Category: Archived Articles

By: Alyssa L. Ochs

Much of the winemaking process focuses on growing and harvesting grapes and turning raw materials into the amazing beverage that is loved worldwide. But once those bottles, cans, pouches or boxes get filled, some essential work is still to be done.

  End-of-line packaging is an integral part of getting wine into the hands of consumers and establishing a brand image. Therefore, it’s good to know all the details that go into the packaging process to make it as efficient, safe and cost-effective as possible.

Machinery and Materials for End-of-Line Packaging

  Various machinery exists for end-of-line packaging solutions, including depalletizers, decasers, case erectors, packers, partitioners and case sealers. Some wineries use an automatic process, while others rely on old-fashioned manual labor to package their wine.

  Automation is typically implemented when a winery’s line speeds get to at least 120 bpm as a way of reducing labor, producing more product or adding diversity to packaging sizes and configurations. While automation requires a significant up-front investment, it can help keep winery employees safe and take production to the next level.

  Pallets, cartons, shrink wrap, Styrofoam and Tetra Paks are commonly used to ship wine. Ensuring that wine is protected from damage is the top priority during shipping, but the aesthetic appeal of the packaging is also a consideration for wineries to keep in mind.

End-of-Line Recommendations from Industry Experts

  The best way to learn about end-of-line packaging solutions is to talk to companies specializing in this part of the winemaking process.

  Bryan Sinicrope, Vice President of Sales and Marketing for A-B-C Packaging Machine Corporation in Tarpon Springs, Florida, told The Grapevine Magazine that his company offers several options for packing, including robotic and pick-and-place machines for bottled wines. He said that these robotic and pick-and-place machines have features to protect both the closure and label during packing to preserve package integrity. For pouch-packaged and cartoned wine, robot packers provide maximum flexibility to pack into cases or trays with servo-powered product feed, gentle robotic packing and quick changeover at the operator station.

  “We also offer a semi-automatic carton packer for smaller operations that package wine in cartons with speeds up to 10 cases per minute,” Sinicrope said. “This packer uses one attendant to supply cases to the packing section, while the packer automatically orients and stacks the cartons. The packed cases feed to a case sealer.”

  A-B-C Packaging has been providing packaging solutions since 1940 and serves a variety of industries, including beverage, automotive, electronics, chemical, pharmaceutical and more. The company offers machines that close and seal the top case flaps with adhesive or tape and square the case as it is sealed for maximum stability on the pallet.

  They also sell low-level, robot and semi-automatic palletizers to accommodate wineries’ budgets, space, flexibility requirements, speed and personal preference. Sinicrope said that the low-level machines are easy to install and help keep operating costs low due to the floor-level control and simple maintenance.

  “These palletizers convey cases into layers with complete flexibility for pallet patterns,” Sinicrope said. “The patterns are programmed into the HMI, and new pallet configurations can be set on the plant floor. Also available are empty pallet feed, slip sheet insertion and full pallet discharge. These palletizers are a good solution for most wineries.”

  Meanwhile, A-B-C Packaging’s robot palletizers can handle multiple product types with minimal hardware because these machines stack cases on pallets in preset configurations with the option to easily program new patterns. A-B-C Packaging’s semi-automatic palletizers can be converted to full automation for small wineries looking to upgrade their equipment.

  “They require one full-time operator who creates the pallet patterns by orienting cases from the line,” Sinicrope said. “The palletizer lifts and stacks the pallet layers. Completed pallets are removed by a forklift driver who also positions the next empty pallet.”

  ABE Beverage Equipment, a company based in Lincoln, Nebraska, also serves the winery market and has expanded its equipment solutions to address rapid growth in canning and ready-to-drink packaging options. In fact, the company changed its name from American Beer Equipment to ABE Beverage Equipment in 2020 to better reflect its all-encompassing lineup of equipment solutions for nearly every beverage market. Amanda Podwinski handles sales and marketing for ABE Beverage Equipment. She told The Grapevine Magazine that in addition to canning lines for carbonated and still beverages, ABE offers the AutoPak Can Carrier Applicator, an end-of-line automatic carrier applicator for six- or four-packs of cans.

