Category: Winery Info

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!

By: Gerald Dlubala

  Winemakers choose a yeast strain based on several enological characteristics, including its tolerance to temperature, ethanol and sulfur dioxide, ability to provide quality fermentation, and ability to produce the desired aromas with minimal potential for foaming or clumping. Each fraction of the yeast contains specific, targeting properties that allow them to aid in the fermentation process and improve the overall quality of the wine. Yeast is the catalyst for creating up to 80% of all of the aroma-active compounds found in wines, including two of the most important ones, higher alcohols and esters. Yeast derivatives, used to improve wine quality, color, oxidation and mouthfeel, can also mimic the effects of a wine aged on lees when using targeted products selected and identified by experts. The better a winemaker understands them, the better wine they will produce.

  Using active dry yeast has become the preferred method for winemakers to get consistent fermentation and flavor complexity in their wines from batch-to-batch, negating much of the inherent risk of going with natural or spontaneous fermentation. Natural fermentation brings a high degree of unpredictability regarding starting times and stuck or sluggish fermentation cycles that can affect and diminish the quality, flavor and aroma of the wine. Conversely, active dry yeast is the freshest format available and ready to ferment upon contact.

  Traditionally, the active dry yeast is poured onto the surface of at least 10 times its weight in room temperature tap water and gently stirred to avoid or break up any clumps. If needed, there is a 20 minute waiting period to acclimate and have less than a 10-degree Celsius (50 degrees Fahrenheit) difference with the tank temperature. Once it reaches the ideal temperature, the mixture is transferred into the tank with aeration. Additionally, most suppliers recommend the use of rehydrating agents, or yeast derivatives, in the rehydration water.

Expediting Fermentation While Reducing Costs: Fermentis E2U™ Yeast

  Fermentis by Lesaffre, experts in the fermented beverage industry, offers an easier way for winemakers to start the fermentation process by streamlining the rehydration process or completely bypassing it with their line of certified E2U™ active dry yeasts.

  “As a winemaker, it’s always great to have options,” said Fermentis Regional Sales Manager Anne Flesch. “With our E2U™ line of yeasts, you can direct pitch or rehydrate. It is the winemaker’s choice as to which method is the best for them at any given time.”

  Flesch told The Grapevine Magazine that for practical purposes, the best way to direct pitch E2U™ is to pour the yeast directly on top of the tank, or, for whites and rosés, during tank filling after settling. When choosing to rehydrate E2U™, it can be accomplished under a wide range of temperature options, in water from 15-37 degrees celsius (59-98.6 degrees Fahrenheit).

  “Whatever option a winemaker chooses, the wine’s organoleptic characteristics (flavor, wine and color) or composition (levels of alcohol acidity) are not compromised,” said Flesch. “Both standard and E2U™ protocols result in the same performance in fermentation kinetics, so it is ideal for the winemakers who are looking to expedite their process without sacrificing anything related to quality. When time is the most crucial, as time in the cellar during harvest, this helps save that time.”

  Expediting the winemaking process and gaining more time always seems to be on the agenda for winemakers, and by direct pitching yeast, there are benefits throughout the entire process.

  “By choosing to direct pitch E2U™ yeast, the amount of water and heat needed for yeast rehydration is decreased along with the amount of water, energy and additional products used to clean the rehydration materials,” said Flesch. “The winemaker is bypassing traditional rehydration and the time, labor and personal miscues that come along with that process. There is a reduction of chemicals, needed water and heat sources, and labor hours needed, reducing labor costs. A streamlined fermentation task is completed faster and results in saved time and higher quality of work with no investment in rehydration agents, materials or cleaning chemicals. In some cases, a winemaker may potentially be able to replace their propagating/mother tank.”

  “Safety in the winery is also an important issue,” said Flesch. “Comfort and safety levels of production workers can rise by negating the need for extra water hauling or unnecessary ladder use. The possibility of dust inhalation from a yeast-derived product is a real health hazard for cellar workers during harvest. Our Certified E2U™ fermentation aids and functional products work to target and improve those conditions by offering a range of products that are under a physical form, like micro-granulated powder, or a liquified form that offers fewer inhalation probabilities and high dispersibility rates.”

