Category: Distillery

How Beverage Business Owners Can Achieve Financial Freedom

Cyndi
man enthusiastically jumping on high fist

By: Raj Tulshan, Founder of Loan Mantra

They say money can’t buy happiness, but it can help create peace of mind by alleviating stress in professional life – especially if you’re a business owner! Professional financial freedom means taking control of your finances and amassing enough cash and savings to manage daily operations, handle emergencies, drive growth, expand and maybe even sell the business one day.

  For beverage business owners, knowing that payroll can be met, a second location of your bar or location could be opened, staff and vendors can be paid – and there is still enough money set aside for any emergencies can provide stability. We’re all familiar with certain strip malls or vacant locations where different businesses seem to come and go, unsuccessfully. In contrast, towns and cities are identified by the bars, pubs and restaurants that are landmarks, meeting spots and seen as a local staple in their areas.

  Financial freedom offers a variety of benefits that go beyond financial control. A recent study by Harvard Business School found that having more money reduces intense stress, brings greater control, and leads to higher life satisfaction. Other benefits of financial freedom include improved mental health, better relationships, more opportunities, an elevated lifestyle and greater independence.

  The path to financial freedom. We all want financial freedom so how do you get there?

  Become a business owner. Simply becoming a business owner provides an essential freedom that can’t be explained unless you are one. As countless entrepreneurs attest, many people prefer to work for themselves rather than for someone else because they have more control over their future – and their finances. A Baylor University professor found that despite the challenges of business ownership – including long hours and high stress levels – entrepreneurs report consistently higher rates of happiness vs. people who work for others.

  Create a budget. Develop and stick to a budget. Outline operating income, receipts, expenses, loans, rent/mortgage, insurance, utilities, payroll, supplies, equipment, etc. Carefully track spending to account for every dollar. Negotiate where possible, switch vendors or gain better rates for your phone and cable services. Determine which of your products are the best (and worst) sellers and adjust stock accordingly.

  In addition to tracking budget, there are common questions each business owner should ask themselves to manage their financial health. For instance, do you have outstanding accounts? Do your clients pay on time? Have you spoken with your top clients in the past 90 days? Do you have your documentation prepared in case you need to apply for a loan? Loan Mantra’s financial health checklist is a great tool to monitor ongoing questions that will not only help you track your budget, but your continued success.

  Make it “to go” and be in the know. A report released in June 2023 by the National Restaurant Association found that more than half of millennials (62%) and Gen Z adults (52%) would pick a restaurant for takeout if alcohol beverage options were included. Currently only ¼ of adults order alcohol beverages online due to availability or state legislation, but that is changing leaving room for opportunity. It’s also important to know the upcoming industry trends. For example, that same report states that it reaffirms the associations predictions that local experiences would be this year’s hottest trends – 79% of beer drinkers would participate in a tasting event at a restaurant.

  Establish authentic customer relationships. According to the US Chamber of Commerce nearly everyone has been affected by Covid Fatigue over the past couple of years leaving people emotionally drained and physically worn out. As a result, consumers want their shopping and dining experiences to be easy, convenient and satisfying. Satisfied customers are repeat customers. In addition, customers are looking for a deeper emotional connection and a personalized experience.

  Use digital media. For brands to build and maintain customer loyalty, the digital experience matters but it must not make things more complicated for the consumer. Whether a customer is ordering online or on-site it must be intuitive and easy. People find the new hottest brew, bar or pub on social media so having a presence online is a must. Post images of the business with indoor/outdoor dining space, food and drinks. Post happy hours, specials, trivia nights, special tastings, etc. and publicize them. Encourage satisfied customers to leave reviews. Allow customers to order food or make reservations online. Make services like DoorDash or OpenTable available.

  Be frugal. Consider how business magnate, investor, and philanthropist Warren Buffett purchased a $31,500 home in 1958 and still hasn’t moved out of it, even though his net worth is currently $104 billion. He can obviously afford a bigger, more expensive house, but he’s famously frugal. Conversely, controversial rapper and designer Kanye West is known for his extravagant lifestyle. He lives in a $20 million mansion – and rented Madison Square Garden for a stunt with his clothing line – despite being $53 million in debt. In a bizarre move, he asked Facebook founder Mark Zuckerberg for $1 billion on Twitter.

  This is clearly an extreme example, but it shows how financially responsible Buffet amassed a tremendous fortune and achieved financial freedom, whereas financially irresponsible West spent money he didn’t have, wound up in massive debt, and begged a tech guru for a financial handout on social media. While you’re likely not in the same tax bracket as mega-successful billionaire entrepreneurs, you can learn a few lessons from them. Don’t spend more than you have. And keep your endgame in mind. It may be easier to save money when keeping your eyes on the prize.

  Invest.  Go for a long, slow simmer vs. a quick sear. Most investments are like an Italian grandma’s Sunday sauce – they need to simmer for a long time to be any good. Know that you’ll be in it for the long haul. This won’t be a quick sear type of situation, where your money will be tied up only for a short time. While there’s always some risk and market fluctuations involved in investments, putting some of your available funds toward stocks, bonds, mutual funds, Roth IRAs, 401(k)s and other investment opportunities can help grow your wealth and put you on the path to professional financial freedom. Talk to a financial expert about how to build an investment portfolio and choose the investments that will best fit your specific goals.

  Focus. Focus on factors you control. Over the past few years, we’ve seen headlines about banks collapsing, an impending recession, plummeting stocks, and other doomsday stories about how our financial futures are in crisis. Don’t panic. Everything that’s happening today is just part of the normal economic cycle. There will always be recessions, wars, and fluctuating interest rates. Take a deep breath. Unemployment is down. Banks are protected. There’s been recession chatter for years, and it hasn’t happened. Prices and the stock market will fluctuate over time, which is out of your control. Focus on what you can control on your path to professional financial freedom: creating a budget, saving money, and investing.

