There is increasing interest in energy from woody biomass as fossil fuel replacement, yet environmental and economic limitations have reduced feedstock available for bioenergy. Supply could likely be substantially increased with intensive forest management for productivity and utilization as well as forest-based dedicated energy crops. This paper discusses the role of industrial forests in sustainable bioenergy feedstock production and the lessons learned in an operational scale project. Catchlight Energy, LLC, a Chevron|Weyerhaeuser joint venture, evaluated intercropping switchgrass (Panicum virgatum) in loblolly pine plantations for liquid transportation fuel, with the goal of full-scale production. Within Weyerhaeuser, sustainability and operational research were conducted simultaneously. While the environmental research is non-proprietary and being published as it is completed, operational trials were internal. To understand lessons learned, staff responsible for management, planning, logistics, and field operations were interviewed, and perceived and actual barriers to production described. Ongoing environmental research is showing that carefully planned field operations can be conducted sustainably, but energy crop production fell below levels needed for economic feasibility.