  Fermentis created the first yeast liquid autolysate, ViniLiquid, in its fermentation aid portfolio. It has many advantages, including increased safety, superior pump-ability, quick availability to the yeast and shorter fermentation versus using a dry autolysate.

  “Conditions can dictate whether it is advantageous to rehydrate E2U™ before use, but if you choose to rehydrate, you can successfully do so using cold tap water, reducing heat consumption,” said Flesch. “For example, if conditions are toxic or challenging for yeast or your fermentation is stuck or sluggish, rehydrating E2U™ for use is recommended. Sometimes to completely restart a stuck fermentation, our protocol recommends the building of a starter culture. We do recommend rehydration in the case of secondary fermentation for sparkling applications.”

  Flesch told The Grapevine Magazine that the ability of their E2U™ yeast to be directly pitched is due to the high quality and expertise behind the production of the active dry yeast. The strength of the membrane developed during the multiplication process and the drying technology is the key to producing active dry yeast that is highly resistant to rehydration conditions. E2U™ has a four-year shelf life from production date with a recommended unopened storage temperature of less than 20 degrees celsius (68 degrees Fahrenheit).

  “In short, use of yeast and yeast derivatives certified E2U™ can benefit the winemaking community in critically important ways,” said Flesch. “Fermentation is easier, less time-consuming, and more worry-free. Seventy-five percent of winemakers use active dry yeast with their fermentations,” said Lesch. “If all winemakers decided not to rehydrate, we could save up to 600,00 hectoliters (~ 16 million gallons) of water and significant energy each year.”

  “Yeast hydration is now a matter of preference, not efficacity, and yeast derivatives are easy and quick to use,” said Flesch.

Enhancing Natural Processes Through Biotechnology Research and Innovation: AEB Group

  The AEB Group enables winemakers and brewers to improve their natural fermentation processes by offering custom-based solutions using biotechnology and treatment processes. They are the first North American company to develop reactivators to automatically and reliably rehydrate active dry yeast.

  Marco Bertaccini, Regional Sales Manager, told The Grapevine Magazine that AEB Group researches and looks towards providing winemakers the tools and products to take on the latest consumer taste trends, including different strains of yeast and the use of derivatives to match current consumer demand.

  “You know,” said Bertaccini, “in the past, the trend in wines has been the traditional big and bold flavors. For us, that meant using our FERMOL Meditterranée for the big, bold reds and FERMOL Chardonnay for the traditional whites. That demand for the traditional style of wine is still there, but not to the degree that it was. Consumers today are really into fresh, light and easy-to-drink wines with enhanced flavors.”

  For Bertaccini and the AEB Group, that translates into focusing on ester development and the transformation of amino acids into acetate ester. Their current focus is on the increased demand for easy-to-drink wines that feature a fresher variety of aromatics, especially those including citrus. Through research at the University of Modena and Reggio Emilia in Italy, AEB Group has ascertained and developed yeasts that express more of the natural flavor and aroma profiles of wine styles currently in demand.

  “We develop yeast extracts that boost amino acids for certain specific profiles,” said Bertaccini. “The nutrients and amino acids in juices naturally express varietal-specific profiles that we all would recognize. Since we know that aminos are precursors for esters, we can replicate and target specific aminos to produce more of what we want in any specific varietal.

  “For example, we offer our FERMOL tropical strain for white wines, which enhances and delivers more of that fresh, citrus-based flavor and aroma in a Sauvignon Blanc. Chardonnay wines benefit from our FERMOL fleur yeast. For red varietals that already contain great, natural, fresh fruit and berry flavors and aromas, we’ve developed our FERMOL red fruit strain to enhance all of those desirable qualities. These strains use and enhance the unique oenological features of the wine to produce a wine that is easy to drink with fresher aromatics.”

