Bottling Spirits in the United States: A Guide
As the craft spirits industry continues to grow in the United States, many distilleries are turning to bottling companies to help them package their products. Whether you're a small batch producer or a large-scale distillery, finding the right bottling partner is essential to ensuring the quality and consistency of your spirits.
In this blog, we'll explore some of the key considerations when it comes to bottling spirits in the United States, including bottle manufacturing and bottling lines.
Bottle Manufacturing in the United States
One of the first decisions you'll need to make when it comes to bottling your spirits is the type of bottle you want to use. Glass is the most common material used for spirits bottles, and there are many different sizes and shapes available. Some of the most popular shapes include the classic round bottle, as well as square, rectangular, and even hexagonal bottles.
The manufacturing process for glass bottles involves heating a mixture of sand, soda ash, and limestone to very high temperatures, which creates molten glass. This molten glass is then formed into bottles using specialized machines. Once the bottles are formed, they undergo a process called annealing, which involves cooling them slowly to room temperature to ensure that they are strong and free from defects.
While glass is the most popular material for spirits bottles, there are other options available as well. Plastic bottles are often used for lower-end spirits, and they are lighter and more durable than glass. However, they are also more susceptible to damage from heat and light, which can affect the flavor and quality of the spirits inside. Metal cans are another option, and they are becoming more popular for ready-to-drink cocktails and other pre-mixed beverages.
Types of Bottling Lines
Once you've decided on the type of bottle you want to use, you'll need to find a bottling partner that can help you get your spirits into those bottles. Bottling lines are complex machines that can fill, cap, label, and package thousands of bottles per hour. There are many different types of bottling lines available, and the right one for you will depend on your specific needs and budget.
Some of the most common types of bottling lines include:
Gravity Fill Lines: These bottling lines use gravity to fill bottles with spirits. The bottles are held under the filling nozzle, and the liquid flows into the bottle by gravity. Gravity fill lines are best suited for thicker liquids, such as whiskey and rum.
Vacuum Fill Lines: Vacuum fill lines use a vacuum to fill bottles with spirits. The bottles are held upright, and a vacuum is created inside the bottle. This causes the liquid to flow into the bottle, and when the desired level is reached, the vacuum is released, and the bottle is capped. Vacuum fill lines are best suited for thinner liquids, such as vodka and gin.
Piston Fill Lines: Piston fill lines use a piston to fill bottles with spirits. The liquid is drawn into the piston and then dispensed into the bottle. Piston fill lines are best suited for thicker liquids, such as whiskey and rum.
In addition to filling, bottling lines can also be equipped with labeling, capping, and packaging equipment. Labeling machines apply labels to bottles automatically, while capping machines can screw on caps or apply corks. Packaging equipment can wrap bottles in shrink wrap or pack them into cases for shipping.
How to Evaluate the Best Spirits Bottling Partner for Your Brand
Choosing the right bottling partner is crucial to the success of your spirits brand. When evaluating potential bottling partners there are several factors to consider, including:
Capacity: Make sure that the bottling partner you choose has the capacity to handle your production needs. If you're a small batch producer, you may be able to work with a smaller bottling company, while larger distilleries will need to partner with a company that can handle higher volumes.
Quality Control: Look for a bottling partner that has a strong focus on quality control. They should have processes in place to ensure that each bottle is filled correctly, labeled accurately, and packaged securely.
Flexibility: As your business grows, your bottling needs may change. Look for a partner that can accommodate changes in production volume, bottle size, and packaging requirements.
Location: Consider the location of your bottling partner. If they are located far away from your distillery, it may increase transportation costs and lead times.
Reputation: Do your research and read reviews from other distilleries that have worked with the bottling company you're considering. Look for a partner with a strong reputation for quality and reliability.
Working with a bottling partner can also save you time and money by allowing you to focus on building your brand or making sales, while they handle the bottling process. They will have the equipment, materials, and expertise needed to ensure that your spirits are bottled correctly and consistently.
If you’re ready to explore your initial beer, wine, or spirits bottling needs or you are looking to expand to another location, please reach out to us at inquiries@drayhorse.co to learn more about our bottling or canning options in our Philadelphia facility.