Category: Winery Info

 By: Gerald Dlubala  

When it comes to pumps used in the winery, there’s a pump to match every size and budget, and usually, those two variables are the deciding factors,” said Ross Battersby, sales and equipment design professional for Carlsen and Associates, an industry leader in winemaking equipment and systems. 

  “But speed can also play a part,” he said. “Large scale wineries are usually more interested in that aspect, but for the smaller volume wineries, it’s best to use something that gives the user the ability to move it around the facility for different applications. Air operated diaphragm pumps like our Yamada series are popular for wine transfer applications because they are less complicated to operate, gentle on your juice and easy to maintain and service. Positive displacement pumps like our Waukesha 130 are winery workhorses. They are popular choices and loved throughout the wine industry because of their portability and versatility. By simply using a different diameter of hose, you can easily use the same pump for many different applications throughout the winery, including must, moving 30 to 320 GPM.”

  Battersby told The Grapevine Magazine that Carlsen Waukesha’s positive displacement pumps are the best solution for all of a winery’s needs, including bottling, juice transfer, pump-overs, barrel work and must pumping. Positive displacement pumps consist of winged rotors, similar to interlocking ice cream scoops that turn and lock your fruit in and then push it out without causing any structural damage to the grapes. Pump speed is directly related to your desired GPM flow rate. Positive displacement pumps allow the operator to reverse the flow and pump wine back into the tank if and when needed. Battersby said this would be even more beneficial if your lines are configured in short runs.

  “Carlsen Waukesha pumps are operator friendly, reversible, reliable and truly last forever with minimal maintenance,” he said. “Performing annual oiling and occasional O-ring replacement, maybe three or four times a year depending on the amount of use, you’ve got a reliable, multi-use, workhorse pump.

  “But the important thing for operators to know for whatever type or brand of pump they choose to use, is that your enemy is cavitation,” said Battersby. “Cavitation occurs when the pump head can’t quite keep up with the pump speed, causing the pump to start extracting the dissolved gases in your product. It tends to happen whenever the winemaker’s only consideration in the pumping process is speed. It’s very noticeable when the hoses or lines at the end of the pump start flopping around like a fish while making a loud thrashing sound. This will eventually pit the stainless head or crack diaphragms on your pumps. It’s critical to match the orifices on your pump to the diameter of the lines that you use.”

  Battersby said that when looking to buy a pump for your winery, two main features are critical—the number of gallons per minute, or flow rate, and the head pressure, or pounds per square inch. Flow rate is self-explanatory, but your winery layout should always be considered when looking into the head pressure and pounds per square inch capabilities of a pump system.

  “We like to say that short suction provides the best delivery, so it’s best if you’re able to have everything close together for shorter lines and maximum pump efficiency,” said Battersby. “The longer your run, the more friction you have building up with your flow, making the pump work harder to move the wine. Add in the valves and bends in your lines, and it starts to take a bite out of the ability and efficiency of the pumps, especially must pumps. You have to take into consideration the highest head pressure your pumps will experience on your facility’s longest run. If you’re pumping up a high arc into a tank, there’s a lot of head pressure building up.

  “Air operated diaphragm pumps can shut off against this scenario while still holding pressure. If those same lines shut down while using a positive displacement pump and you’re not there to shut it down, the pump will keep rolling and, in short notice, will blow a line. There are pump options to help with this, like a float switch that will shut things off based on the float level. You can also set cycle timers that will switch off and on based on what you set as an adequate cycle to pump the amount of liquid over you want to move.

  “Because of these scenarios, we see a lot of tanks with their own dedicated and fixed base pump, usually a centrifugal pump, for pump-overs. They’ll have a screen over the pump and [be] programmed to do pump-overs unmanned, which is a godsend for wineries experiencing labor shortages. This worked wonders during all the recent wildfires, helping winemakers monitor and control their pumping functions from their iPhones. Winemaking protocols have changed a bit, so this type of slower, shorter bursts of pump-overs has become more common instead of one long pumping session.” 

  Like positive displacement pumps, centrifugal pumps are a reliable, long-lasting pump option for winery applications, complete with minimal maintenance needs and mechanical seals.

  “Centrifugal pumps have gotten a bad rap in the industry,” said Battersby. “In the old days, they were only set up to run at top speed, somewhere around 750 rpm. The only way to change the speed was to use methods to baffle the flow, but then the pump would keep running and shear your liquid apart. Now we have variable speed controls to tune the centrifugal pump to the speed that’s appropriate for the process. Our Waukesha 200 Series Centrifugal Pumps have been very successful, mainly used in wineries for the pump-over process and juice transfers. These pumps can empty a tanker truck in about a half-hour. The centrifugal transfer pumps allow solid particles to pass through without harming or changing their structure that would cause product breakdown. Centrifugal pumps do have to remain below the liquid level because they don’t have the self-priming capabilities of other pumps.”

Gorman-Rupp Pumps Provide Performance And Serviceability

  “We’re probably best known for our self-priming waste and trash pumps, used after the initial winemaking process is completed,” said Jeff Hannan, Product Manager-Centrifugal Pumps for Gorman-Rupp Pumps, a leading producer of waste and sewer handling applications in many industries, including wineries.

  “Our pumps can pass three-inch spherical solids when needed, and they won’t clog or bog down during the process. When we came out with our modified T Series Pumps a few years ago, it changed the way wineries go about their cleanup and waste removal. Our Super T Series, equipped with our Eradicator Solids Management System, can pass two and a half inch solids using three-inch lines, and our four-inch lines will easily move three-inch spherical solid masses. Our Eradicator Solids Management system design is an excellent choice for an easy-to-operate,  no-clog, self-cleaning pumping system.”

  Gorman-Rupp’s Eradicator system incorporates an aggressive self-cleaning wear plate containing several notches and grooves, plus a lacerating tooth to break up solids and pass them through the pump as smaller particles, ultimately reducing clog-related downtime. The Eradicator system’s additional benefits include easy access to impellers, improved efficiency, fewer maintenance costs and lower life-cycle costs. Pumps equipped with the Eradicator system do not use consumable chopper blades and are available in cast iron or hard iron configurations. The Eradicator system can also be retrofitted into all sizes of current Gorman-Rupp Super T Series pumps that are already operating in the field.

  “Our pumps are designed with removable inspection covers, wear plates and material covers,” said Hannan. “We’ve always included back cover plates for manual clog cleaning access, but those plates can get heavy, upwards of 100 pounds, so they weren’t very convenient to move and maneuver. Now we have a separate inspection plate, only weighing about 15 pounds for performing the same task, so you get the quick, pointed access needed without having to remove the entire backplate of the pump. Quicker cleaning means quicker resolution and more uptime, and that’s always the goal. This type of design was initially used to help municipal waste lines deal with those so-called flushable wipes that were not, and still are not, flushable in any way. Anything stringy like that can ball up and get hung up in the eye of an impeller, causing notches and grooving in the teeth and interior parts. The Eradicator system minimizes those issues. Then, with every rotation, the eye of the impeller is wiped clean so that there is no buildup on the impeller, and the waste can continue to pass through the system and lines.”

