Ember & Iron
Stories of American Makers
“Nobody told me to leave. They just made it impossible to stay.” — A developer bought the boat shed where Ray Hollister (71) has roasted coffee by hand for nineteen years. The last 496 bags are going at 50% off.
The shed smells like it always has: scorched sugar, wet cedar, and lake. It is the first week of August, and the roasting floor is already half empty. The green coffee that used to stack six sacks deep along the north wall is down to a single short row. The cooling tray is scrubbed. The order book is on the bench with more crossings-out than entries.
In the middle of it, taking up more room than anything else in the building, sits a 1961 cast-iron drum roaster. Three thousand pounds of it. Ray Hollister has run this machine by hand for nineteen years.
“It came out of a shuttered roastery in Milwaukee,” he says. “Took four men and a boom truck to set it. It’ll take the same to move it, and there’s nowhere to move it to.”
An investment group bought the whole shed row last fall — Ray’s building, the two beside it, the boat launch at the end. The plan is waterfront condominiums. The sale is closed, signed, done. Ray has never argued that part. What he argues is the timing.
“It’s in the handover schedule. December,” he says. “That’s the date. December was enough. I’d have had the last roasting season, I’d have got everybody’s standing orders filled, and I’d have taken the drum down properly instead of walking away from it.”
He is not going to get December.
The rent tripled in March. Then the power started going out.
The condominiums sell faster once the row is empty. Every month Ray is still in the building is a month that costs somebody money. So, starting in the spring, things began happening.
The rent tripled from one month to the next — the lease is a nineteen-year handshake, never written down, never needed to be. Then came a complaint about the smell of roasting coffee. After nineteen years. Nobody will say from whom. Then the access road was closed for construction work, and his green coffee delivery sat out at the gate on a pallet in the rain.
Twice the power has cut out in the middle of a batch. Both times it was scheduled maintenance. Both times nobody told him.
“They can’t put me out until December. So they’re just making sure I don’t want to be here.”
“Forty pounds of green coffee in the drum and the power goes,” Ray says. “You know what that is? That’s two hundred and forty dollars of coffee, and you shovel it out on the floor, because it’s ruined and there’s nothing else to do with it. Second time it happened I stood there a while before I got the shovel.”
He is careful about how he says the next part. “I’m not telling you anybody broke a law. On paper it’s all fine. Rent’s allowed to go up. Roads get worked on. Power goes out. Every single one of those things is nothing on its own.” He stops. “It’s only when you put them in a row that you can see what they are.”
He set the machines for thirty-one years. Then his wife stopped drinking what came out of them.
Ray started on the roasting floor of a large commercial coffee plant at twenty-one years old. He finished as production roastmaster. Thirty-one years, one company. He was the man who set the machines — charge temperature, airflow, drop time, the whole profile that several million pounds of coffee a year ran through.
He was fifty-two when he walked out. The reason was sitting at his own kitchen table.
Marlene — his wife of thirty years by then — had started having trouble in the mornings. Stomach, heartburn, every day, worse by the month. She cut back. Then she cut it out. At fifty-two she stopped drinking coffee altogether.
“Thirty years we sat down to breakfast together,” Ray says. “And then one morning I’m sitting across from my wife and she’s got a cup of herbal tea. That’s all. That was the whole thing.”
He knew what was in her cup, because he had been the one setting the machines that filled it.
Ninety seconds, or twenty-one minutes
Here is the part Ray says most people have never been told, and he would know.
A large commercial roaster does not run for twenty minutes. Where Ray worked, a batch went through in ninety seconds to three minutes. Not because anyone believed that tasted better. Because of weight.
Green coffee is roughly a tenth water. Roasting drives that water off, and the longer and further you roast, the more weight walks out of the drum as steam. A light, fast roast loses somewhere around a tenth of its mass. A long, fully developed roast can give up a fifth to a quarter of it.
“Work it out,” Ray says. “Every point of weight you don’t lose is a point of coffee you get to sell. On the volume that plant ran, one point was real money. Nobody ever said the word flavor to me in a yield meeting. Not once in thirty-one years.”
