American Vinegar Works, a company dedicated to producing flavor-advanced, artisanal-made vinegar, has gone back 200 years to find the right technology. Founder Rodrigo Vargas, a traditionalist at heart, recognized the need for a high-quality, slow-fermented vinegar that could elevate the dishes of American chefs and home cooks. After extensive research, Vargas stumbled upon an 1823 invention by a German scientist that revolutionized vinegar production during the 19th century. Unable to source a machine, Vargas used an illustration from a 19th century encyclopedia to construct a replica and began producing vinegar with a 200-year-old method. With this unique and innovative approach, American Vinegar Works aims to bring era-relevant manufacturing back to New England and redefine the way vinegar is made.
Table of Contents
Background
In the food industry, vinegar has historically lacked innovation compared to other pantry staples like chocolate and coffee. This observation was not only made by professionals in the field but also by Rodrigo Vargas, the founder of American Vinegar Works. As someone with a background in strategic new product development, Vargas saw an opportunity to bring a slow fermented, fully flavored vinegar to American chefs and home cooks. To determine the market need for artisanal vinegar and assess its potential, Vargas hired interns to study non-industrial vinegars and map out their attributes. This research helped him identify the positioning of existing vinegars and the product features that could set his vinegar apart.
Market Research and Product Development
To develop his artisanal vinegar, Vargas knew he needed a deep understanding of non-industrial vinegars. By hiring interns to study these vinegars in specialty shops and online resources, he gained insights into how they were positioned in the market. This research helped him identify product attributes that could differentiate his vinegar, such as being “raw and unfiltered” or “Made in America.” By mapping out these attributes, Vargas could strategize his product development process and ensure that his vinegar would appeal to the target market.
Discovering 19th Century Technology
While exploring traditional methods of vinegar production, Vargas came across an 1823 invention by a German scientist named Johan Sebastian Schutzenbach. This invention was a two-chambered, drip-style machine that recirculated fermenting liquid to produce nuanced, complex flavored vinegar. Inspired by this innovation, Vargas sought to recreate the machine, but faced the challenge of sourcing an actual 19th-century machine, as it was no longer in production. Fortunately, he found a plate etching in an encyclopedia from the 1870s, which he used to construct a small mockup of the machine. With the help of Boston University’s welding shop, Vargas was able to assemble a replica of the machine using food-grade stainless steel.
Challenges and Solutions in Equipment
The initial prototypes of the vinegar-making machine faced several challenges, including clogged tubes and occasional vinegar floods caused by fluctuating temperatures. Recognizing that these prototypes were not scalable, Vargas sought solutions to improve the equipment. He collaborated with Boston University’s welding shop, known for its expertise in constructing rocket parts, to create a simple replica of the machine using food-grade stainless steel. This improved prototype addressed the operational problems of the initial prototypes and paved the way for increased production and scalability.
Establishing a Sense of Place
To differentiate his vinegar, Vargas focused on sourcing locally produced ingredients like beer, cider, and wine. By using ingredients that were indigenous to the region, such as cranberries for Cranberry Apple Cider Vinegar, Vargas created a sense of place in his vinegar. He recognized the importance of high-quality base alcohol and relied on America’s excellent wine and microbrewing cultures to produce vinegar that stood out in terms of taste and quality.
Scaling the Business
As American Vinegar Works grew, Vargas needed to find suitable production facilities to meet the increasing demand for his vinegar. He decided to relocate to a historic building in Worcester, Massachusetts, known as the Whittall Mills complex. This building, which was once used to produce rugs for the McKinley White House, provided a unique setting for vinegar production. By investing in the necessary equipment and expanding production capacity, American Vinegar Works was able to increase its output and meet the growing demand for artisanal vinegar.
Evolving Equipment with The University of Maine
To further improve the vinegar-making process, American Vinegar Works collaborated with The University of Maine’s food science department. This collaboration allowed Vargas to work with experts in the field and leverage their knowledge and resources. Together, they developed a retro-tech double drip fermentation tank equipped with sensors and data capture capabilities. This state-of-the-art equipment allowed for precise temperature adjustments, eliminated flooding issues, and provided valuable data for quality evaluation. The partnership with The University of Maine enabled American Vinegar Works to optimize its production process and ensure consistent quality in its vinegar.
Current Production and Future Plans
Currently, American Vinegar Works produces 15 varieties of vinegar using the retro-tech machine developed in collaboration with The University of Maine. Vargas and his team have also been aging two additional varieties in barrels and plan to release them soon. With an annual production of approximately 12,000 gallons, American Vinegar Works has experienced significant growth. Looking ahead, the company aims to continue expanding its production capacity and release new varieties of vinegar each year. Vargas sees potential for further growth in the vinegar market and is actively exploring opportunities to tap into this market.
Conclusion
The story of American Vinegar Works demonstrates the potential for innovation in traditional food products. By conducting market research, developing unique equipment, and establishing a sense of place in their products, the company has successfully carved out a niche in the vinegar industry. The dedication and commitment to finding the right technology, as exemplified by Rodrigo Vargas and his team, showcase the importance of research and innovation in creating high-quality food products. With their artisanal vinegar, American Vinegar Works has brought innovation to an often-overlooked pantry staple, showcasing the possibilities for improvement in the food industry.