  “This labor-saving system offers a minimal footprint and is adjustable to accommodate a variety of cans and configurations,” Podwinski said. “Carrier applicators are an excellent choice for marketing multi-packs of wine in cans. As competition heats up in the canned wine marketplace, ABE also offers a 12- and 24-pack case wrapping system, perfect for wineries looking for ways to minimize their canned wine packaging costs. The ABE ShrinkPak is designed to shrink-wrap cases of cans when selling bulk, rather than by way carrier packs. Case costs can be reduced by as much as 60% when compared to corrugated packaging.”

Mistakes Wineries Often Make with End-of-Line Packaging

  Every winery has its own preferences and processes for packaging wine, but some common mistakes seem to repeat themselves throughout the industry. One example?  Assuming all packaging options are equal. There is no one-size-fits-all solution for packaging wine.

  “Everyone’s space, budget and resources differ,” Podwinski said. “In the highly competitive beverage industry, there are plenty of suppliers offering one-off parts or equipment. To ensure you receive the most reliable solution, ABE Beverage Equipment provides a comprehensive approach to your beverage equipment line. At ABE, we design and engineer your equipment from the ground up, ensuring you receive the highest quality product. And we don’t stop there: Our world-class team of engineers, manufacturers, customer service techs and support staff are by your side to help you plan, launch, build and maintain your beverage business. We promise our dedicated partnership will extend beyond just providing your equipment.”

  Not considering future flexibility is another common mistake that wineries make with their packaging.

  “While a winery may be packaging only 12-packed cases of 750 ml bottles right now, they may find opportunities in alternate bottle sizes, container styles or pallet configurations as time goes by,” Sinicrope said. “With flexible equipment, they can take advantage of these opportunities without a large capital investment or line downtime.”

Trends and Innovations in End-of-Line Packaging

  Because of advances in modern technology and lessons learned from challenges with end-of-line packaging, companies that work in this niche industry continue to develop promising solutions. For example, A-B-C Packaging has introduced a compact palletizer with a small modular footprint to accommodate tight line layouts. This advancement emerged in response to wineries having limited space for equipment in the packaging area of their production facilities.

  “It occupies from 10 to 30% less floor space than conventional low-level machines, with an open profile and full machine guarding,” Sinicrope said.

Concerning trends and innovations, Podwinski said ABE Equipment products could be used across various industries looking to package, label and produce different types of products.

  “ABE’s innovative equipment solutions span several markets, product types and industries,” Podwinski said. “The equipment we have built for nearly 30 years continues to evolve to meet the needs of today’s entrepreneurs. This includes solutions for a variety of container sizes, shapes and materials.”

Choosing the Right End-of-Line Packaging for Your Winery

  Since there are several options available today for end-of-line packaging solutions, wineries should start researching machines and materials before they are truly needed.

  Sinicrope said wineries should talk to their potential suppliers about the best ways to ship their wine. “Discuss your goals, ask questions and listen to their recommendations, and they can help you find the best solution for your winery packaging line,” he said.

  Ultimately, trends in wine consumption are changing how wineries approach end-of-line packaging and equipment choices. Podwinski said that canned wine is making a substantial impact on how wine is sold.

  “Multiple cans packaged together make a sturdy package that in many cases is less likely to be damaged and [more likely to] arrive safely and allow consumers to take their favored beverage into numerous environments,” she said. “Cans may be new to many wineries, but with the versatility and environmentally friendly impact that cans offer, wineries would benefit from investigating this opportunity further.”

When packaging their product, winemakers look to preserve aroma, color and flavor at a reasonable cost while avoiding the chances of debilitating contamination or premature oxidation. Additionally, wine closures may be chosen depending on the wine’s qualities, expected consumption date or the market in general. The combination of these factors can make choosing the most suitable closure a complex and sometimes confusing task. Closure producers have a lot to offer, whether natural, plastic or technical corks, screw or crown caps. There also exist more unique closures that allow a product to stand out on crowded shelves. The closure industry has become very competitive, driving innovation regarding the best closure choices for any situation. However, it’s still all about managing oxygen ingress and transfer ratios. Because each wine has its own unique factors, it is ultimately up to the winemaker to decide which closure is the best choice for their wine.