“They weren’t roasting for flavor. They were roasting for weight. And your stomach paid for it.”
The trade is not free. Push a bean through that fast and the outside colors up long before the inside has caught up. You get a bean that looks properly roasted and isn’t — dark on the surface, underdone in the middle, with a hard, sour edge left in it that never had time to cook out.
That edge is what a lot of people are actually tasting when they say coffee is “too strong” or “too sharp,” and it is what Ray believes was in Marlene’s cup every morning for years.
(There is real science underneath this. Longer, fuller roasting breaks down chlorogenic acids — which are associated with increased stomach acid — and builds up a compound called N‑methylpyridinium, which is associated with less of it. Researchers have measured the difference. It is not a cure for anything, and Ray has never once called it that. It is simply why a long roast and a short roast do not sit the same.)
Ray’s drum takes twenty-one minutes. Forty pounds at a time. No profile software, no automatic drop.
“Second crack has a sound,” he says. “It’s not the same as first — it’s smaller and faster, like rain starting on a tin roof. There isn’t a machine on this earth that hears it better than I do. I’ve got about four seconds to decide, and I’ve been deciding it for fifty years.”
- Twenty-one minutes in the drum. Not ninety seconds. Long enough for the inside of the bean to finish, so there is no hard, sour edge left in the cup.
- Roasted by a 31-year production roastmaster. Ray set the machines for one of the largest coffee companies in America before he walked out and started doing it the other way.
- A 1961 cast-iron drum, run by hand. Forty pounds a batch. No profile software, no automatic drop — the drop is called by ear, on the sound of second crack.
- Full one-pound bags. Not twelve ounces. A pound, the way coffee used to be sold.
- Whole bean or ground to order. Tell him what you brew on — drip machine, percolator, French press, espresso machine — and it’s ground for it the day it ships.
- Stamped with the roast date, not a “best by.” Every bag carries the day it came off the drum, in ink, by hand.
- Easier on a sensitive stomach. A long, fully developed roast leaves less of what makes coffee harsh. It is the reason Marlene sits down to a cup again.
It took him four years to make a cup his wife would drink
Ray did not walk out of the plant with a plan. He walked out with a severance check and an idea, and he spent that first spring looking for a machine old enough and slow enough to do what he wanted.
By summer he had it. The drum came out of Milwaukee. The shed came from a man named Toivo who owned the boat launch and shook his hand on a monthly rent that never once went to paper. And then Ray started roasting, and Marlene did not drink any of it.
“She’d try it,” he says. “She’d take a swallow to be kind to me and set the cup down. Four years of that.”
He roasted through it. Longer, then longer again. Different origins, different drop temperatures, the whole thing by ear and by hand.
“It was a Tuesday,” he says. “She finished the cup. Didn’t say anything about it. Poured a second one. That’s the whole story — she poured a second cup, and I had to go outside for a minute.”
Marlene has had her coffee every morning for fifteen years since. She is also the one who now packs every order that leaves the shed.
Sixty batches, and then the drum goes cold
When Ray decided he was not going to make it to December, he did the arithmetic on what he could still put through the drum with the green coffee he had on hand and the power staying on more often than not.
Sixty batches. Forty pounds each. Twenty-four hundred pounds — and then that is the end of it.
Sixty batches at twenty-one minutes apiece comes to twenty-one hours of roasting. Ray noticed that before anyone else did, and did not find it as funny as his wife did.
There is no apprentice. Ray took two over the years and neither stayed — “it’s hot, it’s heavy, and it’s a lot of hours to earn not very much,” he says, without any bitterness in it. There is nobody he is handing the drum to, because the drum is not going anywhere. There is no second location. When the roasting stops, it stops.
He has never discounted a bag in nineteen years. Fifty dollars a pound, the same price to a neighbor as to a stranger, and he has turned down every wholesale account that asked him to come down on it. For the final run he has cut it to $25 — 50% off.