  “No matter what type or size of pumps you choose to use, you need to look ease of maintenance, reliability and longevity statistics of the pump, and of course the reputation of the pump manufacturer,” said Hannan. “The maintenance and service needs of Gorman-Rupp pumps are minimal and easy. Clearances between the impellers and the backplate are easily adjusted externally through the use of adjustable and locking collars to get the pump’s settings back to original factory clearance. This is important because as the gap between those parts widens with use, pump efficiency goes down. Being able to check and adjust those gaps from an external vantage point is a big advantage in retaining pump efficiency and uptime.”

  Gorman-Rupp offers full five-year warranties on their pumps, with many local distributors always willing to help and solve problems.

  “Our pumps are pretty simple to work on and maintain, with it being common to now get 25 to 30 years of service out of them,” said Hannan. “Gorman-Rupp pumps are manufactured so that the important and normal wear parts can be replaced on their own without having to replace the whole pump. And our pumps can handle all situations, including caustic cleanup activities.”

By: Cheryl Gray

Annual harvests of wine grapes are already underway, and that means two words are now in motion: crush season.

  Whether in-house winery processing or custom crush and wine production services, crush season 2020 is like no other. While the challenges in each wine region are different, industry experts say that there are universal standards. The checklist includes planning, preparation, equipment maintenance, PPE for workers, supplies, lab testing for grapes, and, this year, health and safety measures that protect against the coronavirus pandemic. Not only is COVID-19 impacting crush season, but unusual weather in some parts of the United States is also affecting grape harvests.  

  For these reasons and more, this year’s crush season demands a new approach. Such is the case in Texas, where Texas Custom Wine Works, located just outside Lubbock, services vineyards across the Lone Star State. Cary Franklin is Vice President. 

  “One thing to note about this year is that we have seen widespread damage across the High Plains of Texas from an early freeze [last] October. Most growers are down 50 to 80% of their average crop. Many plants are completely wiped out and have been cut down and re-planted,” says Franklin. “The Texas wine industry has been forced to become very creative to sell wine during COVID-19 related closures. The loss of sales, combined with a major shortage of wine grapes, is creating a very interesting situation for this harvest and possible effects the industry could see over the next few years.”

  Fruit that survived arrived early this year, says Franklin, some of it as soon as mid-June. The company’s advanced planning and preparation, starting as early as February, is all the more important this crush season. As the fruit ripens, an in-house lab gives growers across Texas an opportunity to test field samples for Brix, pH, TA and seed color. Michael Hellman is Texas Custom Wine Works executive winemaker. 

  “High heat and drought-like conditions this year are causing some very high Brix and early development,” says Hellman. “We are seeing most varieties ripen at the same time. Even some of the reds will be coming in before whites.”

  In addition to standard-issue PPE supplies, such as goggles, raincoats, rubber boots and gloves, Texas Custom Wine Works has incorporated industry-wide COVID-19 protections in its health and safety protocols. Hellman says that other worker protections for entering tanks and press cleaning are standard procedure. 

  “Removing grape skins from a large tank requires tank entry and can release large amounts of CO2 as the skins are removed,” he says. “Our procedures require anyone entering a tank to have proper PPE and an O2 sensor on them with a fan pushing fresh air in the tank before entering.”

  In California’s Sonoma County, the award-winning Rack and Riddle Custom Wine Services begin harvesting the first week of August. The full-service wine production operation is famous for creating sparkling wines using the traditional French process known as Méthode Champenoise. Penelope Gadd-Coster, Executive Director of Winemaking, and a well-respected master of the Méthode Champenoise process, says that planning for crush season happens virtually year-round. 

  “Planning really never ends, as we are evaluating the wines for the blends, evaluating what has worked and what didn’t, upgrading equipment—all working towards the next harvest,” she says.

  Not one to rest on its gold medal wins in international and regional competitions, Gadd-Coster says that Rack and Riddle continually works on ways to make good wine better. Its winemaking team provides a thorough assessment of key fundamentals, such as training and workflow. Consideration of new processes and equipment plays a role in determining what will work towards improving the end product.

  “By May, we are looking at vineyards closely and working with growers,” says Gadd-Coster. “Projects are being evaluated to make sure they will be ready for harvest. About a month before harvest, the meetings become weekly to fine-tune protocols, train teams and check equipment. Then, harvest begins!”

  Key to that harvest is equipment—looking for innovation and keeping existing machinery in shape. Gadd-Coster says both earn equal attention.

  “There seems to always be something we see to make processing more efficient,” she says. “We have a new lees filter and some flotation pumps for this year. Maintenance always wants to check all of your equipment: pumps, crusher, presses, filters, temperature gauges, heating and cooling systems, punch down devices, lab equipment, scale, forklifts, pomace truck—anything mechanical—two to four months ahead of harvest.”   

  No matter the size of the operation, those in the wine industry know to expect the unexpected. Among the largest in the business is Napa Valley’s Trinchero Family Estates, which introduced the world to the first White Zinfandel. Since its founding in 1948, the company has amassed a globally recognized brand portfolio of some fifty wines and spirits. Its harvest begins in early August. Glenn Andrade is Senior Vice President of Winemaking. 

  “We know that preparation for the upcoming harvest starts after the finish of the previous harvest,” Andrade says. “Learning from every step and building onto our knowledge with each passing year is so important. We do extensive recap meetings to determine what our successes were and identify areas where we can make improvements. Hiring staff for harvest is also critical—which we start in January and do through July before harvest. Getting those folks and our regular employees trained on safety is a priority for us. Then, of course, reviewing grapes, barrels and all other harvest ingredients before the fruit starts to come in.”

  Andrade says Trinchero Family Estates has an intensive, year-round equipment maintenance protocol to accommodate its massive operational needs. Its COVID-19 protocols include on-site test kits and a company-instituted emergency response plan. 

  “This year, we’ve added a complete backup team called the Winemaking Response Team, which are individuals within our organization who can be activated if our labor force should be depleted due to COVID-19. This team is being safety trained and trained to jump in with a day’s notice to support harvest activities at any site.”

  In Washington state’s Yakima Valley, Two Mountain Winery begins fruit picking around mid-August, transferring grapes to the winery’s production facility at the beginning of September. Patrick Rawn, General Manager and head of vineyard operations, says that crush season increases the winery and farm labor team by about 30 workers. Equipment maintenance is also a priority.

  “Our primary preparation is ensuring all equipment, both farm and winery, is fully serviced and prepared to operate safely and efficiently. Additionally, any new equipment is installed and operational by [August 1], so any kinks can be worked out, and the team properly trained. We also try to predict what the timing will be so we can be sure our hand labor teams are large enough.  Along with this is training of any additional team members.”

  On the same grape-growing 45th parallel is Black Star Farms. The family-owned winemaking enterprise, located on the Leelanau Peninsula of Northern Michigan, typically begins harvest during the last week of September. Lee Lutes, winemaker and managing member, says that this year’s timetable for the winery could be different. 

  “Harvest typically begins the last week of September with early hybrid white varieties (Cayuga, Frontenac Gris) and fruit for traditional method sparkling wines,” says Lutes. “In a year like this, as we are advanced at this stage, that could move up one week or so. September is the telltale month for our industry, and much will depend on how the weather is during that month. We will be crushing approximately 650 tons of fruit between the two facilities. We farm approximately 175 acres of that, and the balance is purchased from a couple of long-time local growers.”