Aluminum Closures Make a Push in the Marketplace: Herti US, Inc.

  Herti US, Inc. offers more than 40 different sizes of aluminum closures for wine, spirits, olive oil and mineral waters. Their products have diameters ranging from 17 to 43 mm and heights of 12 to 60 mm, used for sealing bottles with capacities of 50 ml up to a U.S. gallon (4.54 l). With various sizes, shapes, and printing capabilities, manufacturers can help winemakers create an overall attractive package with consistent branding and product recognition. In addition, customers can choose from different design options, including up to five color offset printing with matte, semi-matte and glossy finishes. They also offer hot foil printing, embossing and top relief with a wide range of decorative capabilities and liner choices. Herti continually invests in innovative products to satisfy the evolving requirements of wine producers. Vinstar is the trademark under which Herti sells its aluminum closures designed for wine bottle packaging. The most popular standard closures offered for the wine industry are the 22×15, 22×30, 25×17, 25×43, 28×44 and 30×60 sizes.

  Zahari Zahariev, CEO of Herti, told The Grapevine Magazine that aluminum closures now represent a reasonably priced, modern way of closing bottles, which plays a significant role in preserving a wine’s quality, branding and impact, and also the winemaker’s environmental footprint.

  “Aluminum screw cap closures are simply cost-effective compared to other closure choices and suitable for both glass and PET bottles,” said Zahariev. “Aluminum closures offer endless creative possibilities for bottle design, and screw closures are now widely accepted and embraced as a suitable closure for all types of wines. With that acceptance comes an excellent base for the customization that becomes an important aspect of the winemaker’s brand building. An aluminum closure can be a piece of art by itself, but many design options are available to make it stand out as your own.”

  Zahariev said COVID-19 affected the industry because some sectors had to stop working and shut down while the retail, wine-to-go and online markets saw a boom. The standard closure business mainly stayed steady while the demand for luxury closures diminished. The screw closure business for the small bottles used in the aircraft and hotel industry vanished.

  “We look for the trend to get back to normal as restrictions fall or get lifted,” said Zahariev. “The COVID-19 pandemic led to a renewed industry focus on environmental commitment, meaning sustainability along with increased sensitivity about industry effects on our environment. This type of renewed commitment always drives innovation, and it did the same to the closure industry. Increased use and demand for aluminum screw cap closures are just one example of how the desired convenience factor also happened to be environmentally friendly. Aluminum screw caps are fully recyclable, with any production waste reused within the process. In addition to the screw caps, the glass bottle that the cap gets installed on is recyclable, so that’s a real eco-friendly situation.”

  Zahariev said that winemakers should look to, invest in and partner with companies that focus on the winemaker’s needs. Herti continuously invests in the latest production technologies and organizational improvements to guarantee its clients the best service and the highest quality products in an optimal timeframe. While providing the most popular, standard sizes of wine closures, they also offer the more petite sizes routinely used for ready-to-drink, single-serve, and mini bottles supplied by airlines and hotels. They come in 16 standard stock colors with numerous possibilities for decoration and design, making it easy for a winemaker to make the right closure choice for their wines.

  “At this point, winemakers generally know the pros and cons of different closures,” said Zahariev. “What’s important is to be able to get what fits your needs at a reasonable price. Aluminum screw closures offer that over other options and are fully recyclable, and offer numerous sizes and liners with a wide range of possibilities for decorations to enhance and promote unique and consistent branding across the board. In addition, aluminum screw closures offer the consumer the ability to open a bottle without any special devices easily and then have the option to reseal the bottle for later consumption without worrying about spillage. Storage and transportation are easier and don’t require the bottle to remain upright. We build mutual partnerships and maintain continuous contact with every client, and always keep our promises. We believe that your brand tomorrow is our business today.”

Cork is Abundant, Sustainable & Yes, Still Very Useful:

Dr. Dinah Bird, Baker-Bird Winery & Distillery

  Cork and composition cork are the traditional choices for wine closures, and contrary to what some have said, they are not on their way out. Even with the push towards aluminum, the percentage of corked wines has remained consistent over the past several years. But with more closure choices comes the opportunity to fine-tune your needs and choose the closure that best fits your wine, your reputation and your brand. And when you happen to own Baker-Bird Winery & Distillery, you stick with what has allowed you to remain in business since the late 1700s, including using corks in your spirits and wines.