  Bertaccini told The Grapevine Magazine that AEB Group’s latest New Zealand trials featured their Levulia Torula strain and resulted in a huge success. Levulia Torula is an organic, non-saccharomyces yeast developed for varietal aroma enhancement. It is a strain for alcoholic pre-fermentation,  present naturally in the native flora of the must, contributing positively to the organoleptic complexity of the wine while limiting the production of volatile acidity. Levulia Torula is used in sequential inoculations, 24 to 48 hours before a classical strain of Saccharomyces cerevisiae. Its rapid establishment in the must makes it ideal for limiting the spontaneous development of separate strains of unwanted native yeasts. After the growth of the Saccharomyces cerevisiae, the population of Torulaspora delbrueckii dies down and rapidly begins its autolysis during alcoholic fermentation, where it supplies nutrients and contributes to the detoxification of the medium. It also helps reduce the sensations of astringency in the mouth through the release of polysaccharides.

  “We initially only made a small quantity for the trials, but it became wildly popular and quickly sold out,” said Bertaccini. “Levulia Torula provides excellent dominance in fermentation and great control over microorganisms. It is organic and usually paired with another inoculation for a strong fermentation finish. We are seeing the demand grow and now have much more available because of the success of our New Zealand trials.”

  Because it is organic, Levulia Torula has a shorter recommended shelf life of two years and is suitable for all grape varietals, including Sauvignon Blanc, Chardonnay, Gewurztraminer, Colombard, Riesling, Muscat, Sémillon and more.

By: Alyssa L. Ochs 

  Bottle-filling machines are crucial pieces of equipment in the winery for getting products onto store shelves and into consumers’ hands. If your winery has been using the same filling machine for a long time, it might be time to consider an upgrade to match your current level of production and evolving needs.

  Here is an overview of different bottle-filling machines to consider for an upgrade, how to compare this equipment, and tips for choosing the right product for your winery.

Bottle-Filling Machine Options

  Although bottle-filling machines serve the same basic purpose and have similar functions, there are many options available. Overall, there are three different categories of bottle-filling systems: manual, semi-automatic and automatic. A logical place to start with choosing this type of equipment is to first consider the winery’s size.

  Rod Silver handles marketing and sales for XpressFill Systems, LLC in San Luis Obispo, California. He told The Grapevine Magazine that manual fillers are more suited to very small wineries and home vintners because these devices fill just one bottle at a time. However, this is not practical for many wineries in operation today. XpressFill manufactures bottle- and can-filling machines handcrafted and custom-made for the wine, beer, spirits, olive oil and juice industries. The company also offers a volumetric filler, level filler, carbonated beverage counter-pressure bottle filler and hot fill bottling filler. 

  “It is more labor-intensive and less costly, and the production rate ranges from 100 to 200 bottles per hour,” Silver said about manual fillers.

  The next step up is the semi-automatic filler, which requires some manual manipulation of the bottles but automates the fill start-and-stop sequence. These machines can typically fill between 200 and 500 bottles per hour.

  “Small to medium wineries can benefit from semi-automatic fillers in achieving an economic and efficient bottling process,” Silver said. “Even larger wineries will often utilize a semi-automatic filler for smaller bottling runs where it is not cost-efficient to start up a production line.”

  For large wineries, fully automated production lines are the way to go for maximum capacity and efficiency. However, Silver said that wineries should be aware that this setup requires a substantial capital investment and routine maintenance.

Jay Langejans, sales and spirits industry expert for Fogg Filler Company, told The Grapevine Magazine that Fogg’s gravity fillers are best for flat wines. He said its carbonated fillers are best for carbonated wines and still and sparkling wines on the same filler. Fogg filling machines have many applications, including wine, juice, antifreeze, bottled water and pharmaceutical products. Based in Holland, Michigan, the company also offers capping machines, bottle sanitizers, cap sanitizers and sorters.

  “The F2 Series gravity filling machine is recommended for small wineries and fills 30 to 100 standard wine bottles per minute,” Langejans said. “For medium-sized wineries, the F6 Series gravity filling machine fills 90 to 150 standard wine bottles per minute, and for large wineries, the F9 Series gravity filling machine fills 150 to 200 standard wine bottles per minute.”

Comparing Different Bottle-Filling Machines

  Depending on a winery’s needs, bottle-filling machines can be straightforward, operated by hand with manual controls. Filling machines can also be semi-automatic, increasing efficiency on the bottling line while staying within an equipment budget. Fully automated machines reduce labor in the bottling process but require significant commitments of space and money.

