Bottle Prep Best Practices Speakers Chad Joseph Joseph
Bottle Prep – Best Practices Speakers: Chad Joseph, Joseph Wine Works Leticia Chacon Rodriguez, Safe Harbor Winery Shakib Ali, Lange Twins Winery and Vineyards Zoran Ljepovic, Constellation Brands Moderator: Richard Bruno, Vinum Cellars, Inc.
Bottling Prep – Best Practices Off Site Winemaking – Getting wine Ready Chad Joseph, Joseph Wine Works
Personal Background • Work with 3 small sized wineries (5 -10 K cases). • Utilize mobile bottling services at each facility. • Bottle 2 - 4 times a year at each facility. • Bottle 3 - 10 wine lots per scheduled bottling. • Bottle 2, 000 to 3, 000 cases per day. • Lot size vary from 100 to 2, 000 cases.
Definition of a Bottle Ready Wine • Commercially viable wine. • Can be efficiently bottled. • Meets stylistic profile. • Within chemical bottling parameters. • Compliant with labeling requirements.
Steps to Prepare a Wine for Bottling 1. Create a Cellar Blend for Bottling. 2. Adjustments and Additions. 3. Stabilization 4. Filtration 5. Bottling Approval
Blend Evaluation • Composition • Flaws • Additions • Adjustments
Approve a Cellar Blend for Bottling • Taste blend options, approve a blend. • Verify labeling requirements or declarations varietal, alcohol, vintage and appellation. • Confirm bottling projection. • Sensory profile meets stylistic goals. Plan several months before bottling for blending, adjustments, additions and processing.
Flaw Identification and Adjustment • Alcohol content • Aroma taints • Volatile acidity • Acid concentration • Mouth feel • Color
Additions • Acidification / De-acidification tartaric acid & potassium carbonate • Oak adjuncts, granular & liquid • Residual sugar concentrates & juices • Fining agents casein, albumin, gelatin, carbon, copper sulfate, etc.
Stabilization • Heat Stability - Protein instability treated with bentonite (white & rose) • Cold Stability - Tartrate instability treated by chilling and seeding with KHT - Additions of cold stabilization agent (CMC, Mannoprotein) • Microbiological - Analysis (p. H, malic acid, residual sugar) - Direct plating, microscopic, and genetic analysis
Filtration • Sterile Filtration (0. 45 micron) malic acid sweet wines insures microbiological stability • Polish Filtration (0. 65 to 10 micron) no malic acid or residual sugar low microbiological count • Unfiltered no malic acid or residual sugar low microbiological count low turbidity
Bottling Tank Approval • Chemical Analysis • Stability Analysis • Sensory Analysis • Filterability Test
Quality Processing Considerations • Sanitation • Oxygen • CO 2 • Temperature • SO 2 • Timing
“Without a careful, planned approach to execution, strategic goals can not be obtained. ” Lawrence G. Hrebiniak Thank You!