  “Baker-Bird Winery is the oldest, largest wine cellar in America and naturally possesses a great deal of history surrounding our winery,” said owner Dr. Dinah Bird. “Being as historically significant as we are, we want and need our guests to experience the historical and traditional setting of our winery, our town and, of course, our selection of wines too.

  “We know that some wines can be better with the use of the aluminum screw closures, but some can also be better with corks because of the aging and oxidation process they provide and allow, like a Cabernet Franc. The Cabernet Franc is just one wine that benefits from aging and oxidation. It’s part of the wine’s overall process, and you won’t get that process with an aluminum screw cap. As a winemaker, you have to be aware of your product and how it ages and reacts. For example, our estate wines bring a little higher alcohol content, so they naturally oxidize a little faster than those with lesser alcohol content.”

  Bird told The Grapevine Magazine that if her winery ever decided to use different or synthetic closures, it would likely be on their bourbon-aged wines simply because of their higher alcohol content. Higher alcohol content makes the wine’s aroma and taste more time-sensitive due to higher oxidization rates.

  “We believe and maintain that the act of drinking wine should appeal to all of our senses to create a fulfilling and memorable experience,” said Bird. “What’s better than hearing that familiar pop of a cork pulled from a bottle of wine or champagne, releasing the wonderful aromas to all who are around? And it’s always been customary for some to inspect that cork after opening. Much nicer and somehow more elegant and satisfying than unscrewing a cap and simply placing it on the table beside you.”

  “Closure choice is just one part of the overall packaging of wine,” said Bird. “And the wine’s packaging is like the clothing that a person chooses to wear. Some clothes are naturally more casual and others considerably more formal. To me, aluminum screw caps resemble casual wear, and corks are formal wear. A winemaker should choose the package, or clothes, based on the product, the environment, and the circumstances of consumption.”

  Bird said there has been a move towards a broader population of consumers drinking wine, much of that taking place in more casual settings due to the pandemic. As a result, more wine is consumed in informal situations, leading to a broader acceptance of screwcap closures for wines and a wider acceptance of canned wines.

  “The aluminum screw closures have worked well in that they are great for ready-to-drink wines that can be easily resealed and do not need or benefit from aging,” said Bird. “But cork trees are not endangered, and the supply is equally sustainable. As for recycling, natural corks are indeed only a one-use item when it comes to closing wines, but you can be creative and recycle them in other ways. Baker-Bird Winery is proud to provide a total customer experience for our visitors. In doing so, we allow the customers to have a hands-on experience in corking bottles by hand, using our recycled corks and bottles. By recycling our corks and bottles in a creative and fun way, our visitors get a hands-on experience that they don’t get anywhere else. It is a rewarding experience for all involved.”

By: Thomas J. Payette, Winemaking Consultant

Cross-contamination is something we have all been made aware because of the food industry.  We have learned that using the same plate to take food to the grill as well as to serve food from the grill, prior to proper cleaning, may result in a salmonella outbreak causing discomfort to many.  Using a cutting board to prepare a meat or fish and then to cut a vegetable for a salad may result in similar reactions due to a bacterial contamination from an uncooked meat source to a product eaten raw.  Once one focuses on these same principals and perhaps has training in microbiology one keenly becomes aware of the principals of cross-contamination.

  An everyday less seen example outside the food industry is easy to illustrate.  After using the rest room we wash our hands diligently only to turn around and place our hand on the door handle to exit the rest room.  At that instant we have contaminated our hand with microorganisms from other individuals that have placed their hands on the same door handle prior to us.  Perhaps we have all seen the individual that continues to use the paper towel to maneuver the door handle and then throwing away the paper towel.  This is a microorganism conscientious individual that understands the above principal.  COVID 19 also has us all more aware these days to microbes in general.

