D1 Packaging and closure Flashcards
Packaging
Packaging and closure determine the shelf life of the wine. Oxygen play a key part here.
Oxygen must be limited throughout this process as too much lead to oxidation, too little lead to reductive aromas).
When packaging and closing, winemakers must consider:
- the dissolved oxygen in the wine
- the ullage
- the oxygen transmission rate (OTR) of the cork
Packaging options
GLASS
Adv
- delivered in sterile condition
- Inexpensive
- 100% recyclable
- Impermeable to oxygen
Dis
- high carbon footprint due to heavy transports and to manufacture it
- fragile
- once opened, the wine quickly oxidise
- clear bottle may be spoiled by light strike
PLASTIC
Adv
- lower carbon footprint due to light transport
- inexpensive
- 100% recyclable
- range of sizes
- less fragile
- suited for informal setting and quick consumption
Dis
- limited shelf life
BAG-IN-BOX to POUCH (cardboard box with a bag inside made of aluminium foil or plastic) Success in Australia and Sweden
Adv
- lower carbon footprint due to light transport
- inexpensive
- 100% recyclable
- range of sizes
- Easy to store
- less fragile
- good protection from oxygen once wine is poured
Dis
- can oxidise quickly is SO2 in not higher and if poor tap is used.
- limited shelf life of 6-9 months
BRICK or TETRA PAK (paper card with of aluminium foil or plastic layers) Germany major market.
Adv
- can be entirely filled
Dis
- The filling equipment is a bit investment
CAN
Adv
- lower carbon footprint due to light transport
- inexpensive
- 100% recyclable
- Easy to open
Dis
- The filling equipment is a bit investment
Closure
Closure must bust be:
- protect from oxidation
- inert to not affect the wine
- easy to remove
- cheap, recyclable and free from faults
Natural cork
- protect from oxidation
Allow gentle oxidation.
May have different OTR
- inert to not affect the wine
Natural cork may house TCA, leading to cork taint (mould and wet cardboard smell), reducing fruity character.
- easy to remove
requires a tool
- cheap, recyclable and free from faults
Different price range.
Renewable, natural resource
Cork taint may be tackled by:
- Cleaning corks with steam
- Rigorous control of corks to check presence of TCA
- Applying a barrier between cork and wine to avoid contact
- Using a technical cork (Diam cork)
Corks granules are cleaned, agglomerated together, then tested.
Comes in a range of OTR.
Synthetic closures (plastic and extruded corks)
- protect from oxidation
Limited protection
- inert to not affect the wine
Plastic absorb some of the wine flavours, leading to loss of flavour intensity.
- easy to remove
But difficult to reinsert.
- cheap, recyclable and free from faults
No additional costs.
Screwcap (market Australia, New Zealand, UK)
- protect from oxidation
The tin or Saran (cling film)
- inert to not affect the wine
Allows almost no oxygen, this can be lead to reductive fault if wine is not balanced with lowered SO2.
Eliminate cork taint issue.
- easy to remove
- cheap, recyclable and free from faults
Requires different closure equipment
Glass stopper (Vinolok brand name)
- protect from oxidation
- inert to not affect the wine
- easy to remove
- cheap, recyclable and free from faults
Expensive
Does not fit perfectly on every bottles
The packaging operations
Pre-filling analysis
Must be done in the winery or at the laboratory to check that the wine is:
- Stable
- Conform to legal standard on SO2 and metals (copper, iron)
- Meets technical specification:
Volatile acidity, alcohol content, RS, total acidity, pH, Malic acid and lactic acid, stability analysis (protein, tartrate, microbiological), CO2, dissolved oxygen, taint (TCA, smoke)
Bottling
- traditional - minimal treatment
As wine’s natural dryness, acid and alcohol creates an hostile environment for the microbial growth.
- modern bottling - “aseptic bottling”
The bottles are steam-cleaned (82C for 20minutes).
The wine is freed from yeast and bacteria by:
1. Sterile filtration.
2. Heat treatment, flash pasteurisation. The wine is heated at 80C for a few seconds and cooled down rapidly, then bottled.
Filling other containers
Bag-in-box must limited the oxidation during filling to maximise the limited shelf life.
The wine:
- is already sterile filtered and sterile packed (by UV) .
- must have higher SO2, to counter oxidation.
- low dissolved oxygen level
- no ullage
Post bottling maturation
At the winery may increase the cost (due to storage and late investment return).
This is done in glass (impermeable to oxygen) and with an option for cork type and different OTR.
Ullage and oxygen dissolve in the bottle also plays a key part.
Cool dark place with constant temperature (10-15C) and constant humidity, lying on their side so that the cork remain moist.
Oxygen can be positive, primary aroma become tertiary aromas, tannin soften, oak compounds better integrates and the colour change (darker in white, paler in red).
Oxygen can be negative, as too little lead to reductive sulfur compounds aromas (struck match, smoke, rotten egg, cabbage).
Quality control procedure
Hygiene in the winery avoid contamination from organisms that can spoil the wine.
Winery are designed to facilitate cleaning.
This includes the use of stainless steel, hard non-porous floor that slopes to aid drainage, easy to reach/clean equipment.
Pores in oak continue to be a potential risk for spoilage organisms.
There are three procedures for hygiene:
- Cleaning
the removal of surface dirt
- Sanitation
the reduction of organisms to acceptable low level
- Sterilisation
the elimination of organisms (alcohol or steam)
Winery have detailed schedule for cleaning, sanitation and sterilisation
Quality control and quality assurance
Quality control is a set of practices that ensure good quality product.
Quality assurance is the way a business deliver a safe product and protect itself from legal challenges.
This documentation includes cleaning schedule, planning, monitoring, recording of key standards throughout the winery operations.
HACCP (Hazard analysis critical control point)
is a common approach to quality assurance.
It identify the risks, document how serious it is and how it can be prevented and corrected.
HACCP is carried out by the company, this is available for inspection.
Certification to ISO standard (international organisation for standardisation).
The ISO sets international standards.
The wine company ensure standards are maintained.
The certification body conducts external audits and ensure standards are maintained correctly.
Traceability
Is necessary to:
- respond to a complain
- prevent similar problems in the future
Transportation of wine
The options are :
In bottles (premium, super premium)
Adv
- Bottling, labelling and packaging can be done at the winery
Dis
- Higher cost due to smaller amount that can be shipped
- Higher footprint due to heavier weight
- Potential damage due to unstable temperature in transit, potential spoilage of the cable and bottle itself.
- Shorter shelf life due to bottling earlier
In large containers, bulk (inexpensive to mid price)
Flexitank (single use, recyclable plastic bag)
ISO tank (stainless steel vessel) have additional insulation, may have temperature control.
Adv
- Cheaper due to higher amount that can be shipped (one container holds 32000 bottle, rather than 12000 bottles).
- Lower footprint due to higher weight
- Stable temperature and reduced risk of oxidation
- Longer shelf life due to bottling later
- Adjustments may be done to key parameters at the point of bottling
Dis
- Bottling, labelling and packaging cannot be done at the winery, with consequent transfer of business and labour to the country close to the final market. Therefore, it is only available for larger brands.