  Aurora Cellars is also located on Leelanau Peninsula. This full production boutique winery usually begins crush season in late September. Winemaker Drew Perry says that in late August, he spends time with the winery’s vineyard manager, testing fruit in every block twice weekly, charting a trajectory for harvest. As to fundamentals, Perry champions good and constant communication.

  “I begin by looking at what we ideally want to produce and create a master list of all the ingredients I will need to achieve that scenario.”

  Perry says that equipment maintenance occurs a week before the region’s cherry harvest, serving as “spring training” for the grape harvest.

  “Harvest is the most equipment intensive time of year. Much of the equipment we use during harvest is only used for that three-month period,” he says. “The presses, destemmer, crusher, and fruit elevator are our lifeblood this time of year.”

  Crush season 2020 is like no other in recent memory. The combination of a pandemic and adverse weather has affected nearly every facet of the wine industry—from the vineyard to labor to inventory still on hand. The path to recovery, some experts say, includes creative thinking and time-tested perseverance.

By: Alyssa L. Ochs  

Filtration is a technique that winemakers use to clarify wine and remove sediment and haze. Through one of several processes, filtration prevents wine from appearing cloudy and re-fermenting in the bottle. It’s typically done using membranes or pads, but there are various methods that wineries can use to achieve their desired flavor and appearance. Therefore, it’s essential to learn about the basics of wine filtration, including methods of filtration commonly used, maintenance and cleaning considerations and tips for choosing a filtration system that works best for your winery.

The Purpose of Filtration

  One primary reason winemakers filter their wine is to make it look and taste more polished. Filtration also improves the microbial stability of wine, which prevents premature spoilage that makes a wine undrinkable. Typically, white wines are filtered to give them clarity. Some red wines are not filtered because they are better at absorbing off-aromas and flavors. This leads many winemakers to only filter reds when necessary and no more than truly needed.

Types and Methods of Filtration

  Filtration methods vary among wineries based on facility size, budget and wine quality. The most common methods of filtration used today are gravity-feed and pressurized systems. Gravity-feed filter systems offer coarse filtration, are affordable and ideal for small quantities of wine. However, these systems cannot effectively do very fine filtrations. Enter pressurized filter systems, which offer faster processing times and finer filtrations, making them more favorable among larger wineries. Unfortunately, pressurized systems also come with a higher price tag.

  Peter Wojnarowicz, President of Filter Process & Supply in Monmouth Junction, New Jersey, told The Grapevine Magazine that the method of filtration depends on a couple of factors. He said that the size of the winery is the most important factor, followed by the winemaker’s preferred method of processing. Filter Process & Supply started working in the craft beverage market over 10 years ago, giving them the insight and experience to explain each system’s pros and cons and find the right one for your winery.

  “Larger scale wineries use more crossflow systems, followed by the filter press, then lenticular (stacked disc). Rounding out the last method, small mom-and-pop wineries may use a cartridge-based system,” Wojnarowicz said. “Filter Process & Supply can provide all four types of filtration. There are advantages and some disadvantages of the four methods.”

  Filter Process & Supply works with established wineries and start-ups and has a consultative approach that helps people understand that filtration does not have to be a headache, even though it can be at times. 

  “After the set-up and training, our customers become more comfortable in filtering,” said Wojnarowicz. “Our goal is to process the entire batch without replacing filters, as that not only wastes wine but also time.”

  The type of filter pad used during filtration is also something to consider. Filter pads are rated by microns, and each type—coarse, medium and fine—has a useful purpose in winemaking. Coarse pads help polish a wine without making it lose its color or body. Medium-micron pads are a standard, all-purpose pad that will only take a limited amount of body and color out of a wine. Fine pads can remove 80% or more of leftover yeast and sediment and are best used after filtering through a medium pad.

  Depth filtration is a process in which wine moves in a perpendicular flow towards the filter, allowing clean wine to pass through after particles get captured within. These particles build-up, causing pressure in the filter to increase and flow rate to decrease. Once the filter reaches a termination point, the winemaker must clean the system before continuing to use it. There are a few different forms of depth filters used for making wine, including pressure leaf, plate and frame, cartridge and lenticular.

Filtration Strategies and Steps

  There are different times in which a particular filtration type makes more sense than others. The smallest particles in wine are colloidal or precipitated proteins, which are about 0.2 to five microns, compared to yeast and bacteria that are in the 0.65 to three microns range. Grape solids and fining agents can be hundreds of microns in size.

  The first step in this process is pre-filtration, which involves removing the larger particles in suspension. Often this method includes filter pads with diatomaceous earth. These same products can be used to polish wine after this initial phase.

  The next stage moves wine through a sheet or module filtration process to reduce yeasts and bacteria. Finally, sterile filtration with a 0.45-membrane cartridge is performed after the wine is made as clear and bright as desired.

  Crossflow filtration is a technique that was first developed for the food industry in the 1940s and has become popular in winemaking in more recent decades. Developers have created a new membrane that works better for wine, increases flow rates and makes systems more automated and easier to clean. For wine filtration, the common types of membranes are hollow fiber, spiral wound and ceramic.

Filtration Maintenance, Replacement and Cleaning

  Not only is it important to learn about the different methods and processes of filtration, but also the best practices for cleaning those systems and keeping them working. One tip to remember is to store unused filter cartridges in a clean and dry environment. Always follow the manufacturer’s instructions for proper rinsing and cleaning a filtration system after use. Organic matter can stick to the surface of the membrane and clog the filter in an undesirable way if it’s not cleaned and sanitized well. 

  The filter equipment cleaning process involves pumping with an adjustable flow that can be back-pressured and withstand temperatures of around 125 degrees. PBW cleaner, a non-caustic cleaning product made with alkaline, is often used along with SaniClean or StarSan products in large buckets. Set the filter up to soak, purge the filter, rinse with hot water and acid rinse with SaniClean for the best results. Since each filtration system is a bit different, it’s best to check with the company where you purchased the equipment to inquire about the availability and cost of replacement parts.

  “We take the approach that all contact surfaces with wine should be kept clean and sanitized,” said Wojnarowicz. “Sanitizing before use is highly recommended. I have seen customers using the same barbed tri-clamp hose for years and kind of cringe knowing that the hose was clear braid, and now it is discolored beyond recognition, and you cannot adequately clean into the barbs. Fitted hoses are better; however, the lifecycle of hoses should be monitored.”

Common Filtration Mistakes

  Wojnarowicz told The Grapevine Magazine there are a few common challenges for wineries, especially when there are too little filter media with too much flow. 

  “For filtration in general, we size for a two psi or less clean pressure drop,” he said. “Flow rates and pressure differential will vary depending on how coarse or fine the porosity of the media is. With cellulose media, the clean pressure drop is typically higher, between five and 10 psi after wetting out. Generally, the higher the initial pressure, the shorter the life of the filter.”

  Another common mistake that Wojnarowicz has noticed is the inadequate conditioning of the filter media sheet or pad.

