Behind the Scenes of Bottling Day
Bottling day – it’s exciting, stressful, and fast-paced. As the first wines of the 2017 vintage are completed, our team toasts each other with a glass of bubbly in celebration of coming full circle on the first vintage together. We looked back at harvest and laughed at how many lugs of fruit it took to make the 800 cases of Sunset White we just bottled (It was about 800 lugs). We thought of all the time spent tracking fermentations, moving wine from tank to barrel, and of course cleaning equipment - all that time spent just to get to the finish line of bottling day. Even the weeks leading up to bottling day are a frenzy of blending, stabilizing, and filtering. Finally, bottling day arrives. We bottled 1,807 total cases, that’s 21,684 bottles!
It’s a long day and it starts early. A typical day of bottling looks like this:
6:00am: The truck arrives while the sun just barely begins to glow. Coffee in hand, hazy from the morning darkness, I pep up as the generator spurs the bottling truck to life.
6:01am: Full on bottling mode has taken hold of me.
6:02--6:45am: The bottling guys do a test run with a case of bottles, corks, capsules, and labels to calibrate their machines.
6:45am: The rest of the cellar crew arrives and more coffee is a necessity. The first tank is connected to the bottling truck and bottling begins!
7:00am--4:30pm: Unload, fill, reload, stack. Repeat 1,807 more times.
4:30--5:00pm: Clean up time.
The people: We have five positions on the bottling line.
First is the forklift operator. They’re the person that makes sure everyone has what they need, when they need it, where they need it. He supplies the empty cases that are loaded on the truck. He takes the palettes of full cases and stacks them away in the barrel room.
Second is the glass unloader. This person stands on the truck, takes the cases of empty bottles, flips them onto the bottling line’s conveyor, lifts the box off of the upright bottles, and watches as the bottles get taken away further into the abyss of the bottling line.
Third is the box filler. This person also stands on the truck. He is the final check of the full bottles. Labels are straight? Check. Bottles are corked and capsuled? Check. There is actually wine in the bottle? Check. The completed bottles are then placed back into the cases and sent down another conveyor.
The fourth and fifth person stand at the end of this conveyor to receive the full cases. They trade places labeling and stacking the cases.
The in between: So where does the actual bottling take place? Once the glass unloader sends the empty bottles onto the truck, that is where all the action happens. The bottles get flipped upside down and filled with nitrogen to protect against oxidation. The bottles are then circled around in merry-go-round like fashion and filled to the correct level. Next, they get the screw caps spun on. The last step is labeling--the front and back label are adjusted by the slightest millimeters and put on the bottle. Finally, the long conveyor takes the bottles around the back of the machine where they leave the truck and are placed safely back into their case.
Although stressful, bottling day is a relief. We are happy to see our product completed, our hard work paid off. Now we can enjoy the finished product and look forward to the next bottling in May!