Category: Winery Info

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.”

Typically an Absolute Membrane Filter

By: Thomas J. Payette, Winemaking Consultant

The previous article in The Grapevine Magazine addressed steaming the bottling line.  Following steaming, the winemaker will want to perform a check to determine whether or not the process has been successful and that the filter has not been damaged by the steaming process or other handling. 

  The following process is a way to check the membrane filter’s integrity prior to wine bottling use.  During proper steaming, sterility should have been achieved from the cartridge filter downstream to the filling spouts.  Please keep this in mind as we follow this procedure to insure the sterile conditions will not be compromised during the testing process.

Objective/Principal

  The objective of this procedure will be to test a pre-wetted membrane filter with air or nitrogen to determine if the filter will hold a certain level of pressure.  The surface tension of clean water on this filter matrix will determine the amount of pressure the filter will hold.  After steaming and cooled the filter cartridge is considered pre-wetted.  Do not remove to wet the cartridge after steaming.  That would violate the “sterile conditions”.

Procedure

1.     Review the information that came with your filter and contact your supplier representative to see if they have any tips on the procedure or process about to be performed.  They may have helpful recommendations and data for you about that specific filter.

2.     After the steaming operation, described in the previous article, allow the assembly to cool to room temperature.  {If this is not done properly the results will not be accurate because the temperature change inside the closed system will show a pressure drop due to cooling and contraction.} The cooling process may take some time.

3.     Attach a source of compressed air or nitrogen (not Carbon dioxide) with a regulator to the top valve or to any sealed up stream orifice of the filter assembly.  Close all of the upstream valves with the exception of the one you would like to use to pressurize the filter system.  Be aware that any downstream orifice could be a contamination point. 

4.     Make sure all the valves are in perfect shape, will not leak and will have the ability to withstand the pressure that will be applied to the filter.

5.     Slowly turn the pressurized air source on and allow it to flow into the upstream side of the membrane housing. [Note: use a clean source of air that does not have any wine residue on the tip of the hose or any possible chance of introducing yeast or microorganisms.  Being the upstream side of the filter this should not be a problem but remember we are about to bottle a wine in a sterile environment.  Try not to introduce any micro-organism: Think Cross Contamination!]

6.     Using the regulator adjustment, allow the pressure to slowly increase up to the designated pressure for the micron rating of the filter.  (Typically 18 PSI is sufficient for a 0.45 micron rated membrane that would hold 20 PSI wetted.  Do double check this number with your supplier in the event this rating changes since publishing of this article. )  The test pressure will be in the literature of the filter package or it can be obtained from your supplier’s technical department.  Be aware, some filters have the same hold pressure even though their micron rating may be different.  Be certain not to “slam” the filter with immediate pressure.  That action may rupture the filter media and that filter may not pass the test or perform the filtering function as designed and desired.

7.     Allow the pressure to rise slowly while monitoring both the pressure gauge on the filter housing and the gauge on the regulator supplying the compressed air or nitrogen.  There should be little or no discrepancies between them.  This also indicates the gas is flowing into the filter housing.  One may see a slight amount of water come through the down stream side of the unit though a bleed valve.   This is normal since some water may “push” off the outside of the pre-wetted filter. Do not disassemble the down stream side of the set up because it will compromise the sterility of the bottling.  [Do make sure an outlet for air is open on the downstream side of the filter so the indication of a pressure, on the up-steam pressure gauge, is not a false one caused by back pressure from a closed valve]

8.     Once the proper pressure has been achieved and both pressure gauges agree – turn the valve supply of the gas into the housing to the off position.  Record the pressure gauge and the time of day.  One may disconnect the gas supply at this time since it should not be needed anymore for this test.  Allow the filter, without any downstream back pressure, to hold the upstream pressure with only the dampened filter holding back the gas.  If the filter holds this pressure for the length of time obtained from the literature in the filter box for that cartridge or from the technical department for that filter, the filter passes the test!  [For clarification : It is the surface tension of the water in the matrix of the filter that is holding back the gas].

9.     Time the holding pressure for the designated time for that filter.

10.   At this time, double check to see that the pressure does show the proper pressure; then slowly open a back stream valve.  Make sure to listen to hear that indeed pressure is coming off the filter housing set up and that the gauge was not stuck at the desired pressure.  Do this slowly so the filter does not go through an abrupt change in pressure that may damage the filter media just proven to be appropriate for the function of sterile filtration.[ If it passed ]

11.   Record any data that may be required by the bottling department or winemaker showing the filter was tested and checked out ready for use.

12.   Double check that all the downstream areas are still attached and that their sterility has not been compromised.

13.   Start the flow of wine for the day’s bottling run

14.   Pull samples at different times of the day and test them under the microscope ( if equipped and your winery has the expertise ) to insure the designated function did its job and continues to the job.  Numbering pallets as you bottle is a smart operation in the vent you find a filter failure during a days bottling run.  { Not a norm typically by the way }.

15.   Some wineries, after the day’s bottling, will re-wet the membrane with water and follow the testing procedure again to confirm the integrity was not lost on the filter during the day’s run.   This give “back end assurance” as performed as expected and desired.

  The above test should be performed each time a new or stored filter is installed into the filter housing and each time you bottle.  In many instances winemakers are able to get 10,000 cases or more through their cartridge filters before compromising the sterile bottling conditions.  Your supplier will be able to guide you with knowledge on how many cases or steamings your cartridge filter will be able to withstand. Typically I become most concerned of the steaming so I will discard a filter after a certain number of steaming or after a certain amount of time under steam.

Supplemental Notes:

•     Perform this procedure, for the first time, on a day you do not plan to bottle or on a day you have plenty of time to think the process through – not being rushed.

•     Check with the cartridge supplier to determine if the filter purchased has a “steamable life span”.  If so be sure to record the amount of time each cartridge has been steamed and discard the filter when appropriate.

•     Make sure that only water is on the filter during the testing of the filter as other “contaminants” may give a false reading of passing the test.

•     Setting the filter housing up with a male quick disconnect at the top port will greatly improve the ease of attaching the source of the desired gas.

•     The author prefers nitrogen since some compressed air has oils or odors that may interfere with the wine or the testing process.

•     Many cartridge filters were designed for the pharmaceutical industry and they are made to very strict standards.  Handle them with care!

•     Wineries now have the luxury of purchasing a machine to perform this function; however they are not inexpensive and this process, when mastered, does not take long.  The results are inexpensive and easy to obtain.  What is the machine fails ?  Will you have the expertise / knowledge know?

Review:

•   Contact your supplier to review the Hold Test operation with them.

•   Make sure the filter assembly is cooled to room temperature before testing

•   Use Nitrogen to pressurize the unit.

•   Make sure the pressure reading is not caused or influenced by a downstream obstruction.

•   Be cautious of downstream Cross-Contamination.

A Word About the Hold Test:

  The hold test should be performed in the clean environment of the bottling room under strict standards and precise conditions.  Keeping a keen eye on the process for cross-contamination possibilities, potential sources of error and other out of the norm conditions will lead to the winemaker’s ultimate success each and every time this is done.  A sterile bottling will be achieved providing the consumer with fresh and consistent wine each and every time they relax with one of your products.  One can not express the importance of doing this procedure correctly.  The winery’s success depends on the proper execution of sterile bottling and that process rest heavily on testing the membrane before bottling and overall proper steaming of the complete bottling line.