  “I have seen wineries use the pads and stacked disc right of the box with no rinsing or conditioning,” he said. “Conditioning with citric acid recirculation helps remove the initial wet cardboard taste associated with cellulose. After a 20-minute recirculation, flush with an adequate amount of fresh water, and the taste should be neutral.”  

Choosing a Filtration System

  Every experienced winemaker has a preferred way to filter wine, which is one of the many reasons why winemaking is more of an art than a science. Before purchasing a pump-based system for filtration, vintners might want to see if the product is available to rent. Wojnarowicz said they will typically pilot-trial equipment on a rental basis so the customer understands what is involved.

  Determine the capacity needed for filtration and talk to filtration companies about what types of systems can best accommodate that volume. Since each filtration pad rating is useful for different levels of clarification, wineries may benefit from keeping multiple pad types on hand.

Pumps for Filtration

  Pumps are an essential part of the filtration process, and winemakers should work with companies that can guide them towards the best pumps to use for this purpose.

  “If a customer has an existing pump, we incorporate the pump into the process as long as it makes sense,” Wojnarowicz said. “We have the ability to provide equipment for both large and small wineries. While the pump can matter, rubber impeller pumps are the most popular. Positive displacement pumps work well, as the flow tends not to decay as pressure builds. I do not care for diaphragm pumps due to the pulsing, which interferes with a stable gauge reading. Pulsation also disrupts the particle build up on the filter and can force irregularly shaped particles through the media.” 

  Filter Process & Supply recently became an East Coast distributor for Francesca Pumps after meeting with their North American representative at an Iowa trade show. Functions of this pump include pulling a vacuum from 8.5 meters, running dry for 90 seconds without damage, having a pump panel programmed for spraying the cap as many times as necessary, and not de-gassing wine due to excessive suction. This pump also has an optional function for filling barrels without fear of overflowing and pumping whole grapes from the de-stemmer into the fermenter.

Current Filtration Trends

  As with many aspects of winemaking, some filtering methods and processes are currently trending with winemakers. Fining is sometimes used as an alternative to filtration because it is a more affordable way to get control over tannin profiles while also achieving heat stability. Crossflow technology and new lees recovery developments are trending because of the energy efficiency potential. For example, crossflow filtration methods now have lower water consumption and waste production, are more resistant to heat and chemicals and have lower polysaccharide and polyphenol absorption.

Wojnarowicz said that the primary trend his company has seen is the use of backwashable media. However, while he agrees that backwashable media is cost-effective for use in the beer market, wine is another matter.

  “I would hate to recommend a backwashable media to a winery and find they stored the lenticular media for three months, then found it had odors and mold growth throughout pore structure,” Wojnarowicz said. “Even if stored based on the factory instructions, cellulose media is an organic, and organics can decay and pick up minute flavor notes. Pall Filters is a big promotor of backwash media for wine, but from what we have seen and discussed with knowledgeable industry personnel, why risk using a previously used depth filter on a flagship wine? I am not saying it cannot be done, but not everyone will re-condition media correctly.”

Filtration Tips and Advice

  Among the many best practices for wine filtration are to rinse the filter with clean water before the first use and always sterilize the filter materials with hot water. Make sure to follow the product specifications for the specific filtration system you choose and keep up with regular maintenance. Also, understand that filtration has its limitations when it comes to wine because merely using a filter won’t make a cloudy wine clear or drastically change the flavor profile to something it wasn’t meant to be.

  Wojnarowicz said that when reviewing a start-up or existing winery’s filtration goals, the gentle impaction of wine on the filter media will yield a larger throughput compared to pumping as fast as possible to get through the process. He also said the correct sizing of the pump and the filter media are crucial.

  “As a general rule, we recommend about one-half to one GPM per square foot of filter media,” he said. “You can certainly go two to three GPM per square foot or more, but the higher flow will compact the solids and pore structure, shortening the media life. Most 40-plate filter presses have one-inch ID on the piping, so flowing 15 to 20 GPM is about the maximum we recommend. The surface area and micron rating typically dictate flow recommendation.”   

  Wojnarowicz also said that the type of pump can also affect the wine. 

  “The suction side of the pump can de-gas wine, which degrades the wine,” he said. “There are sensors available to alert the operator of too much suction. If you are using a clear hose, the bubble formation in the hose can be the telltale sign.”

By: Thomas J. Payette, Winemaking Consultant

Fining trials on white, blushes and some rose wines can be critical to determine the least amount of bentonite needed to achieve heat stability or protein stability.  Other fruit wines may need fining also.

  The most difficult part of fining trials is to have an understanding of working with such small volumes of wines in the lab and how to apply the trial calculations to the larger tanks.  Once one has a clear understanding and methodology the tasks become easier.  It may take several fining trials under ones belt before it becomes second nature and the task becomes “a piece of cake.”  It is recommended an outside lab be used to mirror your winery lab until such point the internal winery lab technician feels comfortable doing the test on his or her own.

Why Fine?

  It is important to do bentonite fining trials on even perfectly clear wine.  These perhaps perfectly clear wines may contain proteins that, when becoming warm or hot, may denature and form a haze, cloudiness or even sediment in your bottled wine. Although your winery is generally very cool you must anticipate “outside abuse” of your product and protect it because anything wrong in a bottle with your label on it – reflects poorly on your winery.

  Below is a list of equipment and instructions to perform your own trials in your winery lab.

Equipment Needed:

  Most winery labs have the basics and one should be able to acquire these additional items with little financial outlay.  Here is a list of basics.

1.   Bentonite from your cellar bulk fining agents.

2.   375 milliliter screw cap wine bottles (splits) – may reuse these.

3.   500 ml  beakers

4.   500 ml Erlenmeyer flasks

5.   Millipore filter apparatus plus ample 0.45 micron filters.

6.   545 DE as a filter aid, if needed

7.   Vacuum source for filter

8.   20 x 150 mm test tubes with screw caps

9.   Test tube rack holder or coffee cup

10. Stir plate with magnetic stir bars

11. Good scales to weight fining agent / bentonite

12. Good eyesight or a Nephelometer (optional)

13. Distilled water or tap water (non-chlorinated) for mixing bentonite.

14. Graduated cylinder ( 100 milliliter )

15. Pipettes 1ml, 2ml, 3 ml, 4ml, 5ml.  Or serological (preferred).

16. Crock pot cooker or similar

17. Wine glasses – don’t forget the wine glass!

  Agents should be made fresh each time a fining trial is to be performed or kept less than a month at room temperature.  Always remix the bentonite slurry before using in a trial.  Use bentonite directly from the cellar to make sure the trial will match/reflect the desired reaction in the wine tank.  If different batches of bentonite are used in the lab and cellar – the results may vary.

Instructions

1.  Select and prepare a 5% bentonite slurry solution by carefully dissolving 5 grams of bentonite in about 80 milliliters of 80 degree F water.  After properly mixed bring to volume with water to exactly 100 mils to make the 5% solution.  This step may be done in the 100 milliliter graduated cylinder listed above.

2.  Collect the proper volume of wine from the wine tank desired to perform the fining trial on.  Make sure the sample is representative of the complete wine tank otherwise results will not be reflected properly after the fining has been completed in the wine tank.   If planning to do 5 different levels of additions in a trial you may need 3 liters or more of wine.  Break down the volume of wine into 6 – 500 ml Erlenmeyer Flasks and have them remain as close to the cellar tank fining temperature as possible.