“I’m not doing that to move product,” he says. “There’s twenty-four hundred pounds and then there’s nothing, and I’d sooner it was in somebody’s kitchen than in a dumpster behind a condominium. And I know what a can of coffee costs at the grocery store right now. I’d like people to be able to say yes.”
Update — this week
We have had more orders in eight days than in the whole of last year. The final run is down to 496 bags. When they are gone there will be no more — the drum does not leave the building, and Ray is not starting again somewhere else. If you want a bag, please do not wait on it.
— Marlene Hollister, Marlow Market Co.
Letters from the people drinking it
“I’d been down to one small cup in the morning for years, and even that I paid for by ten o’clock. I’m three bags in now and I have two cups like a normal person. I don’t know the chemistry of it and I don’t much care. I just know what my mornings are like now.”
“I’ve been drinking the same red can for forty years so I’ll admit I expected to be unimpressed. First thing I noticed is what wasn’t there — that sharp bite at the back of it. I went and made a cup of the old stuff to compare and couldn’t finish it.”
“We’re across the lake from him and we’ve watched three of these shed rows go to condos in ten years. I ordered two bags out of pure spite, if I’m honest. Then I drank it and ordered two more for a better reason.”
How to order it — and how to know it’s his
Ray’s coffee is sold only through Marlow Market Co., the small online shop Marlene runs out of the shed itself — the only place the coffee from the final run exists. It has never been in a grocery store, and it never will be.
“Marlene does all of it,” Ray says. “Orders, boxes, the postage. I roast and I carry. That’s the arrangement and I’m not allowed to change it.”
Payment & shipping: all major cards, PayPal, Apple Pay, and Google Pay. Whole bean or ground to order. Orders ship within 2–3 business days of roasting. Free returns within 90 days.
A word of caution: as the story has spread, listings have started appearing on marketplaces using Ray’s name and photographs. They are not his coffee. There is one drum, it is in Duluth, and everything that comes off it ships from this shed. If the bag has no hand-stamped roast date on it, it did not come from Ray.
What you’re actually buying
This is the cup a man spent thirty-one years learning how not to make.
Ray Hollister knows exactly what happens to coffee when the only number that matters is weight, because for three decades he was the one hitting that number. He walked away from it at fifty-two, spent four years failing, and got it right on a machine older than most of the people who will drink it.
Twenty-four hundred pounds. And then a three-thousand-pound drum sits cold in a building that is coming down.
Ray’s guarantee: drink it for a week, then decide
A 90-day, no-questions-asked money-back guarantee, on the last coffee he will ever roast.
“Drink it for a week. If your mornings aren’t better for it, you shouldn’t be paying for it.”
Take the bag home. Make it the way you always make it — same machine, same scoop, no ceremony. Give it a week of ordinary mornings. If it doesn’t belong in your kitchen, send it back and get your money back. No questions asked, and you do not have to send back what you’ve already drunk.
More letters
“I bought it for my husband, who is impossible to buy for and has opinions about coffee he did not earn. He read the whole article standing up in the kitchen. Then he drank it and said ‘well, hell.’ That is the highest review he has ever given anything.”
“Coffee at my store has gone up so much this year that I actually stood in the aisle doing math. A pound of Ray’s is not much more than the can, and it is not remotely the same thing. That comparison would have been laughable five years ago. It isn’t now.”
“I ordered one bag to see. I have since ordered four more, and I understand there is a limit to how many I can get, which I am not happy about. My wife says I am hoarding. I am hoarding.”
DISCLOSURE: This is a paid advertisement. The owner of this site has a material connection to the products shown on this page. Please review the full return policy before ordering.
Testimonials reflect individual experiences and results may vary. Images are for illustration; because every batch is roasted by hand, colour and flavour may vary slightly from bag to bag.
Nothing on this page is medical advice, and no product described here is intended to diagnose, treat, cure, or prevent any disease. References to roasting chemistry describe published research on coffee composition, not a claimed health benefit of this product. If you have a persistent digestive complaint, please speak to your doctor.