  Have an emergency plan.  Create an emergency plan, ensuring that you have enough savings to cover daily and unexpected business expenses. Without adequate funding in place for emergency expenses (the air conditioning breaks, the plumbing isn’t working, the roof leaks), as well as for the inevitable periods of higher spends (e.g. extra products and staffing around the holidays, etc.), you’ll get stuck in a cycle of borrowing to fund necessary operating expenses or to repair what has been damaged, rather than using capital to look ahead to the future.

  Find financial partners.  Who is your banker, attorney and loan officer? Does the banker have a vested interest in your community? What are the financials? Does the bank have good leadership? Do you have an attorney in case you need legal advice, or someone should make a claim against your business? What about a loan officer or provider? If you need assistance with funding to cover the business in a pinch, to handle an expansion or to keep you aware of current government subsidies that you might take advantage of.

  Having the right partners in place before you need them can mean the difference between a quick phone call and financial mayhem. Find a financial team that will be trustworthy, provide insight and are available when needed.

  You should have complete confidence in their knowledge, experience and capabilities. Talk to them about your business financial status and goals and create a financial plan to help you achieve financial freedom and long-term financial health.

  “For business owners, becoming financially free is a desirable – and achievable – goal,” Tulshan explained. “It takes dedication, determination, and consistency, but follow these tips and you will be well on your way to financial independence.”

About the Author

  Neeraj (Raj) Tulshan is the founder and managing partner of Loan Mantra, a one-stop FinTech platform that democratizes the loan process by providing corporate sized services and access to new entrepreneurs, small and medium sized businesses.

Scaling Production with Precision

Cyndi
manufacturing machine for beverages

By: Kris Bohm of Distillery Now Consulting

Many beverage businesses start off with the owners or the founders serving in production manufacturing and in sales roles. As the business grows it is no longer feasible for the founders to serve in many of these roles as the needs of the business change with growth. One of the challenges many founders face in scaling their business is maintaining consistent manufacturing practices when they are no longer the person who is responsible for those practices. Training for new employees in small businesses can sometimes be inconsistent or informal.  When training is not implemented cleanly enough that a newly hired employee can fulfill their responsibilities fully it can be frustrating for all involved. Lets take a look at some easy to implement solutions that can help your employees do the best job possible.

  One solution to this problem is creating Standard Operating Procedures (SOP). When you detail in writing each step of the manufacturing process in a document that is readily available to those performing the task, you should get more consistent results. Standard operating procedures can be tedious to create but will save you time in the long run and give your employees the confidence to perform complex tasks with ease. In the process of beverage manufacturing there are many complex steps. Without a set of standard operating procedures it can be extremely difficult for a new hire to fully grasp their roles and responsibilities.

  The optimal steps in training a new hire are the following. Create a written set of operating procedures that are clear and easy to follow. Review the SOP with employees and discuss the steps with them as well to confirm understanding. Once an employee has a basic understanding of the operating procedure the person training the employee along with the new employee should go through the process detailed in the SOP together. By having the trainer first complete the process while following the SOP it will fully demonstrate for the employee how the steps are done. This on hand training will often bring up questions from the employee being trained that might not otherwise come up. Once the employee being trained has seen the process completed following the SOP it is best for them to then complete the procedure outlined in the SOP in the presence of the trainer. It is critical at this step that the trainer does not work hands on with the new employee but is there to only observe and answer questions. If the trainer at this point feels that the employee grasps the SOP and is able to complete it then it is time to move on to additional training. Although this method of training can feel arduous and redundant for an employee, training like this will build their confidence in performing a task that may seem difficult for them. Training this way will also ensure that the manufacturing process will continue to be performed to the correct standards. Implementing a training of this type for all complex tasks will give the creator of the SOP trust in the individuals tasked with completing the process in the SOP.

 Let’s take a look at what a standard operating procedure looks like for a process in a business and talk about some of the key points that you will find in an SOP.

  Let’s go through the practice of generating an SOP:

1)   Go through the process yourself of completing the task that needs a SOP.

2)   Write down all steps and processes required to complete that task.

3)   If there are certain measurements critical to completing the task such as volume temperature or time, include this info in the steps.

4)   If there are complex controls or tools in the process include pictures to help further clarify the written steps.

5)   Place notes in the SOP if there are any hazards in the process or safety concerns.

6)   If there are many steps it can be helpful to add a checklist to accompany the SOP.

7)   Once the SOP has been written, seek feedback on it. Have another person read the SOP ask if they could perform the task.

8)   If the feedback is positive implement that SOP by training your employees.

9)   Put the SOP in a binder or place where it is nearby the location where the task is performed.

  This process of putting in the work to create easy to follow operating procedures, will make work better for everyone. An SOP will guide your employees as they do tasks and give them the confidence that will require less oversight by you. This does not mean that an SOP can replace a manager. The true purpose of an SOP is to provide a resource to ensure complex activities can be done correctly by all who perform it. As a business grows and scales new employees will need to learn how to do their job. The better SOP program you have the faster a new employee will be able to work independently.

Software Options Available for Breweries and Distilleries

Cyndi
woman swiping card in cashier

By: Alyssa L. Ochs

As the craft beverage industry continues to grow, many tech companies are focusing on the needs of breweries and distilleries around the country. There are many benefits to incorporating software into a beverage production business, including reducing human errors, automating repetitive tasks, getting staff organized, harnessing the power of data and ensuring quality control. Software is available for accounting, inventory, packaging, purchasing and scheduling. Breweries and distilleries also use software for sales, quality control and legal compliance. Mobile app software is an option in this industry, as well as all-in-one management software that takes a comprehensive approach and handles various functions. Meanwhile, some producers embrace a more manual process and rely basic spreadsheets and paper recordkeeping.

  So, what are today’s breweries and distilleries using for software, and how are those products working for them? Representatives from two breweries and two distilleries weighed in on this topic and told Beverage Master Magazine about their experiences with software. 

BOSQUE BREWING CO. Albuquerque, New Mexico

  One brewery that Beverage Master connected with on the topic of software is Bosque Brewing Co., which has multiple New Mexico locations in Albuquerque, Bernalillo, Santa Fe and Las Cruces. With a history dating back to 2012, it is one of the largest brewing companies in the state and has grown from a small startup producing 350 barrels the first year to more than 10,000 barrels annually.

