By: Alyssa L. Ochs
Bottling and canning are critical steps in the brewing and distilling processes, yet new ideas and industry trends are now influencing how beverage producers approach their packaging. Bottling still has its place in the craft beverage world for certain products and to adhere to consumer preferences. Yet more producers are turning to canning due to the reduced environmental impact, lower production costs and process efficiency.
Breweries and distilleries benefit from choosing packaging systems that allow quick adaptation and flexibility if their needs or customer demands change. That’s one reason manufacturers have created machines that can handle both canning and bottling processes with minimal changeover downtime.
Here’s a look at current bottling and canning opportunities and best practices to consider for modern breweries and distilleries.
Getting Started with Canning
Craft beverage producers typically get into canning to sell more products because it’s convenient and profitable to sell canned beverages to-go behind the taproom bar. Oktober Design, a Grand Rapids, Michigan-based can seamer company, told Beverage Master Magazine that a single-head canner offers a low barrier to entry into production canning. Oktober began online sales in 2016 and has a location in Sparks/Reno, Nevada to serve West Coast customers in addition to its vibrant West Michigan shop.
“Even a manually loaded seamer can seal over nine cans per minute, making it quick and easy to offer cans in display coolers, local markets and convenience stores,” said Dennis Grumm, Oktober CEO and engineer. “This lets you test how your products perform in new venues, offer distribution samples and try out different can sizes. It’s a tool you’ll wonder how you lived without.”
Grumm said that getting started in canning is surprisingly straightforward and that the most challenging decision is often choosing your initial can size. But if you decide to switch sizes later on, it’s easy to swap out the necessary parts to accommodate different cans.
“Ordering a can seaming machine and cans from our website is as simple as click and buy,” said Grumm. “We’ve also curated a wealth of how-to videos that cover everything you need to know. And if you have any other questions, we’re always just an email or phone call away.”
Examples of Canning Systems
Brewers and distillers have numerous options when choosing a new canning system. A good canning system will preserve the taste and quality of your products while extending their shelf life and boosting your brand reputation. With an effective canning system, you can customize your production, ensure proper hygiene, achieve consistent fill volumes, maintain consistent carbonation and continually deliver fresh products to your customers.
Pneumatic Scale Angelus, offers open-air CB50F and CB100F systems with magnetic flowmeter technology to fill up to 100 cans per minute. The company’s CB50C design utilizes counter-pressure filling technology perfect for ready-to-drink cocktails, hard seltzers and sparkling wines. Pneumatic Scale Angelus also offers a full rotary design with a compact footprint to fill up to 150 cans per minute in a smooth, continuous motion.
Regardless of your chosen company, there are two main types of canning systems: single-head canning machines and full canning lines. Single-head canning machines are great for smaller breweries because they are affordable and easy to use. While full canning lines are considerably more expensive, they take care of the entire process, from purging to filling and canning.
With an increasing number of beverage companies now canning more than just beer, it’s important to consider systems that can accommodate canned cocktails, hard seltzers, kombucha and cold-brew coffee. Look for canning systems that let you package various beverage types and fit into your space. Some canning systems support higher carbonation volumes than others, so assess the filling technology, tubing and flow control dials of the machines you are comparing.
Choosing a Can Seamer
A can seamer is a valuable piece of equipment in the craft beverage industry and might be the key to boosting your to-go sales without breaking your budget.
“Our most popular product across both breweries and distilleries is the Model 8 Automatic Can Seamer,” said Grumm from Oktober. “What varies is typically the can size chosen for different types of beverages. Craft breweries often opt for 16 oz. or the large 32 oz. cans, while premium beverages are often offered in 8 oz. or 12 oz, ‘sleek’ cans. The versatility of the Model 8, which can seal any can size, makes it the favorite in many craft beverage categories.”
Grumm said that many of Oktober’s machines have sealed hundreds of thousands of cans with minimal maintenance.
“A simple wipe-down every day and a dab of grease in a couple of spots periodically is all it takes to keep your seamer running smoothly,” said Grumm. “If anything does go wrong, it’s usually a quick adjustment or a small, inexpensive replacement part that we can guide you through replacing with common hand tools. After nearly nine years in the business, we still don’t need a dedicated service team, and we plan to keep it that way.”
Sustainable Bottling Ideas
One reason why breweries and distilleries are switching to cans is for sustainability. However, modern technology is paving the way for sustainable bottling systems that give beverage producers more choices without compromising their values.
Innovative companies are experimenting with alcohol bottles made from recycled PET, which are far lighter than glass and BPA-free. The British packaging company Garcon Wines makes these bottles flat so they fit nicely into cartons without extra packaging and in larger quantities on shipping pallets. PET bottles can often be refilled multiple times and recycled, offering shatterproof properties and lighter weight.
Graham Packaging sells recyclable PET cans and bottles for beer, wine and spirits. Its products have a proprietary barrier technology that provides excellent oxygen, carbon dioxide and light protection. Meanwhile, the sustainable bottles are easily accessible with recloseable screw caps and are easy to transport, lightweight, recyclable and shatterproof.
Another company, Frugalpac, makes bottles with 77 percent less plastic than a standard plastic bottle and that is resistant to humidity, spills, premature spoiling and breakage. The Carlsberg Group created a “green fiber bottle” made from paper, and other beverage organizations have been working toward creating totally organic paper bottles. Meanwhile, some craft beverage makers participate in BottleDrop Refillable programs to pursue sustainability goals while controlling supply needs and overcoming potential shortages.
Consider Contract Canning and Bottling
Many breweries and distilleries contract out their canning and bottling to an outside company. These companies often handle the entire packaging process for you and can provide advice about the best bottles and cans for your products.
Outsourcing this work can be beneficial because canning and bottling equipment can be prohibitively expensive and challenging to set up and maintain. Staff members must also be adequately trained to operate it safely and effectively.
To choose a contract canner or bottler, determine your budget and assess the menu of various companies’ services. If you don’t have the time, space or money to control your own packaging process, a contract arrangement may provide new avenues for experimentation and expansion as your business grows.
How to Boost Your To-Go Sales
To-go sales can dramatically improve a business and turn on-site consumers into brand advocates outside the tasting room. To-go purchases are investments in your brand, an opportunity for greater public exposure and ensure a higher likelihood of customer return.
Grumm from Oktober advises producers to use clear, engaging signage to inform customers about their to-go options and prices.
“This simple step can prompt impulse purchases and drive last-minute sales,” he said. “Train your staff to mention to-go options, especially when customers show interest in specific products. Highlighting that they can enjoy their favorite items at home can encourage additional purchases.”
Whether you choose cans, bottles or a combination of the two, it’s essential to research and understand what options are available and how they could affect your bottom line. As Grumm mentioned, simply having your staff members ask customers if they want to make a to-go purchase can create a huge jump in sales, thereby justifying a new canning or bottling investment in the long run. Research shows that customers who make to-go purchases are also more likely to return to your business, which is a great way to expand brand awareness and help it succeed. You can go one step further with this effort by creating attractive, eye-catching displays for your to-go products near the exit and offering discounts on seasonal products or rewarding loyal customers with special to-go deals.