Bottling Prep – Best Practices On-Site Winemaking, Planning and Compliance Leticia Chacon Rodriguez, Safe Harbor Winery
When it comes to bottling : Always expect the unexpected ! • Winemaking Planning and Preparation • Bottling Requirements/Compliance for our Clients • Bottling Planning • Bottling Best Practices
Winemaking Planning and Preparation • Wine blending • Wine stability and additions: For heat stability consider 3 -4 weeks prior bottling • Wine cross-flow filtration: A few days prior bottling • Wine final additions and preparation (CO 2, FSO 2, DO) • Wine ready to bottle
Wine Ready to Bottle Information • One page with the following information: Ø Basic information: Owner (contact), tank, lot number, bottling date (bottling location), volume Ø Label alc Ø Wine composition: Vintage %, Variety %, Appellation % Ø Brand COLA (Certification /Exemption of Label/Bottle Approval) Ø Wine analysis: Alc, FSO 2, TSO 2, DO, CO 2, RS, VA, Turbidity (Filterability), Heat Stability, Cold Stability
Wine Compliance (by TTB) Vintage 85% or more for State or County 95% or more viticultural area Appellation of origin 75% or more Country, 85% or more State or county viticultural area Varietal 75% or more Alcohol ≤ 14% +/- 1. 5 % Alcohol for > 14% +/- 1. 0 % 100% Estate bottled Two varieties: stated in the label Reference: Code of Federal Regulations Title 27, Part 4 – Wine labeling regulations- ttb. gov
Bottling Requirements/Compliance for Our Clients Ø Letter that authorize us to bottle (Client & Trade name) Ø Labels to submit to TTB on line (jpeg files < 750 KB) Ø Fictitious Business Name (DBA- Doing business as) application: County Recorder, publish and TTB (Basic Permit) • Next steps: Ø Dry goods scheduling and contacts Ø Finish goods schedule and contacts
Bottling Planning • Our matrix: various clients (>10) from runs of 500 cs to 90 K cs • Run one shift about 3 to 3. 5 K cases with a mobile line • Information from each client: time and estimated cases to run • Calendar format for bottling – Ideally add some flexibility • Paper work (work order, BOLs, dry goods inventories, pallet tags) • Dry goods scheduling and contacts • Finish goods schedule and contacts
Bottling Best Practices • Communication • Partnership with client, suppliers, shipping companies, internal company • Positive approach to any issues – There is always a solution • Always expect the unexpected Thanks so much to all our clients, my Safe Harbor team; and our bottling partners: bottling line team and suppliers. Thank you all very much!!
On-site Bottling, Packaging & Suppliers Shakib Ali Lange. Twins Winery
Benefits of a Mobile Line VS Own Line Mobile Bottling UPSIDE • Facility or employees not required. • Skilled technicians are provided. • Ideal for multiple small lots. • No capital requirement. • No worry of idle equipment. DOWNSIDE • Scheduling conflicts. • Equipment and change part limitations. • Wine readiness. • Production setbacks may push bottling out longer than expected.
On-Site Bottling Having Your Own Line UPSIDE • Control over process. • Scheduling Flexibility. • Known Equipment Capabilities. • Greater Quality Control. DOWNSIDE • High Initial Investment. • Equipment Maintenance. • Trained Bottling Staff. • Complex process such as sanitation, filtration and equipment expertise.
Packaging Qualification • Test your materials as soon as possible. • Standardize your materials. • Use what you know works. • Give yourself time to adjust materials or the equipment. • Test the package across the entire line. • Do not assume, even slightly out of spec materials may not work. • Different suppliers have different specifications.
Packaging Form
Check Materials • Receiving Documentation – Make sure the materials are what you ordered. – Check that quantities are correct. – Do you have enough materials to complete the bottling? – Save and file all incoming material paperwork and log lot identifications. • Important Inspections and Verifications – Glass: Inspect prior to unloading to make sure it is correc – Capsules/Screw caps: Are they correct size, color, brand, decoration? – Labels: Upon arrival check vintage, varietal, appellation, alcohol, etc. – Is the label rewind correct for your labeler?
Have a Plan for Rework • Mistakes are a part of bottling. Plan for it. – Have a dedicated space, workers and materials available for rework. • Minimize rework: – Pay constant attention to the line. – Group materials by package, label them and keep them separated. – Set standards and tolerances and adhere to them. – Train employees on what the correct package should look like.
Vendor Qualification • Know Your Vendors – Meet personally with each sales representative. – Ask for their Quality Control representative’s contact information. – Meet with QC representative prior to running a new package. – Request that this representative be available for startup. • References – Ask for references of other wineries using the same materials. • Ask for samples – Check and test the samples to see if they meet your specifications.
Vendor Qualification • What to ask when talking to a Sales or QC Representative – Any problems that previous customers have had? – What QC standards are used? – Do they perform QC testing on their product? What are those procedures? – Are there any setup tips that they may have for you? – Who to contact if there is an issue? • What to do if you do have an issue – – Inform them immediately. Save samples of the defective product. Hold suppliers accountable. Do not feel obligated to stick with any supplier.