Bosque’s production manager Tim Woodward told Beverage Master Magazine that his brewery uses Ekos for inventory and production management. He also uses a few self-built spreadsheets for forecasting, sales and analysis. The brewery handles accounting with separate software not directly tied to Ekos functionality.

  “Bosque has been using Ekos since 2015,” Woodward said. “At the time, it was very affordable and relatively simple to use. The tools in Ekos addressed what we needed most: inventory management. We are able to track inventory, manage orders, invoice sold product, track costs, review pertinent data and oversee production steps with relative ease.”

  But while fully functional, Woodward said he often runs into little “Ekos glitches” that can be frustrating, such as the services being laggy.

  “Cleaner, more functional report systems with intuitive interfaces would be wonderful,” Woodward said. “I pull a lot of data from Ekos on a daily basis, and sometimes manipulating the report parameters to pull accurate data can be cumbersome. Ekos has done a wonderful job developing product planning calendar with drag and drop features, which is very lovely. They have other modules, such as order hub and keg asset tracking, which we do not use or have not found to work with our particular business model but are helpful pieces. Another offering which would be nice is perhaps a more robust server system to support software operation.”

ALVARIUM BEER CO. New Britain, Connecticut

  Nick Palermo, the head brewer of Alvarium Beer Co., told Beverage Master about the software programs his team uses in New Britain, Connecticut. Alvarium launched New Britain’s first microbrewery, founded on the principle of creating an inclusive and communal taproom while revitalizing a historical city.

  On the brewhouse side of things, Alvarium Beer Co. uses Beersmith to fine-tune recipes and DIY templates on Google Sheets for its calendar and brewing schedule, individual brew sheets and inventory of raw materials and packing materials. Alvarium uses Google Drive to store nearly everything related to production, from brew logs to SOP’s, manuals, inventory and supplier contact information.

  “Beersmith is one of the founding tools that many brewers have used in a homebrew or production setting, allowing quick integration and easy ways to edit recipes with something that is fairly familiar and quick to learn,” Palermo said. “We ended up choosing to use Google Sheets and Drive because of the ability for company-wide visibility and editing capabilities.”

  “We are an increasingly growing brewery in Connecticut, and such quick growth over the last couple of years has led to use needing to be able to combat the ebbs and flows of this industry,” he said. “Whether we need to make a quick change to the schedule, edit a recipe from home or have different departments be able to access information without complication, we found our method has been working really well as we expand.”

  “I’d say the biggest challenge we face with our method is the need to manually enter all of our data and make changes in the templates as we see fit,” Palermo said when asked about challenges with Alvarium’s current software. “Lack of auto-entered data does take up a little more time when it comes to keeping track with inventory and can lead to some mistakes.”

  In the future, Palermo would like to see more flexible software plans for different brewery sizes and needs, with costs to match. He said that having a method to integrate software programs more easily into companies with a system in place or smaller staffing structures would also be helpful.

  Cherokee Robbins, the director of sales for Alvarium, told Beverage Master Magazine about software this brewery uses for other purposes.

  Robbins said that Alvarium uses Google Business software, such as Gmail and Google Drive for recordkeeping, Google Sheets for reporting and inventory and Google Docs and Google Calendar for events, appointments and employee schedules. She says these pieces of software are user-friendly, easy to access and meet requirements for digital storage. Alvarium uses Untapped for Business to store information about brewed beers, to allow customers to view beers and check in and to use the menu board to list available products. Robbins said this software is user-friendly and great for keeping track of customer reviews, archiving past beers and helping other businesses find products.

  Alvarium uses Square POS in the taproom for on-premise and online transactions. The team likes this software because it is easy to add, customize and categorize items with an online store that is set up as an extension for customers to shop. However, she has noticed that sometimes items can “disappear” in Square POS, or if they are intentionally hidden, customers can still find them online and order something that is no longer available. After experimenting with various email marketing platforms, the brewery uses Mailchimp for analytics and to monitor communications with its customer base. However, sometimes these emails have ended up in spam folders even after the team has certified and legitimized its domains.

  After interviewing approximately nine different CRM/ERP-related software companies, InSitu hit the four major categories of importance for Alvarium’s sales and distribution team: QBE integration for accounting, inventory management, mileage tracking and logistics for sales routes and customer relations.

“This is a relatively newer software for us, as we started using this in February of this year,” Robbins said. “There is much to learn with all of its functions, but there are times when we may have delayed connectivity issues with its integration to our QBE. Our account representative has been great with staying in communication and finding resolutions for us when we need help, so that is a huge plus. Sometimes support teams with software can be hard to get in touch with when you need something fixed right away.”

  Other types of software the Alvarium team uses include Adobe Illustrator for signage and labels, Canva for business cards and marketing and QuickBooks Desktop Enterprise for accounting and payroll. It uses Prolific as its delivery-routing software to optimize routes for delivery drivers with self-distribution, Eezycloud’s remote desktop for multiple users to access QBE and Workable and Glassdoor for job postings and recruiting.

  When asked what she would like to see in future brewery software offerings, Robbins said, “It would be ideal if all of the platforms we use can be lumped into one software for a brewery our size, especially because we have a hybrid business model with the taproom, self-distribution and now working with a wholesaler. I know there are options like Encompass or Lily Pad available, but those can be pricey and are geared more towards larger distribution networks. I have also heard of a few software platforms that other breweries have worked on creating themselves in the past few years that fit close to what we ideally would need, but there seems to be an important element missing such as integration to QBE, delivery routing software logistics or the CRM portion for our sales force.”

MUDDY RIVER DISTILLERY Belmont, North Carolina

  Caroline Delaney, co-owner and CFO of Muddy River Distillery, told Beverage Master Magazine how her company approaches software in Belmont, North Carolina. Muddy River is the oldest rum distillery in the Carolinas and launched in 2011 with 500 square feet of space in an old textile mill before growing its production from 35 bottles per day to more than 1,200.