  Looking at our own cellars, we may find many areas that need work to prevent microbiological cross-contamination.  This article will explore some areas that are culprits in the spread of microorganisms.  Every winemaker needs to have great hygiene and sanitation in the cellar to have the control a winemaker needs to make sound wines.  After reading this article, the cellar will become a different place as other sources of contamination become evident to the cellar team.

  SAMPLING: Most wineries, with sound wines, may taste from vessel to vessel while returning the leftover portion back to the vessel sampled with no worries.  This is one of the major areas that may need tightening up if the winery is experiencing problems.  Winemakers sample from one vessel to another perhaps expressing discontent in one form or another.  Often the discontent is directly linked to a spoilage bacteria or yeast that is growing “unchecked”.  The novice winemaker may rapidly move through the cellar’s containers in hopes of quickly reaching a vessel that has not progressed negatively.  What some winemakers don’t catch on to is that they are indeed the culprits to the spread of the very element with which they are not happy.  When sampling a container, look inside the vessel for a potential surface film. This may indicate a spoilage position for that wine.  Know the sulfur dioxide and ph of the wine.  When experiencing spoilage yeast or bacteria, be sure to sanitize/sterilize the sampling instrument and wine glass between samples.  Do not return the leftover portion to the vessel and be careful to discard the leftover in an area to be cleaned.  Do not dump it in the drain or on the floor for reasons to be explained later. (In clean cellars where sound wines are made it is not usually a problem to sample and pour back wines – only in unsound conditions should one avoid this habit.)

  TRANSFERS: If working with wines that are known to have some risk of infection – always move them last in the day of the transfers. Clean the hoses, pumps and other areas of wine contact between movements.  An example: If 40 barrels need to be racked and one barrel may be suspect to have some spoilage, rack the 39 barrels first then rack the last barrel separate to another tank – do not mix it into the blend.  If the wine is to be returned to barrel give serious consideration to returning the suspect wine to the same barrel from which it was removed to “contain” the spoilage and create a quarantine type situation.  Once the movements of any suspect wines have been made, thoroughly clean the pumps and hoses before resuming to the next transfer.  Be sure to clean the racking wand or any other devices that have had contact with the suspect wine.  Mark the exterior of these suspect vessels so others will be aware of the problem and cross-contamination will be minimized during sampling.

  TOPPING: Another area of great concern for cross contamination is topping.  Make sure to top wines with only clean sound wines of the same type or variety.  Often the topping wine of choice may be a recently sterile filtered dry wine that the winemaker has prepared for bottling.  This wine should have a greatly reduced yeast and bacterial load.  Always use clean wines for topping because the risk of spreading organisms is great here.

  BLENDING: If potential spoilage wines have been caught early, quarantined, and arrested they may still be used in a final blend in small quantities.  If the wines have been cared for and kept “in check” they may add to the complexity of the wine.  This should always be determined by a lab blending trial first.  The trick with blending is to wait to the last possible moment to make the blend to achieve protein, color and tartrate stability of the wine prior to bottling.  This should be done in stainless steel because it is easier to clean and sanitize after removing the wine from the vessel.  After blending, the wine should be filtered as soon as possible to eliminate the bacterial load.

  HANDS & CLOTHING: As with many processing and preparation cellars, always wash your hands frequently especially after handling wines that are suspect.  Be certain not to wipe your hands on your clothing, prior to washing them, after handling suspect wines.  This is the main reason that early in this article it is recommended to move suspect wines last in the day.  Always wear clean clothing from day to day.  Think in terms of what to do when.  If starting a yeast culture for sparkling wine production and bottling a sweet wine all in the same day, use common sense to work with the bottling first and then to work with the yeast starter culture.  Otherwise a major cross-contamination could occur resulting in a re-fermentation of the bottled wines.

  INSECTS & CREATURES: Insects and other mobile creatures are a large source of contamination that is more difficult to control.  For this reason a strong sanitation program is always recommended.  Fruit flies and other flying insects are always a difficult battle during crush and throughout the year.  Incorporate the elimination of these creatures, as best as possible, as a major part the sanitation program.  These insects fly from the drains to open vessels and handling tools such as: hoses, fittings, buckets, racking wands, pumps, filler spouts and many other areas.  Every surface they land on will have a cross-contamination residue left on it from their previous landings!  This was the reason under “sampling” it is recommended best not to pour samples known to contain spoilage yeast or bacteria on the floor.  These areas may become a food source for the insect or simply may be an area of contact for an insect or other creature.

