Bottom Line Up Front (BLUF):  Due to emergent health code changes, the Denville Dept of Health has asked me to make changes that effectively forces my home based operation to a more compliant "base of operations".   (Commercial Refrigeration & Dishwashing are the main issues).       Until I can make such improvements, or find tolerable workarounds, I'm legally unable to take jobs.      The ultimate long term solution is to work from a warehouse on commercially zoned lot somewhere, which will resolve a multitude of other issues as well....but this will take $$$ & time.    In the mean time, I'm exploring some workarounds to allow continued operations into the 2012 season, but it's not looking good.    I may not be able to operate this season...     For more in-depth details, please read on:

PLANTING THE SEEDS FOR PROBLEMS:  In 2006, I formalized the business and applied for my catering license for my "Home Based Operation".    When my first Dept of Health inspection came along, I honestly thought I'd be shut down immediately!     Much to my surprise, the Health officer loved what I was doing, encouraged me, and provided guidance on how to operate safely.    Although everyone knew that the facilities were not perfect, they were considered "Good Enough".    Based on the apparent "Green light", I invested heavily in the business (more trucks, trailers, roaster, equipment) and made sure I remained in compliance with the Dept of Health.  The business grew...

 My "Base of Operations" was conveniently located on my 1/5 acre private residence on a residentially zoned lot.        Under normal circumstances, a "Home Based" catering business would be completely disallowed, but I "skated by" because of my uniqueness.  On my property, no commerce took place, no cooking or food prep took place, no actual jobs were conducted ...and my food safety was impeccable. (I took all the required state mandated training).      What *did* occur at my property:  Job staging, trailer/truck parking, dishwashing, cooler cleaning, and trailer restocking/maintenance.  Activity took place on occasional Fridays-Sundays, for just a few months, and was generally short duration.          But I always knew that having a growing commercial operation on a residentially zoned lot was going to be an issue, sooner or later.       As my name got out there, I was performing multiple jobs per weekend, for ever increasing headcounts.   Truck/trailers and Staff were coming and going at all hours.     More and more food was being handled.   It was clear that I had outgrown my facilities, but I limped along anyway for 6 years and made it all work.  And I kept my fingers crossed that the Zoning Officer wouldn't serve me a "Cease and Desist" letter.      In the mean time, I started looking at real estate to be the next "EPPO World Headquarters", but failed to find a solution.  

DEFICIENCIES:  I operated legally for 6 years without any issues, and passed all my health inspections.   Everything changed when I contacted the Dept of Health for my annual 2011 inspection.   The new health officer made me aware that the NJ Health Codes have been updated.   What was "allowed" (or tolerated?) before, is no longer going to be allowed/tolerated.    Unfortunately, the operation is now considered deficient in 2 areas.    Deficiency #1.)  Safe Pig/Meat/Food Holding.      In the beginning, the DoH instructed me to surround the pig/meat completely with large bags of ice in a massive cooler to hold overnight.    The new guidance dictates that Ice is only OK for storage of food for <4 hours.   Anything longer than that must be under mechanical refrigeration (or dry ice).   The "Fix" seems to be a Refrigerated Truck (which I will consider buying).    It would be helpful to have a large walk-in cooler too, but I can't have that on a residentially zoned lot.      Deficiency #2) Dishwashing.    In my garage, I was previously approved to use a dedicated Double-basin Stainless Steel sink for the few things I needed to wash (a bus bin full of knives, cutting boards, tongs, and a few other items)..   (A Triple Basin SS Sink has always been the desired equipment, but due to the small volume of dishes to be washed, I was granted an exception).     That exception is no longer granted.   I now need to be in full compliance with the code.  Although the two deficiencies are generally simple to resolve, they CAN'T be resolved on my residential lot.      If I don't resolve the deficiencies, my 2012 Catering License won't be granted and I won't be able to operate.

[It is important to note that I was never formally "shut down" by the Dept of Health.  The public was never at risk.   I've never failed any inspections.   I was always compliant and followed the guidance of the Health Inspectors immediately and they were happy with me.      The DoH are NOT seeking to shut me down, in fact they are trying hard to work with me.    For that, I'm appreciative.]

ZONING:  This brings me to the Zoning issues.   Interestingly, the Denville Zoning officer DID visit me recently, and did NOT see a reason to shut me down for the "current" operation.    Zoning goes hand in hand with the Dept of Health though.        At my house, to make the improvements to comply with the Dept of Health, I'd violate the residential zoning codes.     I simply cannot add the triple basin stainless steel sink and hand washing station to my garage.   There's no more room.     But even if there was room, the garage itself is noncompliant.   (jammed with other crap, no tile floors, etc).       I can't add exterior grade walk-in refrigerators to my property.   I can't add any more outbuildings.   I shouldn't be using the interior of the house for anything, especially food storage.     Parking several refrigerated vans in my driveway may violate noise ordinances.       If a neighbor happens to get pissed at me and calls in a noise complaint, the Zoning officer won't have a choice, he'll have to shut me down.