  Delaney said that her distillery uses QuickBooks for accounting and payroll and Square for POS and retail sales. She noted that QuickBooks is straightforward for day-to-day accounting, and Square has the lowest credit card processing rates without a monthly fee. She was familiar with QuickBooks from previous companies and says while it can be limiting, the next step up in accounting software is much more expensive, and most offerings require contracts.

  Yet running sales reports with multiple customers, states and distributors can be tricky and lengthy, she said, plus QuickBooks raised its payroll fees this year.

  “It seems like once you are signed up with Whiskey Systems or similar systems, they have all your data and it would be hard to switch back or to another software,” she said. “And the monthly fees are quite a bit higher than POS systems, so that will add up. Since we were pretty limited here in North Carolina, we weren’t able to sell unlimited bottles and cocktails until late 2019. We are under construction on a building where we will actually have a bar and event space, so I am looking into changing payroll and POS systems.”

  Delaney shared that Muddy River Distillery does not use distilling software for federal reports but that her husband, Robbie, developed his own system for that purpose and is still using it with the distillery’s production manager. 

  “I know he has spoken to some of the companies, but has not made the switch because of the monthly fees and not wanting to get into a system and get stuck with them,” she said.

STILL 630 St. Louis, Missouri

  Another spirits producer that shared details about its software usage with us is Still 630, which makes award-winning, handcrafted spirits in downtown St. Louis, Missouri. David Weglarz, the owner and distiller of Still 630, uses as many organic, local ingredients as possible in his spirits, with an old-world double distillation method that captures all the flavors while consistently embracing the adventure of experimentation. 

  Weglarz told Beverage Master Magazine that he uses Google software for his distillery’s spreadsheets and recordkeeping. He chose this option and still likes it because it is free and not localized to just one computer that could be damaged.

  “It allows us to edit simultaneously from different locations, and since it’s not based on one physical computer, it’s more safely guarded against a catastrophic loss,” he said.

  However, Weglarz acknowledged that Google Docs and spreadsheets are not specifically built for distilleries, so challenges have inevitably occurred while using this strategy.

  “It’s just an excel-type format so I had to build my own spreadsheets to make it work correctly,” he said. “But I did that, and now I have my own personal distillery software. It’s certainly not as fancy and sleek as the pre-packaged software solutions, but it works and the price (free) is right!”

  In the future, Weglarz would like to see more cost-effective software options offered in the distillery industry. He says that his distillery is priced out at the moment, something many craft beverage producers can likely relate to.

Conclusions and Opportunities

  Based on our conversations with craft beverage producers across the U.S., a few things stand out about what is working for software and where improvements can be made. In general, craft beverage producers are pleased with user-friendly software that offers multiple applications, features analytics to optimize processes and gives multiple users access to shared data. Affordability is paramount for craft beverage producers, and if software seems too costly, they often settle for free solutions that require more manual entry and monitoring despite the extra labor and risks.

  There is a need and demand for software for small breweries and distilleries with limited budgets and modest distribution networks. Many current solutions cater to large operations and are financially out of reach for smaller and emerging businesses. Integration is important to brewers and distillers, yet many of these businesses feel that they understand their needs better than what any software provider could provide and prefer to take a DIY approach, creating their own internal systems to get the job done internally. Therefore, there are significant opportunities for software companies to focus on the basics and adjust their offerings with tiered options to connect with breweries and distilleries in mutually beneficial ways.

Cheers to New Beginnings

Cyndi

How Start-Up Distilleries Can Get It Right the First Time

bronze distillery machine

By: Cheryl Gray

Starting a new distillery can be a daunting task. Failing to do it properly will inevitably cost the owner time and money.  

  The industry is flush with experts to guide start-up distilleries in the right direction when it comes to equipment, building, layout, local health regulations and environmental requirements – virtually everything to consider when launching a well-tooled distillery.

  Few companies know better what a start-up distillery requires than VITOK Engineers, headquartered in Louisville, Kentucky. The global consulting engineering firm, launched in 1967, offers a singular source for multiple engineering disciplines and targets a wide range of chemical plants and manufacturing facilities, including distilleries.

  In its early days, VITOK Engineers was local. Still, its engineering expertise was far-reaching, with a client list that the company says included the United States Navy, for which VITOK designed and built CO2 scrubbers for the Navy’s nuclear submarines. By the mid-1980s, new leadership at the company introduced the distilling industry to VITOK, which already had a solid foundation for the design of a complete chemical processing facility. In the 40 years since, VITOK touts a solid reputation for designing and optimizing every aspect of distillery production, with more than 500 distillery projects sprawled across the United States, Canada, Mexico, the Caribbean and Africa. The projects range in size from small craft distilleries to more established facilities and some of the world’s largest and most recognized distilleries that manufacture up to 50 million proof gallons per year.

  CJ Archer is Vice President of Marketing for VITOK Engineers and has been with the company for nearly two decades. As an electrical and controls engineer licensed in more than 20 states and the Caribbean, Archer points out what sets VITOK apart from its competitors.

  “What sets VITOK Engineers apart from other companies is our ability to serve all engineering disciplines within our organization,” he said. “Continuity and flow of information between engineering disciplines is important for the successful completion of a large project.”

  Archer says that with distillery start-ups, it is important to gather critical information up front, beginning with what kind of spirits the distillery will produce and the proof gallon output the client desires.

  “Our engineers will then produce a Process Flow Diagram (PFD),” he said. “This helps to determine the vessel sizing, pump sizing, still size, boiler size and chillers.”

  The next steps, Archer says, are evaluating current infrastructure, such as available sewage, water and power, to help determine any additional power distribution equipment, water treatment or RO requirements that may be needed.

  “This PFD and supplemental infrastructure equipment will reveal the size, scale and types of equipment. From there, our staff can calculate and perform a Total Installed Capital Cost Estimate for the facility.