3.  Label the Erlenmeyer flasks at the rates desired to be tested in the lab trial.  Typically each wine will have two controls, a one pound per thousand, two pound per thousand gallons and so on up to 5 pounds per 1000 gallons trials.  Some varietals may require more bentonite but those will start to identify themselves in your winery and each year you will “know or anticipate” they may require more.

4.  Now we know the above mixed solution is a strength that 0.24 mils of a 5.0% solution per hundred milliliters of wine sample will equal a one pound per 1000 gallons addition rate.

      Extrapolating that out for example:  If one prefers to make a 400 milliliter trial and to settle in a 375 milliliter screw cap bottle one would add 0.96 milliliters of a 5% solution to a 400 milliliter sample to represent 1 pound per thousand gallons; mix and transfer into the 375 milliliter bottle. Further – add 1.92 milliliters of a 5% solution to 400 milliliters of sample to equal 2 pounds per thousands and so on.

      Metric:  For those that prefer metric the addition can be viewed this way.  One pound per thousand gallons equals 454 grams per 3785 liters or 0.048 grams in 400 milliliters.  This is the same as the above calculation using 0.96 milliliters of a 5% solution in 400 milliliters.

5.  When adding the bentonite slurry to the wine – make sure to be mixing the sample well yet do not use shearing force mixers such as a blender.  Use the amount of agitation one can expect to have in the wine tank while adding the fining agents while mixing in the cellar.  Always try and mimic the actual cellar experience as closely as possible in the lab.  If your lab has a magnetic stir bar assembly these work very well.

6.  Continue to mix the samples thoroughly after the addition of the agent or agents.  Perhaps a minute or so on a magnetic stir bar mixer.

7.  Discontinue mixing and transfer the wine into a labeled 375-ml wine bottle and place the screw cap on top.  The label should reflect the addition rate of that sample such a 0, 1,2,3,4,5.

8.  Place, in a dark area, in the cellar or lab at or near the exact wine tank temperature if possible.

9.  Allow to settle overnight or several days.

10.      Decant into a labeled beaker at least 250 mils of the 400-ml samples from each fining trial.  One portion, approximately 50 milliliters per person, may be transferred into pre-determined labeled clean wine glass for visual, sensory and palate evaluation.   The other portion should move forward for further lab testing for the protein stability examination.

11.      The above analysis will allow one to taste different fining agent levels to help understand the rate of bentonite added and the expected sensory changes, if any, found at different levels.  Remember to incorporate an unfined sample in your tastings and lab work as a reference point to determine if a fining should be performed, at all, on a certain wine.

12.      If the wines are not settled enough for visual examination one can employ the 0.45 micron filter listed above to filter out suspended particles.  If sensory is to be done after filtrations make sure to treat the filter pads prior to use with a light citric acid solution.  This will remove any filter pad flavor.  This same filtered wine can then be moved forward to the protein testing below.  Use a new filter pad for each sample to eliminate sloughing of the proteins from one sample to the next.

Simple Protein Test

  Using the clean, dry 20×150 mm screw cap test tubes above fill each one about half full with the varying filtered fining trial levels created above.  Label each test tube respective to its “pounds per thousands” contents.  For each wine have a control sample that will go through the heat treatment described and one that will remain with no heating.

  Collect each sample after filtering in the lab in its respective test tube labeled 0,1,2…5.

  Heat the test tubes in a crock pot with water to roughly 70 degrees C ( near 160 degrees F) for 8 hours.  (See photo bellow)  This is a great place to use the test tube holder or coffee cup.

  Remove the test tubes from the heat source and allow to cool to room temperature.  Visually inspect, under a bright light source, for any sediment or haze that may have formed in the test tubes of wine.  Compare to the control sample as well.  Re-examine the following day to see if other changes have taken place with a flocculate formation or haze.  Most winemakers may use eyesight while others trust the Nephelometer listed above.  (I have always just used eyesight)

  Determine what fining level gives the wine the desired protein/heat stability.

  Once you have determined what amount of bentonite is necessary to make the wine protein/heat stable then perform the fining in the tank at that same rate.  For example if you find two pounds per 1000 gallons remained clear in the testing after heating then you have determined that rate should be used in the cellar after proper rehydration of the bentonite.  Once the wine is racked off the fining agent and collected in a clean tank you should perform another heat test, without the trials as a pass / fail test only, to determine if the wine performed in the tank as the trial predicted.  Always double check the results after performing the fining in the tank. 

Other Helpful Tips:

  Make sure the wines or juices are low in Carbon Dioxide gas since the bubbles may attach to the bentonite preventing it from settling in the tank or lab beaker.

  PH affects the rate of settling – lower pH wines generally settle faster in almost all cases.

  The bentonite protein reaction is a positive negative charge reaction – and then settling allows separation from the reacted bentonite.

  Most winemakers leave the bentonite in the wine tank to settle roughly 20 days.  Anything past 30 days may result in the proteins sloughing off the bentonite since the positive /negative charge may weaken.

  The ultimate goal of a fining trial is to use the least amount of fining agent possible to achieve the stability desired for the wine.

  Use pipettes to accurately measure the fining agents.  Serological pipettes offer nice results with incremental additions. Think of how you can perform fining trials in your lab and set aside future time to work with your plan.  You will be amazed at how much refining can be done to wine and how easy it really is.  Make this a part of your work improvement schedule for the year to come!

  Summary: Recall this is only one task to perform on white / rose wines wines generally prior to bottling.  Often three months from bottling is a time to look at the blends to perform finings and other stabilities before bottling.  Bentonite finings in the cellar should settle 20 days, roughly, to avoid heavy racking losses.  Don’t forget aroma trials also before adding bentonite.  Copper additions before adding bentonite may help remove any excess copper after reaction.  Cold/tartrate stability actions are typically taken after achieving protein stability.  Those wineries still going “unfined and unfiltered” may look at their products with the above tests just to make sure they are comfortable with the possible results.

By: Gerald Dlubala

The proper bottling of your wine is important. Timing, experience, state of the art equipment and expert knowledge are critical to the wine’s integrity, taste and shelf life. However, many wineries don’t have the budget for all the intricate machinery needed to bottle wine properly, or the expertise and availability of dedicated technicians to keep bottling equipment running at peak performance.

  Mobile bottling has filled that void, and for good reason. The average production winery may only need a week to 10 days for product bottling a year, making it hard to justify the number of resources it takes to purchase, run and maintain an in-house bottling line. Some wineries have chosen to let go of their in-house bottling machines, citing the amount of maintenance, upgrades and training that goes into keeping up a system that remains idle most of the year. Others have used mobile bottling since their inception. The benefits of using mobile bottling include utilizing the resulting space for more useful purposes, saving money once used on necessary machinery and technology upgrades, and the use of industry experts rather than needing to train employees on the ins and outs of the bottle machine each year. 