The RIGHT way to operate is out of a custom outfitted warehouse on a Commercial property somewhere, so I can legally set myself up for professional operations, and have all the room I need for commercial apparatus.     This is a place where I can have trucks/staff coming and going at all hours, deliveries from suppliers, and there'd be no impact on neighbors.    Easier said than done.  

FINANCES:  The over-arching limitation is the finances.     This is a part-time seasonal operation.   It's a hobby that only had to break even and make a few extra $$$ to make it worth my while.  (I have a well paying full time job which pays the bills).         I operate for about 5-6 months with the lions share of work jammed into 3 months, when the money actually flows.       There's really not a huge profit margin here.    Without making any changes (operating rent free at home) it's barely worthwhile to run the operation, but I do it because it's a passion!.    The business simply can't tolerate a huge increase in overhead.         Here's several scenarios for business continuation:

RENTING OF COMMERCIAL PROPERTY:   At a minimum, I'd need about 1000sq feet.   A commercial rental property can physically be the answer for the logistical needs, but it is clearly not the financially responsible path forward.     With rentals typically going for $2K/mo, I'd be ok during the few months of catering season, but for the other 7 months, I'd decimate any profits by carrying this huge overhead.  

PURCHASING COMMERCIAL PROPERTY: The purchasing of commercial real estate seems to be the best path forward, as the investment would be it's own financial maneuver which should result in equity growth.       But this is a complex undertaking, and very expensive for the area I live in.  I've already been looking, but it'll take years to find and improve the right place.  It's certainly not the immediate solution..  Before I make this plunge, I have to be sure I'm doing the right thing, as I need to fully understand the complicated zoning and constructional issues to contend with.      So far, I've not found the perfect place that both supports the logistics and is affordable.        An added complexity is that many commercial lots in this area don't allow "outdoor storage", which means I cannot keep trucks and trailers, or "conex" storage containers outside.  

OWNING RESIDENTIAL/COMMERCIAL PROPERTY:   This would be very desirable, since having the operation and my residence in the same location is what I'm used to.     But this is also a very complex undertaking  since there are zoning issues to contend with, and  limitations imposed by the Highlands Act.     It's also very expensive in my area.   I'd need 2 acres.     It's a $750K undertaking to improve a lot to the point that it would work for me.    Very often, these types of lots are not in locations I'd actually want to live, or are very far away from where I'd like to live.   Some of the lots I've seen have been disasters that likely have environmental issues (former junkyards with spilled oil).

Whichever way I go with real estate, this seems to force an overhaul of the business such that more income streams are developed.    I'd need to operate year round to keep the bills paid.   More people, more trucks, more equipment, more headaches.    This goes from a casual business to the "Monster" operation, which was never my goal.  However, it may be inevitable if I go forward.      

SHORT TERM FOR 2012 Season:    I'm looking into workarounds to keep operating into the 2012 Season.   I understand fully the negative ramifications of taking a season or longer off :  (Loss of customers, loss of staff, years of experience and training evaporates.   And I may very well loose my momentum enough so that I won't start up again).    To take short term steps to marginally operate, I'd purchase the refrigerated van, and I find some other place to wash dishes and store food under commercial refrigeration.    There's be a host of logistical and operational changes to contend with as well.    I have one possibility so far, but details have not been ironed out.      Working like this seems to be a gigantic logistical headache, so I'm not holding much hope.  I'll know more in the next few months.   

WHAT IF I CAN'T SORT SOMETHING OUT FOR THE 2012 SEASON?     I can't legally operate!  And I drop insurances to lower overhead.    This means that I won't take paying jobs.         Actually, it may be a breath of fresh air for me.     Imagine having free weekends again, like the "beautiful people"!    Mt Biking trips, Camping trips, Music festivals...all of which I love to do.      I have plenty of projects that I've been blowing off.  In fact, I'm currently FINALLY renovating my kitchen.     I'd enter a few BBQ competitions, the experience which would be amazingly beneficial to my BBQ business.     And I can put more time and energy into the real estate/facilities search. 

WORST CASE:    I shut the business down and have a huge yardsale.    And I have a life again.   LOL.

So, friends, clients, and staff...   I'm truly in a pickle here.     Because I haven't been successful in the establishment of proper facilities, my business has hit a huge roadblock, and I'm the only one to blame for it.    I was hoping the facilities issues could be worked out in a more seamless fashion, gradually, and invisible to clients...but here I am today with a train wreck on my hands.      Be assured that I'm trying to rise above these issues, move forward, and come back better and stronger than ever.     I'm not ready to fold this business yet, as it always seemed like the perfect retirement plan (7 years away from retirement).     But I have some serious behind-the-scenes issues to wade thru before I can legally take work again, and if I can't string together the right facilities, that make logistical sense, and financial sense, then I'm done with it.     This may take some time to resolve. 

The story is evolving.  This is just my feelings as of right now, given everything I know.   Please check back.    Thanks for reading this far!