  VITOK Engineers can design and optimize every element of the beverage distillation process, from the receipt of raw materials to the proofing and bottling. Our staff can design the process, specify the equipment, design the building, define classified areas, specify and design instrumentation and controls and program the controllers, even tablets. We can also help you with the intricacies of environmental permitting.

  Our depth of experience enables us to provide clients with an expansive overview of projects, as well as a unique, cross-disciplined perspective on the design process. As an employee-owned company, the staff members of VITOK take a vital interest in building loyal client relationships. We are constantly striving to improve our services and technology while providing cost-effective solutions for project challenges,” he said.

  Archer points out other equipment and protocols distilleries can deploy to optimize production. Examples include automated control instrumentation, which serves the dual purpose of standardizing the process and freeing up labor. Another factor to consider is achieving maximum energy efficiency, which saves money. Archer explains that this means distillers will want to know if they can achieve an energy benefit from chillers, versus a cooling tower or aquifers. Examining the mash cooling systems and techniques are also on the checklist. Distillers may want to look at introducing solar to enhance so-called “green” branding, which Archer says is not a significant increase or decrease to the overall cost of implementation.

  Another point Archer mentions is installing power efficiency equipment to help save on energy costs. The power efficiency equipment helps distilleries coordinate with utility and correct for any apparent power overages. Also, comparing continuous operation, versus batch operation, as potential energy savings is another area to consider. Finally, Archer says that examining the number of shifts, timing and staging process of operations can help improve energy efficiency.

Another expert company that assists distilleries with installing equipment for both short- and long-term use is Trench Drain Systems, which manufactures and distributes drainage systems for distilleries, wineries and breweries. Engineer Michael Schroer started Trench Drain Systems in the basement of his home in 2004, selling only about three products. By 2017, the company had purchased a 10-acre property with office and warehouse space large enough to service a clientele that now spreads throughout all 50 states, Canada and the Caribbean. Schroer explains why his firm is different from others in the industry. 

  “When buying a drain system for your distillery, winery or brewery, you will most likely have to go through a distributor who interfaces with a manufacturer,” he said. “Your distributor usually won’t have the knowledge base to cover all the particularities of the drain and its installation. Trench Drain Systems is both a distributor and manufacturer of drainage systems. We have a full understanding of all brands of drainage systems. We can make custom drains when needed. We have a full engineering department and provide drawings for your installation, something that a distributor doesn’t do. In short, we are specialists in drainage systems. We have the flexibility to handle many product lines while being able to customize your drain when needed.”

  Schroer describes what key steps his company takes in helping new distilleries make the right choices when it comes to installing a drainage system that meets specific needs. 

  “I like to start this discussion by asking who owns the property where the project is being done. The reason being, if that facility is rented, the process is going to be a five-year project, and if the owners see themselves going to another location that they will own, the trench drain can be downgraded a bit. There will be differences in the drain channel chemistry, in general, when we are speaking about the drains of beer vs. wine vs. distillate manufacturing.  

  However, if you have a five-year lease on a building and have to foot the bill for the trench drain, consider a drain that will last as long as you need it. When you get into phase two of your project, where you own the building, it makes sense to have a longer vision for the drain design. That includes having a system that will handle the rough and tumble start-up period when construction equipment may be involved. It also is good to look at your future development when you may want to showcase your process and change your look from something industrial but practical to something more commercial or customer-friendly and aesthetically pleasing.

  After that detail is revealed, we need to consider the temperature and chemical demands of the process on the trench drain system. Breweries are the most demanding on drains, as they have high-temperature solutions and a wide range of chemicals that are put into the drain. And breweries will have differing drainage needs in different parts of the facility, depending on how the consumer will interface with the operation. Wineries and distillates don’t see the high volume of daily cleaning and temperatures as does a brewery. They generally don’t need drain systems that have high-service demands. Generally, these facilities have a lower drain budget unless the owner is going for an aesthetic, which costs more,” he said.

  Yet another company that helps new and existing distilleries make critical equipment choices for the long and short term is Della Toffola Group. Headquartered in Italy but supported in the United States by Della Toffola USA in Santa Rosa, California, the company positions itself as a global frontrunner in designing and manufacturing state-of-the-art technology solutions for a wide range of beverage products. Della Toffola recently entered the distillery market by acquiring Frilli Srl, another worldwide company founded in 1912 that specializes in designing, building and refitting distilleries and distillation systems.

  Experts agree that careful equipment planning is the key to a successful operation, no matter the size of a distillery or whether it is a start-up or a more established production house. Those experts also agree that success begins with a thorough consultation with a company that respects a distillery’s immediate needs and what it will take for the operation to expand.

Go BIG or Go Home

Cyndi

Selecting the Right Size Still for Your Distillery

brewing beer machine

By: Kris Bohm of Distillery Now Consulting

The craft distilling movement is growing larger every day in North america. In 2003 there were approximately 60 operating distilleries in the USA. Fast forward to today and there are over 2200 active distilleries. When it comes to starting a distillery one daunting challenge every business owner faces is equipment selection. Selecting equipment is often done by forecasting demand. Without any sales history this forecast is tricky to create. Most folks go about deciding what equipment to buy based on budget and what kind of quantities of spirits are expected to be sold. If you ask almost any distillery owner if they are using the same size equipment they started on they would tell you no. Nearly every established distillery has needed to add on additional equipment or sell their existing equipment to bring in larger equipment to meet demand. Selecting the right size equipment is a critical decision, which I would like to help you make. To better inform you let’s explore common equipment sizes and examples of distilleries expanding.

  The first question often asked by a new business in planning is how large of a still do I need?

The answer to this question will not be the same for any two people. Instead of trying to provide a definitive answer let’s talk about the potential output of different size stills. To first define the potential output it is essential to decide on product line up. The still used to distill rum is very different from that for vodka production. If you are planning to distill gin, you certainly do not want to use the same still for distilling whiskey. What I can tell you with certainty is that you will outgrow a homemade 50 gallon still before you even open the doors of your distillery to the public. Let’s also explore the potential output of stills to compare and contrast their potential capacity.