Quality Bottling with Experienced Professionals

  Dave Scholz, President of Signature Mobile Bottlers, knows the importance of bottling in maintaining the integrity of a winemaker’s product. He operates his mobile bottling company as if the wine he’s bottling is his own. Reflecting this, Signature Mobile Bottlers offers the same quality and convenience of having a permanently installed bottling system, but in a customized trailer that comes to you when you need it and out of the way when you don’t. The winery need only provide power, employees to assist, and the consumables, meaning bottles, labels and closures. The price for bottling with them starts at about 20 cents per bottle.

“After your wine has gone through all the necessary stages of filtration and is in a storage or holding tank, we’re ready to bottle,” said Scholz. “Our trucks back up to your dock, and the wine is pumped to our trailer to begin the bottling process.”

  That process starts with the empty wine bottles being fed onto an unscrambling table where Signature uses inverted bottle cleaning and nitrogen to expel any debris while simultaneously removing oxygen from the bottle. Since nitrogen is heavier than air, the bottles are turned upright and conveyed to the filler while remaining nitrogen filled. A gravity-fed rotary filler dispenses the wine into the oxygen-free environment, pushing the nitrogen up and into the bottle’s headspace. Auto leveling devices ensure exact fill levels before quality sealing by corking or screw cap. Corks are compressed and driven into the bottle under vacuum, and screw caps are installed using 400 pounds of downforce.

A final nitrogen dose using Chart Industries dosing machines form and create the seal between cap and bottle. Mechanical arms with rollers adjusted with precise tolerances form the threads and safety seal for perfect capping. Signature Mobile Bottlers use multi-head capsule spinners to apply Tin, Polylam or Aluminum capsules to provide that complete, finished bottle look. Labels are applied using Impresstik Vacuum belt labelers, so the winery must have the labels prepared to the correct specifications. Once the wine is bottled, sealed and labeled, the bottles make a U-turn and are conveyed back alongside the trailer wall to be packed and sent out ready to ship.

  “We bottle everything at roughly 60 bottles per minute, which gives us 1,800–2,000 cases per day,” said Scholz. “We’ve found that’s a good rate, both for bottling and the human side of the process. Additionally, changeovers between varietals can take place more quickly at this speed, averaging about 15 to 20 minutes per changeover versus an hour on higher speed lines. We do have a high-speed truck available if someone needs faster speeds, but the 60 bpm rate is a reasonable daily output and seems to work best for our customers.”

  Scholz told The Grapevine Magazine that with 15 mobile bottling trucks on the road, Signature Mobile Bottlers have the largest fleet in the business. “We use our bottling trucks nearly every day. Every harvest, our trucks are torn down to replace normal wear parts and be put through a comprehensive maintenance program that keeps our machinery tolerances at original factory specifications. Our trucks and systems are continually updated and serviced, virtually eliminating the chance of breakdowns during the critical timeframe of bottling. On top of that, our technicians are on the job every day, bottling wine under every type of condition and specification, rather than being a general employee that is expected to also run a bottling system for a few days out of the year. They’ve seen most issues and know how to react on the spot.” 

  “We’ve been doing this for 31 years, so I’d like to think we’ve learned some things,” said Scholz.

Mobile Bottlers Become Partners in the Winemaking Process

  Brandon Dixon is the general manager and executive winemaker for Noboleis Vineyards in Augusta, Missouri. Noboleis Vineyards has successfully used mobile bottling services since 2011. 

  “We’ve been with Old Woolam Custom Bottling since the company’s inception,” said Dixon. “The mobile bottling service that Old Woolam provides fixes all of the problems that we had when we bottled our wine on a manual line. The manual line consisted of a rinser, sparger, six-spout gravity filler, corker, capsule spinner and labeler and took six people to run efficiently. Even then, it was still a very slow process compared to an automatic bottling line, and our wine was still being exposed to a fair amount of oxygen. On top of that, it was a constant headache to keep the bottling line in proper working order for when we needed it. Conversely, there is very little oxygen pick up using an automatic line, and our maintenance responsibility is zero, so it became an easy decision for us to switch to a mobile bottling service when one became available.”

  Dixon told The Grapevine Magazine that by using a mobile bottler, he can bottle considerably more wine in a day while using only four people, and can do it using only three if needed. Noboleis typically bottles between 2,000 and 2,500 gallons per day, a significant increase over the 300 to 400 gallons using their manual line.

  “Brent Baker, the founder of Old Woolam Custom Bottling, is always there on bottling day,” said Dixon. “He sets the line up to our specifications, steam sterilizes it, and is responsible for keeping it running efficiently during bottling. The only hurdle we had to overcome to be able to use a mobile bottler was to install a dedicated electrical circuit and a specific type of outlet so the bottling line could be plugged into our power.”

  “We start to schedule and prepare for bottling about four to six weeks in advance. Once we have a date scheduled with Old Woolam, we order all of our bottling supplies,” Dixon said. “Prior to the day of bottling, all of the wines we’re bottling are filtered to 0.45 microns and finished however would be appropriate for that particular wine’s style. On the day of bottling, we set up the filter again because we will run the wine through the filter just before it goes into the bottling line. We use 0.45-micron pads and a 0.45-micron absolute membrane filter. This ensures that our wine is sterile as it goes into the bottling line. This step is just a precautionary step that helps us winemakers sleep at night! As we are setting up the filters, the bottling lines are being steam sterilized. The set up takes about 60-90 minutes, and then once everyone is ready to go, bottling starts.”

  “Old Woolam offers the option of corks or screwcaps for closures,” said Dixon. “The only real limitation with using an automatic bottling line is the size and shape of the bottle that we can use. There are several parts on the line that need to be changed out when changing the size and shape of the bottle. Old Woolam has the change parts for all of the standard sizes and shapes, as well as a few non-standard sizes. Old Woolam is typically able to meet all of our bottling needs except for a few exceptions. We have a few small volume specialty wines that we use irregular-shaped bottles for, and we do continue to bottle those wines on our manual line.” 

  Notably, many mobile bottlers use gravity fillers, making them unable to bottle carbonated or under-pressure wines. Dixon told The Grapevine Magazine that it isn’t a big deal for Noboleis because they don’t currently have a need or the equipment necessary to carbonate their wines.

  “When looking for a mobile bottler, it’s important for wineries to look for a great working partnership like the one I have with Old Woolam,” said Dixon. “The prices are fair, he’s reliable, hardworking, and goes out of his way to make sure our expectations are met. At the end of the day, I would never want to go back to bottling all of our wines on a manual bottling line. It wouldn’t be feasible given the volume that we have grown into. We would spend all of our time bottling!”

Protecting Your Product, Productivity and Profit

By: Cheryl Gray

For any winery, end-of-line packaging is the protector of hours expended by both man and machine to get the finished product safely from vineyard to glass.

  Such a huge responsibility is shouldered by companies whose integrity is measured solely by how carefully they help winery clients select the right end-of-line packaging to accommodate their needs.

A-B-C Packaging Machine Corporation

  A-B-C Packaging Machine Corporation, a privately held, family-owned business founded in 1940, counts itself in that number, selling packaging machinery to a wide range of companies manufacturing consumer packages goods. Since the 1960s, the end-of-line packaging company has been an equipment supplier to some of the wine industry’s biggest names, providing a complete line of machinery for winery packaging focused on the dry end of the packing line. Brian Sinicrope is Vice President of Sales and Marketing.