  Langejans from Fogg Filler said, “Your production capacities for the whole line or the winery, in general, should be considered when picking the right-sized machine.”

  In addition to the size and the degree of automation, some bottle-filling machines have special features, such as the ability to apply screw caps, which may be enticing for a winery with specific bottling goals. Other differences to consider when choosing a filling machine are speed, portability and ease of maintenance and cleaning.

  The number of spouts on the machine determines filler speed, but the amount of wine in the holding tank is also a factor for how fast the bottles fill up. It can be beneficial to have an adjustable machine to fill different-sized bottles and other types of wine packaging. Semi-automatic machines that apply screw caps eliminate the need for spinners and corkers, which can ultimately increase bottling speed. Although screw capping is a more expensive feature, it uses less labor and creates better consistency.

  Cost also varies depending on the filling machine. There is an industry-standard of between $2.00 and $4.00 per case for mobile bottling. Multiplying annual case production by that amount will give vintners a sense of how that compares to buying or upgrading a filling machine.

  Many wineries start looking into semi-automation when they get to approximately 4,000 cases per year, and then at full automation when producing between 5,000 and 10,000 per year. An entirely manual bottling process for a small winery might require an investment of around $10,000. Once the winery reaches 2,000 cases per year, that investment looks more like $20,000, and then up to $40,000 as they exceed 4,000 annual cases produced.

When Is It Time for an Upgrade?

  For many wineries, there comes a time when it is necessary to reconsider a current bottle-filling machine either because of functionality or capacity. When that time comes, wineries must assess their current and projected production levels. Of course, if the current system keeps breaking down or requires constant repairs, this is a clear sign that a replacement should likely happen sooner than later, so production speed and product quality don’t suffer.

  Silver from XpressFill told The Grapevine Magazine that there are five primary factors for evaluating the benefits of an upgrade: cost of equipment, rate of production, cost of maintenance, cost of labor and equipment lifetime.

Choosing the Best Bottle Filling Machine for a Winery

  While the mechanics of a bottle-filling machine are important in getting the most out of this time-saving equipment, it’s also beneficial to work with a trustworthy and reliable equipment provider. Consider the usefulness of the technology and how relevant that technology would be to winery operations. Also, consider the amount of staff training required to operate the machine and ensure workers’ safety and productivity.

  Silver from XpressFill said new wineries should not over-purchase a system that could take two or more years to reach the equipment’s full capacity.

  “It can be a major financial expenditure that takes too long to recover the investment, if ever,” he said.

  For wineries trying to decide when to upgrade a bottle-filling machine, Silver said to perform a cost-benefit analysis based on the downtime, maintenance and hourly operating cost of the current system versus the replacement.

  “Although a new system may have much greater production, the time for setup, configuring for filling and cleaning after filling may be much more labor-intensive and result in a net reduction in cost-effectiveness,” he said.

  Calculating the pros and cons of investing in a new machine can be challenging and time-consuming, but it can also be worth the effort if it saves the winery money and helps get more wine out in the world for people to enjoy. Regarding cost, special feature options and customer service level, it pays to shop around before settling on a new machine or investing in the winery’s first filling system.

By: Alyssa L. Ochs  

  Moving wine from one location to another is an integral part of a winemaker’s responsibilities, and for this job, you’re going to need an effective pump. There are several types of pumps commonly used in winery settings, and each one has a unique purpose and specialty. It’s a good idea to have a clear understanding of winery pump options available because choosing the right pump can either help or hinder your operations, ultimately making your winery more or less efficient over time.

Types of Pumps Used in Wineries

  Depending on what you need a pump to do in the winery, you might choose a piston pump, diaphragm pump, centrifugal pump or peristaltic pump. Other products commonly used in winery settings include volumetric pumps, Moineau pumps, flexible impellers and gear pumps. Meanwhile, you can find customizable pumps in various sizes and configurations.

  Jeff Hannan, product manager for centrifugal pumps at Gorman-Rupp Pumps, said the company’s Super T and Ultra V Series pumps equipped with the Eradicator solids management system are the best for handling waste such as seeds, stems, skins and all other types of stringy solids.