  A 100 gallon still often much less expensive than larger stills and is the size selected by some start up distilleries that are starting lean. A still of this size can only produce small quantities of distilled spirits at a commercial scale. Further a 100 gallon still requires considerable time spent in labor operating it with not very good returns for the labor. Although a 100 gallon still is going to be less expensive than bigger stills, it is likely that demand for spirits will outstrip the capacity of a still of this size quickly.

  A 500 gallon still has the capacity to produce a solid amount of distilled spirits. In fact a 500 gallon pot still is one of the most common size stills you will find in new craft distilleries. A still this size has the capacity to produce 2 barrels of whiskey per day if well managed. This is plenty of whiskey for a startup distillery. Depending on your business model a 500 gallon still may provide plenty of capacity for several years. A strong successful distillery will likely outgrow the capacity of this still within 5 years.

  Continuous column stills are measured based on column size diameter For simplicity we will call them column stills in this paper. An 18 inch column still will process 9 gallons per minute of wash. This means on a given work day this still has the capacity to produce up to 25 full size barrels of whiskey in a single day. As you can gather, this is vastly more efficient than a pot still.

For a column still to operate it will take a sizable quantity of mash to produce this much whiskey and therein lies the largest challenge for a small distillery. To grow into running a continuous column still requires immense resources in capital and real estate compared to a column still.  A distillery running a column still will need much larger, cookers, fermentors, heating and cooling capacity then is commonly utilized when operating a pot still.

  For many established distilleries who are selling a decent volume of spirits the addition of another pot still may not be the best choice to increase the production of your distillery. For many whiskey producing distilleries the logical leap is to grow your production by adding a continuous column still. If the intent of your distillery is to be a regional or multistate distributed business a column still might be your best choice.

Lets Look at Two Examples of Growth in a Distillery

  At Grand Canyon Distillery they launched their business in 2017 with a single 250 gallon still. With goals to produce grain to glass bourbon, single malt whiskey, vodka, rum and gin. These ambitious plans and diverse portfolio quickly stretched the limits of their production capacity very early on. Within 9 months of launching their spirits the distillery worked out a large distribution deal that landed them in nearly every liquor store and grocery store in Arizona. If the distillery was going to meet their growing demand for white spirits there would be almost no room to distill whiskey to age. With whiskey being the primary long term goal, an expansion of equipment was needed. To increase capacity Grand Canyon added additional distilling equipment far sooner than anyone expected. With the addition of a 500 gallon still to support the demand for production, the folks at Grand Canyon got back on track to be able to distill enough product to meet demand. Only 3 years after the second still was added to their equipment Grand Canyon added a 3rd still to increase capacity even further.

  At Finger Lakes Distilling they launched their distillery in 2008 with a single Holstein pot still.

Only 3 year after launching the distillery had outgrown their capacity to produce enough whiskey to meet demand. Finger Lakes took a big step up in production and added a 12” column still new cooker and larger fermentors to their equipment lineup. With the addition of this still Finger Lakes Distilling had increased their capacity 10 times. In the 10 years since they added this column still the distillery has consistently been able to meet demand with a much lower labor cost per proof gallon produced. In this example the addition of a column still allowed Finger Lakes to gradually increase their production without the limitations that come with a pot still.

  As new distilleries move from establishing their foothold in local markets to growing state wide and beyond. A strong growth in demand will often follow this growth in territory. In many instances especially with whiskey the demand will outstrip supply and action must be taken to increase production. For anyone who has been to any of the bigger distilleries in Kentucky or Tennessee, you would have seen that every big distillery operates a continuous column still for whiskey production. A continuous column still is vastly more efficient on many levels. Continuous columns have much larger output per labor hour and use much less energy than a pot still per proof gallon produced. Stepping up from using a pot still to a continuous column still is a logical evolution and is a step that nearly every whiskey producer will make at some point when they reach a certain size.

Is Your Brand Something to Talk About?

Cyndi
woman in shocked

By: Hanifa Sekandi

In the overly social world that we now live in, it can be hard to stand out. How does a brand become noteworthy? What makes a brand worth talking about?

  While you diligently craft your new alcoholic beverage, with hopes of becoming a formidable brand, it is important to remember as good as it may taste on the palate, it must also be as memorable to the imbiber. What do people see when they think of your brand? What feelings are evoked beyond an inebriated mind? Will people run to their local liquor store to purchase it? Now that production has finished, you know you have made a quality product. It is time to build a brand that is indeed something to talk about. 

  Fortunately, you have access to millions of people worldwide in the palm of your hand. One social media post can turn your brand into an overnight success. The truth is it does not happen overnight. There are strategies implemented before top-tier brands disseminate their marketing campaign to the masses. But, with just one post or compelling article written by a reviewer, a brand can quickly become a household name. Should you consider influencer marketing? It is an effective tool, but it is not necessarily the only way to spread the word. Instead, consumer reviews and testimonials are part of a long-term marketing plan for sustainable growth. View your customer as a micro-influencer who will host parties at their home, for example, and share your beverage with guests. They will also share photos and videos with their family and friends on social media. It is up to you to guide them, so let’s get started.

Build a Sustainable Strategy

  What most brands learned once social media became a tool to advertise is that it can be quite exhausting. Let us be honest; it is a free advertising tool that can yield impressive results when used wisely and innovatively. But guess what…social burnout is a thing! Most brands hit the ground running only to find out that they have run out of stamina and, more importantly, marketing content. It is important to build the ship before you set sail. Further, you must be building marketing materials that can be used for the entire year! If you are fortunate to hire an editorial or marketing manager, they will help you plan and execute marketing strategies that are viable daily, monthly and yearly. The biggest mistake that new and old brands make in modern marketing is thinking they can build as they go or create limited marketing resources. Remember, view your brand as a ship. Would you set sail with holes in your boat or without life jackets? Would you trust a captain who just goes where the wind blows or someone with skills, expertise and instincts? Of course, you will have to take risks, but your ship should still have an anchor. 