  “The dry end of the packaging line starts with the bottles being delivered to the winery. These are either delivered in reshipper cases or bulk pallet loads. If reshippers, the bottles must be unloaded from the cases to feed the line, using a decaser. Then, the cases are transported to the packer for repacking. When receiving bottles in bulk, the winery will use a depalletizer to unload and single file the containers from the bulk pallets to feed the line. At the other end of the line, filled and finished bottles are packed into either reshipper cases or new cases (if the bottles were purchased in bulk), then on to case sealing, and finally, palletizing for shipment or warehousing.”

  Sinicrope told The Grapevine Magazine that case sealers are another must-have component of a winery’s automated end-of-line packaging operation.

  “Case sealers are always used at wineries that use reshipper case packaging, as they are needed to seal the top flaps of the cases after the bottles are packed. A-B-C manufactures several models for various speeds and that seal with either hot-melt adhesive or pressure-sensitive tape. A-B-C case sealers have exclusive features to manage the flaps of the reshipper cases to ensure smooth folding and sealing of the inner and outer flaps, without the need for a separate flap positioner,” he said.

  “Case sealers are also used on lines that receive their bottles in bulk. In this scenario, a case erector will set up and seal the bottom flaps of corrugated cases. Then, the cases travel to a partition inserter that erects and inserts either a corrugated or chipboard grid into the case. After the bottles are packed, the case goes to a top case sealer that closes and seals the top flaps.  Finally, [the case goes] on to the palletizer.”

  A typical A-B-C winery client runs anywhere from 15 to more than 20 cases per minute. Sinicrope added that while there are trends, the purchase of end-of-line packaging machinery depends upon a robust assessment of a winery client’s need. 

  “A winery transitioning from reshippers to bulk may need a depalletizer, case erector, and partition inserter, and use their existing packer, top case sealer and palletizer. Or, a winery may decide to automate their palletizing, and we supply only a palletizer,” Sinicrope said. “Many companies are evaluating robotic equipment, and we offer robotic packers and palletizers as well. So, I would say, although there are trends, the equipment purchased depends on the application.”

  For small wineries packing fewer than ten cases per minute, the cost to fully mechanize every aspect of end-of-line packaging might be prohibitive. Therefore, many opt to perform end-of-line packing functions manually. However, Sinicrope said that A-B-C offers a semi-automatic palletizer that can improve productivity for small wineries looking to automate this specific element of end-of-line packaging.

  “Fully packed wine cases are heavy, and palletizing can be labor-intensive, even at low speeds. In addition, there is a potential for liability because of the repetitive motion of the task. Our semi-automatic palletizer lets one operator slide cases into the pallet pattern at the conveyor level. Then the layer is lifted and placed into pallet formation. The machine eliminates the repetitive lifting and potential strain of manual palletizing at an economical cost.”

  Sinicrope told The Grapevine Magazine that A-B-C typically works with customers packaging their products in corrugated cases with partitions, and those cases are palletized for shipping and warehousing. The packaging materials used and equipment deployed has proven to be a successful combination for its clients.

  “A corrugated box with partitions is highly effective at protecting products during shipment and final delivery. However, it is important to make sure the packaging equipment performs secure case sealing and that the packed cases are not subjected to enough moisture that could cause corrugated failure.” This, he said, is rare. “Corrugated boxes have been a standard for packaging for many years because they are durable, provide good product protection and superior stacking strength. Today, companies are looking for sustainable packaging solutions, and corrugated boxes are a cost-effective, renewable solution.”

Wine Country Shipping, Inc.

  Wine Country Shipping, Inc., does precisely what its name implies. In business for more than 25 years, the company services approximately 150 wineries, retail outlets and hotels throughout Sonoma County, California. Its sister company, Wine Country Cellars, LLC, provides more than 10,000 square feet of temperature-controlled storage space for winery products. Janice Laskoski is President and Managing Owner of Wine Country Shipping and sole owner of Wine Country Cellars. Using rigid quality control standards in packaging and shipping, Laskoski told The Grapevine Magazine that the priority for both of her companies is to protect what she describes as her winery clients’ “liquid assets.”

  “If time has taught us one thing, it is that every customer wants their wine shipped quickly, safely and easily. That is the premise upon which we have built our reputation,” she said.

  Wine Country Shipping uses cartons, pallets or shrink-wrap pallets for end-of-line packaging materials. Quality control includes careful inspection of all items before, during and after packaging to ensure nothing goes amiss during shipping. Laskoski said that using the right packaging makes a tremendous difference in protecting winery products during both shipping and final delivery.

  “The right packaging is very important. Styrofoam has proven with our partners, UPS and FedEx, to be the most reliable, but pulp is being requested more and more due to the environment,” said Laskoski.

Tetra Pak

  Tetra Pak cartons are the end-of-line packaging choice for wineries doing business with California Natural Products. The company, located in the San Joaquin Valley in northern California, has been in business for 40 years with customers across the U.S. and Canada. The attributes of a Tetra Pak are attractive to many consumers. Among them is sustainability, since the product is made from at least 75% recyclable paper derived from responsibly managed forests. It is portable, flexible and unbreakable packaging, designed with a “grab and go” concept popular with consumers. The Tetra Pak also has the convenience of a resealable cap, giving the option of either consuming now or storing for later use.

  Tom Jansen is Vice President, Business Development for CNP.  He said that using a Tetra Pak format for end-of-line packaging benefits wineries in other tangible ways. “Tetra Pak protects the product by eliminating oxygen entry and light from exposure to the product, which is ideal for wine. Tetra Pak is lighter than glass or cans and allows for more efficient delivery as a result.”

  Tetra Pak is one of three companies under the umbrella of the Tetra Laval Group, a trio of firms headquartered in Switzerland. Tetra Laval Group provides end-of-line packaging equipment for the wine and spirits industries, covering critical needs such as packaging, secondary packaging, conveying and palletizing.

  Bandit Wines is one brand that prefers Tetra Pak cartons because of its own mission to utilize eco-friendly end-of-line packaging. Take, for example, fuel efficiency. The California-based wine producer said its shipping costs are lower before and after filling because of the lightweight and space-saving features of Tetra Pak cartons. Bandit Wines also said that for consumers, not only do they buy a wine product that is convenient and environmentally safe but also packaged in a container that holds 50% more wine than a comparably sized wine bottle.

  Boris Munster, Vice President of Contract Manufacturing, Tetra Pak U.S. and Canada, told The Grapevine Magazine that as a global innovator for end-of-line packaging, Tetra Pak is in a position to help wine producers and their products stand out.

  “Wine is traditionally bottled in glass, but several wine producers have discovered the advantages of using Tetra Pak’s packages,” Munster said. “Carton packages are available in a wide range of sizes and are printable on all sides, opening big opportunities for design and branding.”

  From machinery to shipping to branding and more, there is virtually no end-of-line packaging need that is not essential to getting wine to the marketplace and into consumer’s hands.