  Headquartered in Mansfield, Ohio, GR Pumps designs and manufactures pumps and pump systems for the food and beverage industry and at least a dozen other applications. The company also manufactures submersible, rotary gear and standard centrifugal pumps to handle waste applications, sump applications and other fluid-handling needs.

  “With the ability to pass up to three-inch spherical solids, Super T and Ultra V Series pumps are designed to eliminate clogging and increase up-time,” Hannan said. “With thousands of installations in the toughest applications you can find, these pumps have a proven track record for performance and dependability.”

  The Eradicator’s three-part solids management system consists of a lightweight inspection cover, an innovative backplate that incorporates an obstruction-free flow path, and an aggressive self-cleaning wear plate with integral laser cut notches and grooves. This is combined with a revolutionary “tooth” design to constantly and effectively clear the eye of the impeller. 

  “Upgrade kits are available for existing Super T or Ultra V pumps in the field,” Hannon said. “The upgrade kits provide everything you need to put the best self-cleaning pump technology in the industry to work for you.”

  Ross Battersby, who handles sales and design for equipment and machinery at Carlsen & Associates, said his company sells three main pumps for winery applications. Carlsen & Associates is a Healdsburg, California-based premier wine equipment supplier that has engaged in researching and refining the winemaking process for over 20 years.

  Carlsen’s Waukesha 130 positive displacement pump is a versatile pump with many applications, including filtering, barrel-filling, emptying and bottling.

  “These pumps must in three-inch lines from the de-stemmer to the tank at 15 tons per hour, transfer wine in two-inch lines at up to 130 gallons per minute, and also go in reverse,” Battersby said. “You can use pressure transducers, switches, float switches, batch controllers and timers with this pump.”

  Another popular Carlsen pump is the Yamada NDP 25 double diaphragm air pump. It runs on a max of 22 cubic feet per minute of compressed air and is commonly used by boutique wineries for transfers, press pan duty, small tank pump-overs and barrel filling.

  “Air pumps are the gentlest of pumps when set up correctly and can be used in nearly all situations,” Battersby said. “There are two principle controls on the pump, a ball valve to control airflow and thus pump flow, gallons per minute and a pressure regulator that will control line pressure, commonly not above 30 psi, depending on the application. With our Electric Air solenoid, you can use float switches and timers to automate the pump. A key feature is the ability to shut off against the pump without damaging anything.”

  Battersby also mentioned the 2085/10 or 15 hp centrifugal pump. These large-scale transfer pumps move wine in three-inch lines at speeds between 250 and 350 gallons a minute. They are often used in tanker truck loading and unloading, large-scale wine blending, racking off huge tanks, press pan duty on large presses and pump-overs for massive red fermenters.

  “The scrolled impeller, combined with a variable frequency drive, means there is little-to-no sheer in the pump head, so provided the correct line size and speed is selected, there is no cavitation,” said Battersby. “They are extremely efficient and easy to use.”

  Battersby said his company previously sold a line of flexible impeller pumps, less-expensive pumps that perform various tasks. These are entry-level pumps commonly used by small startup wineries. However, Carlsen & Associates stopped selling these products because the maintenance and service requirements failed to meet the company’s standards for quality.

  “The rubber impellers break up over time, they fracture if they go in reverse, they leak and you can never run them dry,” Battersby said.

  Another pump-like product from Carlsen is the Bulldog Pup, an inert gas-powered barrel racking wand that works by sealing the racking wand in a barrel or keg. The Bulldog Pup displaces the wine using compressed inert gas to push it out of the barrel, into the wand and out of the hose to a tank or barrel.

  “At about $700, it is the least expensive ‘pump’ you can buy and also the gentlest, with the fewest moving parts,” he said. “These units also stand the test of time with readily available spare parts, a design that hasn’t changed and reliability that’s second to none. You can find these in the Carlsen & Associates Annex section.”

Maintenance for Winery Pumps

  A big part of having pumps in the winery is keeping them clean, sanitary and working well for many years.

  Hannan said that consideration must be given to reliability, the low total cost of ownership and overall uptime when selecting a pump for any waste application. He also said that it’s best to choose pumps that are easy to maintain and designed to prevent clogging. 