  So, how do you build a sustainable brand? Your first task is to discern the “why”? What makes your alcoholic beverage unique? Is it premium gin? Does your brand use sustainable production methods? Is it a family-owned business? You need to build the story to draw a connection to your brand. White Claw is a notable example of a low-cal RTD beverage that jumped in front of the line from what seems like out of nowhere. Their brand is built around a health-conscious consumer who enjoys drinking without worrying about the scale. They found their “why” and then focused on reaching their targeted consumers. Some consumers gravitate toward brands that have a compelling story. Some brands have attached their beverages to an impactful cause, pledging that a portion of their profits will go towards it. Back Country Brewing, a brewing company located in Squamish, BC, has effectively incorporated giving back to the community as part of its brand ethos. They have also effectively created a brand built off creatively thought-out branding. The continuous colorful and playful references to the outdoors are displayed on beer cans and paired with names that complement the brand’s rustic outdoors theme. Damn Alligator Just Popped and Don’t Cross the Streams are great beverage names that stand out but are in alignment with what their consumer would expect.

  Once you have figured out the “why” and what makes your brand unique, you can start to build marketing materials around this. It will also help you design a logo and select colors that you will utilize throughout your marketing initiatives. This stage is just as important as the product development stage. The same amount of care you put into ingredients, quality and taste must also be applied now. So, you are ready to get started. What is next? Consistency!

Stay Consistent

  Stick to your plan and only make minor adjustments. The foundation of your marketing strategy should be solid. It is okay to make minor variations, but your goal should be to build and evaluate your initial plan. It is easier said than done because this is a competitive industry. Do not forget your “why.” Focus on who you believe would enjoy your beverage and stay laser focused. Devise a marketing plan that includes a calendar that you religiously follow. Always be two steps ahead. What does this mean? Some months of the year have holidays or special days like National Pancake Day. When creating marketing materials with images, blogs and videos, mention and highlight these designated days.

  Unfortunately, there are no days off. There is nothing worse than looking up a brand online to find that they have not posted on their blog for a year or last posted on their social media a week ago. Curate behind-the-scenes features that allow your consumer to see how the beverage is made. You can also give them a glimpse into the trials and tribulations of your business experiences. Do you label your bottles by hand? Share this! It is easy to get discouraged initially. The idea that no one is looking will cross your mind several times. What you do not see during this time is the opportunity to push boundaries and try things that are out of the box before your consumer has an attachment to your product, and then there is little room for change. If you decide to build a blog to support your alcoholic beverage, view it as a mini-magazine and schedule a feature at the same time every week. Be sure to include it in your newsletter along with new product launches or sales. 

  As you build a consumer base, predictability is the only way to stay afloat. As stated above, White Claw appeals to the wellness consumer, and Back Country Brewing the outdoors consumer. There is no need to reinvent the wheel. Expand and elevate your initial marketing strategy. Add new elements or products that complement it. This will help you stay consistent, give you more time to engage with your consumers and build a brand that is not a one-hit-wonder.

Imagine Your Brand in the Future

  Where do you see your brand five years from now? Ten years from now? Do not get caught up in current trends. This is why a sustainable strategy and consistency are the gold standard. You may have wondered why that blush wine in the odd shape bottle still does well with little marketing. This is what long-term, effective brand development looks like. This vineyard’s goal was to design a bottle that was aesthetically pleasing to the eye so it would be a great decor piece, while at the same time elegantly displaying the wine. This is a brand that understands that it appeals to a consumer who likes the finer things in life. Consumers will stay loyal to a product because it is consistent and because they feel connected to the brand’s mission. 

  Will the consumer tire of your product in the summer? Or are you a lifetime brand, like many exemplary legacy brands built around sports or music? If you would like to be the go-to campfire brewer, keep an eye on this consumer’s changing habits and desires to grow with them. 

TAKEAWAYS

Strategy: A solid blueprint will steer you toward success.

Consistency: Keep going even when no one is looking.

The Future: Can you stand the test of time?

Greenbar Distillery: Going Beyond the Spirit

Cyndi
cozy cabin lounge

By: Gerald Dlubala

Located in the arts district of Los Angeles, the Greenbar Distillery operates in a historic brick building built in 1905 and positioned in the same diverse neighborhood that houses iconic residents like Warner Brothers Music, Soho House and Hyperloop. Intermingled with high-end coffee shops, trendy barbershops and homeless tents, husband-and-wife team Melkon Khosrovian and Litty Matthews transformed an old strip club into the Greenbar Distillery in 2011.

  “Our space is colorful, modern, vibrant and warm,” said Khosrovian. “It is multicultural and optimistic, invoking the classic positive vibe of LA, where people come to fulfill their dreams, whatever they may be. There are giant windows overlooking our production floor, so customers can see and understand what we’re all about. We were the first distillery in Los Angeles since at least the Prohibition Era. For the true cocktail lover, Greenbar Distillery was the only exposure to the industry for at least a decade, so we wanted to make sure that if cocktail lovers found us, we did the best possible job to make their cocktail experience positive and up to all of their expectations, while showing them what goes into running a distillery.”

  Khosrovian tells Beverage Master Magazine that the distillery came about out of necessity to keep up with the demand for their homemade spirits beginning in 2004. Neither Khosrovian nor Matthews had any actual distilling or spirits experience. They met in graduate school, and their experience with spirits was only from the consumer side of the bar. But within two years, their home distilling hobby blossomed and became more work than a hobby.

  “We were engaged and doing the normal family circuit, meeting each other’s families, relatives and friends,” said Khosrovian. “For us and our heritage, that meant hosting big gatherings with big meals and frequent toasts featuring our homemade, fruit-based, high-proof alcohol. Litty is a trained chef and foodie with an educated palette, and she considered our homemade alcohol to be slightly medicinal and, frankly, not very good. She would politely pick up her glass for the toast but set it down again without drinking. That was awkward for me, so I set out to make something she would enjoy by incorporating the same culinary skills and techniques she used to produce her amazing food. Additionally, we took trips to the farmers’ markets to find ingredients to add in different ways and improve our alcohol’s flavor and aroma. We had some success, which we quickly bottled for future family gatherings using homemade printed labels. The ultimate feeling of success was when family and friends asked for more, and then friends of friends started requesting bottles of our product.”