By: Gerald Dlubala

A wine bottle is more than just a vessel that gets wine into the hands of consumers. The wine inside that bottle reflects the winemaker, providing a story of their life and their passion. It creates an identity and image for the wine that becomes the brand. Creating a label that is reflective of these components is important for both the winemaker and the consumer. There are many options out there, whether purchasing the labels from a printer, going paperless, printing them in-house or a combination, each with advantages and uses. One thing stays consistent when considering a label—it needs to reflect the brand and image the winemaker believes in while also attracting the shelf-surfing eye of the consumer.

Professionally Printed Designs are Limitless

  “A label designed to grab attention on the shelf is the name of the game, and that’s what we do best,” said Katie Harrington, Marketing Manager of Blue Label Packaging Company in Lancaster, Ohio. “The sky is the limit regarding wine labeling, and that presents an incredible opportunity for wine producers. We know that the labels are what grabs the consumer’s attention and encourages them to pick the bottle up. There are so many ways to do that now, that it’s only up to the imagination as to what comes through our door.”

  “With the flexibility in budgets that we see from wineries, there are endless options, even for small runs,” said Harrington. “Self-adhesive and pressure sensitive labels are the most common in the wine industry, and we can always help the winemaker with sizing needs based on what they want to do, how they want to do it and how they apply the labels.”

  After that, the choices are endless, starting with a choice between standard traditional paper labels through increasingly sturdier estate paper selections. Paper labels are still the most widely used in the industry, and because there are multiple types and combinations of paper to choose from, winemakers have a bit of an advantage when not having to keep their wines refrigerated.

  “Paper textures with a linen or cobblestone feel are examples of great bases for eye-catching designs,” said Harrington. “The interesting thing is we’ve actually found that a label’s texture or combination of textures is at least equally as important as the design itself in establishing brand and product identity.”

  The bevy of options carries on through label design as well.

  “With new clients, we’re here to listen and then show you the possibilities regarding textures, color choices, design types and enhancements like die cuts, embossing, foil stamping, double-sided printing or a combination of any of these and more,” Harrington said. “It really is exciting as to what can be done, and then there are options for almost every step along the way as well. If you are interested in foil stamping but your budget doesn’t allow it, we can actually simulate that sheen and label pop by doing things a little different with a combination of color blocking and our translucent inks. Some winemakers choose to be unique with variable imaging, where every single label is different but themed or connected in some way. For example, we’ve had labels printed with each label featuring different sections of a map or different pictures that are all related and connect with their brand or image. And we’ve all seen the labels with printed codes so that the consumer can scan them and get information on the wine, winery, winemaker or whatever message the winemaker wants to pass along. Codes can also be added for tracking or origination purposes if needed. And if desired, finished labels can be coated with a UV varnish to protect the label from damage during shipping or to add texturized appearance like a gloss, satin or matte finish.”

  Harrington told The Grapevine Magazine that Blue Label Packaging uses HP Indigo printers and can attain the entire color spectrum using their four or seven color units, making color choices endless. Unlike many label designers and printers, Blue Label does everything in-house. There is no outsourcing because of labor-intensive or highly technical functions that need to be incorporated.  

  “Label designs have become a very important marketing tool for winemakers, and the trends have shown some interesting choices and patterns,” said Harrington. “There is a prevalence in adventuresome packaging, with winemakers choosing to either go very minimalistic—using just one base color or a foil to distinguish their brand and leave the wine to provide the experience—or to go all out with the most ornate and design loaded label possible. They’ll use several passes on the same label for layering, coming up with scenes using foil, embossing, special die-cut layers or a combination of options. The labeled bottles are almost too much like art to discard after emptying.”

  Harrington also said that recently, some wineries have begun to embrace labeling practices seen mostly in the brewing industry.

  “One other thing that is just starting is the increased use of the shrink sleeves that are popular in the beer industry. They have their own tamper seal and provide 360-degree coverage, which in the label aspect means 360-degree label printing and decorating availability. Right now, we see it mostly in the small travel packs or four-pack small bottles, but it’s another option.”

Screen Printed Wine Labels Offer Simplicity but take Planning

  Screen-printed labels are a natural transition from paper labels, allowing wineries to get rid of the need to purchase, set up, operate and maintain a labeling machine. Screen printing generally delivers a freshened-up look from original paper label artwork, transposed onto the wine bottle surface. After the bottles are loaded up with ink, they travel through a lehr-type oven, meaning a long kiln with an end-to-end temperature gradient, common in glassmaking production. As the bottle moves along the kiln’s path, the screen-printed label gradually cools, making it durable with no print or color errors or runs.

  The advantage of using screen printed labels is the potential for simplification and added durability. The wine bottle can be used as the background color rather than starting with a colored paper background. Although screen printing can generally handle up to 10 colors, including pricier precious inks like gold and silver, the average winery uses only two or three, and rarely more than six. Screen printed labels are less likely to be damaged by scuffing or rubbing during transportation and distribution, and refrigeration, humidity or moisture are not as much of a concern as they are with paper labels. Once bottling is underway, the setup and management of the filling process are streamlined by one step since there’s no need to apply labels.

  The disadvantage to screen printing is that it takes additional upfront planning and reliable logistical scheduling to make sure that enough bottles are printed and on location for bottling. Depending on the printer company and the number of bottles to be screen printed, the turnaround date on having bottles shipped out, printed and returned can range from one to three weeks.

Etching Provides Distinction & Elegance

  Bottle etching is a process that delivers a distinctive version of a label or brand image by carving into the bottle’s surface. It can be done on filled bottles because it is a cold process, blasting a very fine silicate, like aluminum oxide, through a series of nozzles to permanently, but gently, engrave the label onto the bottle. Once the label is etched onto the glass surface, paint can be applied to complete a true work-of-art label. The number of passes and color changes the bottle goes through is determined by the complexity of the image.

  Because etching is a labor-intensive and pricey option, it’s generally reserved for special occasions wines. Etched label bottles are great for fundraisers, gifts, wine club memberships, special releases or for display in tasting rooms. They can also be made to commemorate personal milestones like anniversaries, birthdays or wedding party gifts, or winery production milestones like bottles or barrels produced. Etched bottles are kept for their artwork as keepsakes, and, when coupled with matching etched glasses, can make an ordinary occasion elegant and memorable.

Self-Printed Labels for Flexibility and Convenience

  Printing labels in-house offers the ultimate in flexibility and is a quality option for wineries that have multiple small runs with different products or like to change their label design or type frequently. Smaller run wine producers that prefer an on-demand, do-it-yourself approach to creating labels can do that with the right equipment. Companies like Primera Technology, a leading manufacturer of specialty printers, offer equipment that specifically caters to wineries that want or need to print their labels in-house. The printers are operated and controlled from a PC or laptop and are compatible with both Windows and Mac environments.

  Machine costs run the spectrum based on what the winery wants to do and how fast it needs it done but generally start around $1,000. Production from a cartridge of color ink will always depend on the coverage needed for the label. So, as with a budget for a professionally printed label, it’s wise to consider the color choices and design complexity. Circular and nonstandard labels are accommodated by readjusting the print settings. 

  Printing labels in-house is an advantage for wineries that need label changes quickly or frequently produce specially bottled wines for private or public functions, seasonal specials, corporate gifts or any event requesting specialized labeling.