  CHEMICALS & DRY GOODS: Chemicals and other dry goods are often an overlooked source of potential problems.  Using scoops for one material and then using them for another before cleansing will result in a cross contamination.  Soiled scoops will always transfer one material to the other as they are used.  Open containers of chemicals such as acids, bentonite and sugar bags must be avoided.  Cross-contamination is not always microbiological!  A classic example of this is one who uses a soiled scoop from citric acid and then places that same scoop into a container of metabi-sulfite.  This will result in a huge and persistent sulfur dioxide aroma cloud near the incident.  Seal all bags / containers after using them because contamination from insects and other potential rodents may result in problems.  If not already a standard procedure, reseal all open cork bags and other dry goods materials immediately after opening and partial use. 

  AIRLOCKS & BUNGS: Airlocks and bungs need to be thoroughly cleaned after each use.  Airlocks are exposed to moisture and liquids.  This moisture will support bacterial and yeast growth, which must be eliminated before placing them on another vessel.  Since containers may pull a vacuum during a cool down in the cellar after fermentation and draw some of the water into the container.  Clean them thoroughly before storage and before use.  When storing airlocks be sure to blow out any water and allow them to air dry.  Bungs are similar.  When working with barrels remove the bungs and clean them with a cleaning solution.  Rinse them in a low ph water solution to rinse and neutralize the cleaning solution and then replace them on the vessel.  If possible it is best to have a large number of extra clean bungs available to use with the current day’s barrel work.  If so – one can collect the bungs off the barrels for that day’s work and soak them in the cleaning solution.  Clean and rinse them at your leisure after the day’s work.  Allow them to dry and they will be ready for the next day of barrel work.

  POMACE: Remove all pomace from the winery as soon as possible.  It is a food source for yeast and spoilage bacteria.  Try to take the pomace as far from the winery as possible and consider treating it with copious amounts of hydrated lime to elevate the ph and to keep odors in check.  This elevation in ph will prevent lower ph bacteria from growing and result in safer pomace as far as cross-contamination is concerned.  Birds, insects and animals may visit this pomace pile before traveling to other areas, perhaps near or in your winery, carrying spoilage microbes with them. 

  FILTER PADS & DE: Removing filter pads from a filter and placing them in an indoor trash receptacle that is emptied only once a week has never made microbiological sense.  Instead remove them as rapidly as possible from the cellar and get them to a trash receptacle outside and off the property to avoid spoilage yeast from growing and being transferred to other areas in or near your winery.  Not only are they growing unwanted microbes – but also left long enough they will become very pungent!  Diatomaceous earth should be treated the same way or disposed of properly for bacteria growth reasons.

  TANKS: Clean the wine tanks just after emptying.  Once emptied the vessel will be open for insects to fly and move about freely inside the vessel so it should be cleaned.  If residuals of wine are left in the tank they will spoil and become cross-contamination sources.

  SUMMARY: The above examples are just some areas to consider.  Each winery cellar is different and each cellar has unique areas that need attention with regards to the above practices.  Take some time to walk around the cellar and out on the crush pad to explore possible areas to tighten up the sanitation regime to minimize and eliminate cross-contamination sources from the cellar.

  It should be the desire of every winemaker to have and keep a spoilage bacteria-free cellar.  Wines are easy to make and to keep in a healthy condition.  If the wines are kept free of spoilage conditions the workload is less.  Once spoilage conditions exist, the winemaker’s efforts are complicated and more time and effort is needed to focus on extreme sanitation measures.  Every winemaker should employ good winemaking practices to avoid such situations, which are easily avoided with proper cellar management.

  Cross contamination is the number one reason for wine spoilage, as the microbe has to come into your winery from one source or another to begin to grow.

  You will find your winery a different place after you review your cellar and identify sources of cross-contamination.  The wines will improve as a result of your diligence to remove cross-contamination sources, once identified.

Bon Chance!