Just a few miles outside of Central City, Farmstead Butcher Block is proof that even in challenging times, opportunity can emerge from necessity.

What started as a vision during the uncertainty of the COVID-19 pandemic has grown into a thriving processing and retail operation serving producers and consumers throughout western Kentucky and beyond. While the retail store recently celebrated its fifth anniversary on June 6, the business itself is still relatively young. The retail store opened in 2021, followed by the processing facility in April 2022.

According to manager Raysha Doss, owners Cliff and Carol Jo Welch saw a need during the pandemic for additional processing capacity in Muhlenberg County.

Originally, their plans included poultry processing. The disruptions of COVID exposed weaknesses in food supply chains and highlighted the importance of local processing options. While poultry remains part of their long-term vision, the realities of building and launching a processing facility during the pandemic caused the business to evolve in a different direction.

As construction progressed, the Welches quickly realized there was significant demand for livestock processing. Today, processing remains the foundation of the business.

"We're a processing facility with a retail store," Raysha explained. "Most of our business comes from processing."

Building During COVID

Launching any business is difficult. Launching a processing facility during a global pandemic presented an entirely different set of challenges.

COVID-related shortages and construction delays affected nearly every phase of development. Materials were difficult to obtain, timelines shifted, and costs increased. Yet despite the obstacles, Farmstead Butcher Block opened its doors and immediately attracted attention.

"It caused a little shell shock for the area when we opened," Raysha said.

The response confirmed what the Welches had suspected all along—there was demand for additional processing services and local meat options.

Today, the facility performs primarily USDA-inspected processing and serves customers from a broad geographic area, including producers who travel from Tennessee and Indiana. In addition to processing services, Farmstead Butcher Block offers private labeling opportunities for producers looking to market their own products. The reach of locally raised Kentucky beef extends well beyond the Commonwealth. Animals processed at Farmstead Butcher Block have supplied freezer beef customers from coast to coast, including destinations as far away as Florida, Louisiana, Illinois, Kansas and California.

More Than a Retail Store

While the processing side of the business drives most of the operation, Farmstead Butcher Block continues to focus on growing its retail presence.

One challenge the business faces is perception.

"There is a stigma that we're too far out of town," Raysha said.

In reality, the facility is located only about three miles from Central City.

To increase visibility and attract new customers, the business has expanded its marketing efforts. A new website now allows customers to place orders online, and the team is exploring delivery platforms such as DoorDash and other services to make products more accessible.

Community events are also part of the strategy. The business recently hosted a flea market event designed to introduce more people to the location and encourage visitors to explore the retail store.

Fridays and Saturdays remain the busiest days of the week as customers stock up on locally sourced products and specialty meats.

The Importance of Expertise

One of the keys to Farmstead Butcher Block's success has been the people behind the operation.

Raysha is quick to credit Plant Manager Tyler Hollis for helping establish the processing side of the business.

"He has a strong meat science background and knows a lot about efficiency," she said. "We would not be where we are without Tyler."

His experience has helped the facility develop efficient systems and maintain high standards while navigating the challenges of a growing operation.

The business currently employs 16 people, a team Raysha describes as being "like family."

Finding and retaining those employees was not easy, but she considers the workforce one of the company's greatest strengths.

"We have an awesome crew," she said.

For an industry that continues to struggle with workforce recruitment and retention, building a stable team has become one of Farmstead Butcher Block's most valuable assets.

Feeling Every Change in the Market

Like many processors, Farmstead Butcher Block has experienced dramatic shifts in demand since the pandemic.

"We have felt every change in the cattle market," Raysha said.

The business benefited from the heightened consumer demand of the COVID era, but those conditions have changed significantly.

"It is not all doom and gloom, but it is hard," she said.

Like many small and mid-sized processors across Kentucky, the facility is currently operating below capacity. The appointment shortages that once dominated conversations throughout the industry have largely disappeared. Today, the challenge is finding enough livestock to keep facilities fully utilized.

That concern is particularly evident in Muhlenberg County.

Raysha noted that they have been told the county's cattle population has declined by approximately 46 percent. Whether through herd liquidation, changing land use, or shifting economics, fewer cattle ultimately mean fewer animals available for processing.

For processors, that trend raises concerns about long-term sustainability.

"We need more animals to process," she said.

Investing in Animal Welfare

One of the most unique features of the facility is its commitment to animal welfare.

Farmstead Butcher Block utilizes a livestock handling and restraint system designed around principles developed by animal scientist Dr. Temple Grandin, whose work has transformed livestock handling practices throughout North America. Grandin, a professor and autism advocate, is widely recognized for designing systems that reduce animal stress by taking into account how livestock perceive their surroundings and react to visual distractions, movement, and noise.

The system is designed to keep animals calm and comfortable while moving through the facility, reducing stress for both livestock and employees. Grandin's work has become a cornerstone of modern humane handling practices and is used extensively throughout the meat industry.

For Farmstead Butcher Block, the investment reflects a broader commitment to quality, efficiency, and responsible animal care.

Looking Ahead

Although the business has evolved since its original concept, Cliff and Carol Jo have not abandoned their initial vision. The facility hopes to add poultry processing in the future.

In the meantime, the team remains focused on expanding retail sales, attracting new customers, and continuing to support livestock producers throughout the region.

Like many KAMP members, Farmstead Butcher Block finds itself navigating a very different environment than the one that existed during the height of COVID. Capacity is available. The challenge now is creating demand, attracting livestock, and helping consumers recognize the value of locally processed meat.

Despite those challenges, Raysha remains optimistic.

"It is not all doom and gloom."

That outlook may be one of the business's greatest strengths. In an industry facing changing markets, shrinking cattle numbers, workforce challenges, and evolving consumer habits, Farmstead Butcher Block continues to invest, adapt, and look for new opportunities.

Only a few years after opening its doors, the operation has already become an important part of the local processing landscape—and its story is still being written.