a new account, that’s my high-point,” said Johnson, a former truck driver who is part of the Shenandoah Family Farms sales force.

When hard ice cream production begins next month, the plant will roll out vanilla, chocolate and strawberry and begin adding flavors with 11 flavors planned at this time. They will concentrate on volume packages for grocers and soft-serve mixes for restaurants before adding a line of other types of ice cream products.

“For the most part, our awareness building is getting farmers face-to-face with the end consumers,” Churchman explained how ‘engagement marketing’ is being utilized. “We will utilize all avenues such as radio, television and print advertising, but we are also sponsoring many local events and will have our farmers and staff there. They are important members of their communities and we want them right there with our customers so the customers can be part of how we grow our company.”

BlogShenFamFarms019

The 21 family farm members of Shenandoah Family Farms are all located within a 10-mile radius of Harrisonburg, Virginia. Currently three farms’ milk is going to the plant. Once all 21 farms’ milk is being utilized by the plant, another 12 producers are on-board to be added.

Churchman said they are using “test-market-moms” as an advisory group of moms and families to advise, test, and decide what to put out. “They can use their social media circles to gain additional feedback for us,” she said.

BlogShenFamFarms004

Ice cream lead Charles Evans is glad to be back to work at the plant under the new ownership. Asked what makes the Shenandoah Family Farms ice cream products stand-out in the marketplace, Evans said “the recipe. It was developed by the farmers and Fred Rodes our plant manager. It’s higher in butterfat content, making it rich and thick. Everyone who tasted our soft-serve today enjoyed it and we’re getting very positive feedback from customers.”

Rodes also stressed that the Shenandoah Family Farms ice cream (both soft-serve and hard) is 100% natural and contains no additives. “That’s kind of rare these days,” he said.

Inman said Shenandoah Family Farms is working with other cooperatives on milk supply balancing and they are working with other processing cooperatives and suppliers to combine additional products for their distribution contracts — including cottage cheese, sour cream and yogurt, as well as the full line of Turkey Hill teas.

BlogShenFamFarms125BlogShenFamFarms093

###

 

 

 

 

 

ShenFamFarms085

Micah Showalter, 2, is tasting Shenandoah Family Farms soft serve ice cream with brother Adrian, 8, and sisters Emily, 9, and Erica, 6. Micah and his puppy are the stars of the Shenandoah Family Farms Whole Chocolate Milk label, shown here in poster size (left) on the wall above him, and all four children with a newborn calf at the Showalter family’s Sun Dial Farm-2 are subjects of the Whole Milk label, shown here in poster-size above them (right). The Showalters are among the 21 farmers in a 10 mile radius of Harrisonburg, Virginia, who purchased and renovated the former Unilever ice cream plant in Hagerstown, Maryland. They started bottling Shenandoah Family Farms Brand fluid milk and cream products at the plant on February 24. They began making vanilla soft serve ice cream mix this week and will soon be doing chocolate. Hard ice cream production begins in April with vanilla, chocolate and strawberry and will expand to 11 flavors over the next several months. Photo by Sherry Bunting

ShenFamFarms093 or 106

Shenandoah Family Farms milk and chocolate milk were served with homemade cookies at the tour of the creamery Tuesday. Photo by Sherry Bunting

ShenFamFarms063 and 063cropped

After Unilever idled the 142,000 square foot Hagerstown, Md. plant in the fall of 2012, it was purchased last August by Valley Pride LLC, a dairy business owned by 21 dairy farmers from the Shenandoah Valley region of Virginia. In addition to updating the ice cream manufacturing equipment, they have invested in milk bottling, which started February 24. Photo by Sherry Bunting

ShenFamFarms-011

Owen Trissel is “over-the-moon” with excitement as he suits-up for the plant tour with his parents Cory and Charity. Owen, 9, and his brother Ian, 4, are the stars of the 2% milk label. One of the features of the Shenandoah Family Farms brand is to engage consumers in farm life through brilliant photography and larger labels. Photo by Sherry Bunting

ShenFamFarms-019

Production manager Tom Francis served as tour-guide Tuesday. He said hard ice cream production begins in April. The Shenandoah Family Farms brand offers chocolate milk is offered in whole milk variety, and ice cream is a higher butterfat, simple recipe made with 100% natural ingredients. Photo by Sherry Bunting

ShenFamFarms110

Dairy producers Dennis Trissel (right) and Randy Inman are two of the original five who met in 2012 at the Thomas House restaurant, Harrisonburg, Va., forming Shenandoah Family Farms Cooperative and planting the idea-seed for taking their milk straight from farms to consumers. They are pictured with Shenandoah Family Farms marketing director Jennifer Churchman who says “engagement marketing” is the hallmark of their campaign and plant manager Fred Rodes (left), who grew up on a dairy farm, then spent the past 25 years on the other side of the fence in the creamery world. He loves working with people, building teams, tackling challenges and tinkering with ice cream recipes. Photo by Sherry Bunting

ShenFamFarms105

Shenandoah Family Farms Cooperative vice president Randy Inman welcomed media and Hagerstown, Md. officials to the grand re-opening tour of the plant purchased by the investment of 21 members of the Valley Pride LLC, where Shenandoah Family Farms Brand milk is bottled and made into ice cream. Photo by Sherry Bunting

ShenFamFarms-Hagerstown

Hagerstown Mayor Dave Gysberts and Council member Don Munson were among the 35 suiting-up for Tuesday’s tour of the Shenandoah Family Farms dairy manufacturing facility. They are all smiles as 44 jobs have returned to the site of the former Unilever ice cream plant that once employed 400 people. Now owned and renovated by 21 dairy producers from northern Virginia, the plant began bottling milk last month, started making soft-serve ice cream mix this week and will be ramping up hard ice cream production as early as mid-April. Photo courtesy of the City of Hagerstown.

ShenFamFarms121 and/or 125

The 142,000 square-foot plant has been updated to make Shenandoah Family Farms ice cream and fluid milk and cream products. Photo by Sherry Bunting

ShenFamFarms067

“Want to see where your milk goes?” That was all the encouragement these children needed to check out the conveyor taking crates of bottled Shenandoah Family Farms milk to the cooler where it was being loaded for delivery to 170 retail and restaurant customers — with 5 to 10 new customers being added daily.

ShenFamFarms095

A year of awareness-building through Facebook and other media brought daily photos of farm children, farm life, and farm calves, cows, dogs and cats right to the computers and mobile phones of thousands of consumers. Photo by Sherry Bunting

ShenFamFarms004

Charles Evans is the ice cream lead for Shenandoah Family Farms. He served the soft-style ice cream to local officials and media Tuesday. (I must say it was tasty!) Photo by Sherry Bunting