Bottling Quality Control Zoran Ljepović Constellation Brands
Bottling Process • • Sanitizing Final Filtering Start up Glass unloading Bottle Rinsing/Purging Wine Filling Corking or screw capping • • Applying Soft Capsules Labeling Case packing and sealing Case labeling Palletizing Bottle Sampling Reporting & Recording
Sanitization • Daily hot water sanitization • Weekly chemical sanitization • Hot water 180 F for at least 30 min with constant flow • Chemicals: caustic and peracetic acid or chlorine dioxide • All filler and corker parts that come into contact with the lip of the bottles should be sprayed with 70% Ethanol
Sanitization • ATP swabbing a good quick check for level of cleanliness • Hot and cold water should be soften (minerals and colloidal silica removed) • Filtration regimen: • water = 0. 2 µm • wine = 0. 45 µm • gasses= 0. 1 µm
Clean Room • • • Always closed Constant positive pressure Good lightening Good exhaust with regularly replaced filters No walk though No storage No bad smell, mold, pest and fruit flies Small drain opening away from the filler Constant humidity and temperature without fluctuation If there is no bottling room the filler need to be completely enclosed with HEPA filter and/or positive pressure
Final Filtration • • • Pre-filter (remove any particulates) Final filter (remove wine microbes only) Filter integrity testing before and after bottling If testing failed quarantine the wine produced Continuously monitor pressure differential before and after filter • Tally total gallons filtered • If not in use filters need to be properly stored in 70% Et. OH or other solutions approved by filter manufacturer based on the membrane material
Line Start Up • Final filter integrity testing • Alcohol check within 0. 1 -0. 2% by Vol. • Dissolved Oxygen under 1 mg/L @ start-up, delta <0. 3 mg/L during run) • Headspace oxygen • Vacuum in the bottle under cork • Minimum pressure under screw cap <10 psi • Fill point & proper ullage (headspace) • Start checking the whole bottle package • Ambient, glass & wine temperature • Label and ambient humidity level • Wet glue temperature
Specification Sheet
Glass Unloading • Uncasing • Unloading bulk glass
Rinser • Spray spouts with 70% alcohol • Clean dust/cardboard from collection bag • Check the air and N 2 flow
Filler • • • Proper fill point Spout leaks Uneven filling Foaming Dissolved O 2 Headspace O 2 Alcohol Temperature N 2 flow Vacuum Monitor wine level in the bowl (site glass)
Corker • • Proper insertion For grease stains Crease and pinching Vacuum Wine Foaming Cork Brand / Vintage Cork Lot / Ref. information
Screw Capping • Check hopper • Check N 2 dosing • Application: slip and torque • Secure seal testing • Damaged capsules • Pressure in headspace
Soft Capsule • • • Proper application without barber pole look or folding No cutting No scuffing Rollers Tension Lubrication
Labeler • Glue temperature (for wet glue) • Environment moisture and temperature • Pressure sensitive labels • Height, tilt, registration • Proper label with alcohol and correct wine info
Case Packer • • • Proper bottle dropping into the case cells No missing bottles Glue application Proper case sealing without gaps Case label with all pertaining information in proper font size
Sample Bottles • It is important to pull bottles periodically throughout the run, each day for further analytical and microbiological testing • At a minimum samples should be pulled at start up, after each break and lunch and at the shut down everyday. • Back-up samples should be kept for a certain period of time after the run in case any problems come up later
Quality Assurance At Completion of Wine Bottling • Complete analysis for quality assurance • Complete analysis for wine export • Plating for checking microbial stability and QC hold release within 14 days • Bottle pre-release tasting 3, 6, 9 & 12 months • Keep all documentation in order for future needs
Product Non-Conformance • What do you do when something is out of specification? – Decide the severity of problem – Isolate all suspect cases – Inform Production Manager immediately – Track and Release or Rework Product • Establishing protocol for *holding* product ahead of time will help reduce a potentially stressful situation later
Post Bottling Review • All analysis and quality reports generated throughout the run should be recorded and archived after they were reviewed by the Lab or QC/QA Manager. • The process of bottling quality is a fluid one. Create the program that works for your winery/ company. • Bottling quality represents the preservation of the product, and the assurance that the consumer will experience the wine as was intended by the winemaker
Question & Answer Session Thank You! Chad Joseph Leticia Chacon Rodriguez Shakib Ali Zoran Ljepovic Richard Bruno
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