  “Gorman-Rupp Super T and Ultra V Series pumps equipped with the Eradicator solids management system are the best choices for self-priming, solids-handling pumps for any maintenance department,” Hannan said. “Externally adjustable clearances between the impeller and wear plate in combination with the new lightweight inspection covers are just a couple of the features that make routine maintenance on these pumps easier than ever.”

  Battersby from Carlsen said that just like a car, a pump will stop working when you need it most without preventative maintenance.

  “Change O rings and seals on a regular basis,” he said. “Change gearbox oils on schedule. Grease the fittings regularly. Treat your pump with respect. Without it, you won’t be pumping wine, and you may not have a job! Keep basic spare parts on your workshop shelf, such as O rings, diaphragms and maybe a speed control. That way, if it breaks, you can replace it with minimal downtime and then replace your spare parts. It is not a huge investment, considering the loss if the pump breaks down and lays idle waiting for repair. During bottling or harvest, this can be critical.”

Qualities of a Good Winery Pump

  A good winery pump should be tolerant of solids and sediment while also keeping oxygen out of the wine. Pumps shouldn’t agitate the wine during their operation and should be relatively easy to clean, sanitize and maintain. Many wineries look for pumps that have compact designs so they don’t take up too much space. Portability is also desirable for pumps if there’s a need to move them around the winery space. Staff training and safety are also important considerations; choose pumps that are easy to operate with a low learning curve so that multiple staff members can use them regularly.

  Battersby offered a few “dos” and don’ts” about using different types of pumps in a winery:

•   Lenticular filters and air pumps are not good together.

•   Small hoses use a small pump. If you don’t have one, slow the big pump way down.

•   Every bend and valve and rise in elevation will cause line loss. Don’t make your pump work hard by pumping too far or through too many obstacles.

•   Pumps are the core of a winery and winemaking. Gravity works to a degree, but to be efficient, you have to use a pump.

•   Rarely does a pump affect a wine. Poor pump operation or maintenance will definitely contribute to poor performance and affect your wine.

•   Barreling down, an air pump is usually best. You can shut off against it. It doesn’t have to be super large as you fill 60-gallon vessels, so running 20 gallons per minute is a fine speed.

•   When transferring huge volumes of wine, use a centrifugal pump and large lines. Put the horsepower to use and get the job done.

•   For must pumping, use a positive displacement pump, progressive cavity pump or peristaltic pump. These pumps will handle the solids of must with little-to-no damage (exemption for whole berries with progressive cavity pumps) and be able to move the must long distances on overhead lines. The Waukesha positive displacement pumps can also be used for wine movements for the rest of the year. Commonly, peristaltic and progressive cavity pumps are put away after harvest.

Choosing the Right Pumps for Your Winery

  For safety and sanitation, winery pumps should be made using food-grade stainless steel with food-safe seals and lubricants. You can also find pumps with special options to suit the winemaker’s needs and preferences, such as non-marking wheels, remote control for off-site operation, pressure and flow sensors, automatic valves, flow meters and different types of connectors. Even with the highest quality pumps on the market, you might need to repair them after heavy use. Therefore, it’s a good idea to work with companies with readily available replacement parts just in case the original parts wear down over time.

  Battersby said that the criteria for choosing a pump are what you are pumping, what size hoses you are using, how far you are pumping, the type of pump you like and how much you’re able to spend. In small wineries, pumps must be able to do many tasks, but it’s advisable to always have at least two pumps so there’s a backup.

  “Some small wineries that pump must have two identical pumps in case one fails, Battersby said. “Not a bad idea if you are handling machine-harvested fruit, which will have metal from the vineyard in it. In larger wineries, you want a pump that satisfies the attributes for just one task, such as must pumping, transfers or bottling.”

  Battersby also said that all pumps are not equal and that while quality pumps cost more money, they are more likely to run for decades with basic and ongoing maintenance. So, while cheap pumps are more affordable to buy, they usually do not have the same levels of service, parts or performance, which will end up costing you more than the high-quality pump in the long run.

  “In cellar operations, you want robust, reliable, dependable pumps with a service crew that can supply advice, technical support, spare parts and training,” Battersby said. “This is what we specialize in at Carlsen and Associates.”