  Khosrovian said that interest in their homemade spirits sparked a serious conversation about which direction to take their success. Luckily for all of us, they chose to start distilling on a larger scale. The first step was renting a small space in a nearby town that allowed a slightly larger scale of production to satisfy the demand from friends and relatives but also allowed them to be able to connect with and supply some of the local bars, hotels and restaurants that had an interest in using their products.

  “This was pre-pandemic when 80 percent of our business was related to being used as a bartender brand in restaurants, bars and hotels,” said Khosrovian. “We had tried to gain the home drinker’s interest by putting recipes on our labels, setting up stands at stores with recipes that they could make at home and hosting classes and tastings to try and see where we could improve our marketing and increase bottle sales, but nothing seemed to work. Actually, the reverse happened, even though our drinks received rave reviews. We were totally baffled but finally realized the only way to pursue our dream of showing customers how to drink better and more interesting things using our products was to make it easier for the consumer and provide ready-to-drink (RTD) cocktails.”

  So, Greenbar started offering three spritz cocktails in cans, and as Khosrovian would later admit, that timing was crucial because shortly after, the pandemic closed the bars, hotels and restaurants, literally all of their income sources.

couple drinking happily together
SONY DSC

Pandemic Problems Lead to Successful Solutions

  “The pandemic took away our revenue stream, and since we already found that consumers were unwilling to put in the work to make our cocktails at home, our only choice at this point was to can our cocktails and provide them as additional RTD options,” said Khosrovian. “Initially, we made everything in-house, including vodka, but now our base alcohol is made to our standards off-site. We use the base alcohols to ferment things like rum and whiskey on site and then redistill things like gin, liqueurs and amaro using our unique flavorings. We initially made and carbonated our RTDs in-house and used mobile canners for packaging, but it became very costly and difficult to get on their schedule and adhere to their specified run sizes. Forecasting our needs that far in advance was also a challenge, so about two and a half years ago, we invested in a medium-speed canning line that allows us to do 100 cans per minute in-house, on-site. With a two-million-dollar investment in additional accessories, we can do everything in-house, from creating the spirits to creating carbonated beverages to packaging.”

  “Today, the RTD market remains about 75 percent of our business, and surprisingly, most of it is in the NA (no alcohol) market,” said Khosrovian. “That fact initially humbled us, but as we began to work with markets, who were quite literally our lifeline to the public, we saw that they were getting a lot of questions about NA or LA (low alcohol) options. Those markets were rapidly growing, but consumers wanted something different than only the juice additives or normally available seltzers.”

  Khosrovian said they dove into the NA topic to see if it was a legitimate option because the idea of cocktails without alcohol was unfamiliar to him.

  “We needed to know what the consumers were really after in these types of drinks,” said Khosrovian. “So, we talked to consumers who either drank alcohol minimally or not at all and found the qualities consumers were after in these types of cocktails were related more to the experience of drinking the cocktail than the actual effects of the alcohol.”

•   They wanted something that changed their mood. With proper flavoring and layering, consumers will respond to NA cocktails in the same ways they do to complex, layered, alcohol-based cocktails.

•   Consumers wanted something that reengineered their brains and jolted them out of work mode and into a more social mode, similar to the vibe that alcohol-based counterparts do.

•   They wanted something they could drink comfortably and slowly, changing the tempo and brain function to initiate a slower pace to their mental state and social interactions.

  “We began to ask ourselves if we could provide these things with NA cocktails and have them function and deliver the overall experience similar to their alcohol-based counterparts. The answer was obviously yes, because consumers are looking for more of these types of options. As a result, NA cocktails can be enjoyed more often and in more situations without the limitations or consequences of alcohol consumption.

Organics, Sustainability and One-Bottle-One-Tree

  Khosrovian tells Beverage Master Magazine that sustainability wasn’t a primary goal of Greenbar Distillery but rather an accidental, fortunate outcome of their business philosophy. In California, where the growing season is year-round, Khosrovian always requests the best aromatic and flavorful produce from partnering farmers. When he inadvertently received a harvest from a certified organic orchard without his knowledge, a batch of chocolate orange vodka was noticeably different. It was better, as in more aromatic and more flavorful, but different. That experience from a grower growing organic to make sure his farm would be a lasting legacy for future generations made such an impression because of the increased flavor and aroma that Khosrovian and Matthews immediately decided to use only organic ingredients from that day forward. But they also researched and learned more about implementing organic and sustainable practices in other production areas.

  “We applied this same way of thinking to our packaging, including bottles, printing, labeling, capsules and so on,” said Khosrovian. “We traditionally used heavyweight bottles with laminated labels on virgin paper that would last 100 years. But who would actually want to keep these things that long? We continually asked ourselves what else we could do to help. Both of our heritages have a tradition of planting a tree for every baby born in the family, and in a way, these bottles are our kids. So, we started a program to plant a tree for every bottle we sold, and the Greenbar name was born. It just felt right to give back for our success. We communicated this to all of our customers, and it sounded noble, but no one knew what it actually meant. We needed verifiable results, so after the first year, we hired agencies to determine what effect this action of planting high-canopy trees in return for bottle sales really had on our carbon footprint. In consumer terms, the results showed that if the average American drinks one and a half ounces of our spirits in a day, they are carbon negative for that day. It’s a little thing, but eventually, it adds up and makes a difference. Since 2008, we’ve planted over a million trees, equating to 10 to 12 million carbon-neutral people daily.”

  “So, now we ask, what has your drink done for you?” said Khosrovian. “We’re not revolutionizing or stopping climate change, but it’s something for the consumer to consider. We still have to deliver on our promise of drinking better and more interesting things with great taste, but if the consumer has a choice between products that give them the same or better experience, then maybe they can look towards products that go beyond the spirit and help out in other ways.”

Staying Within Yourself

  “I would tell anyone starting in this business first to get to know yourself and be true to your feelings because, in the end, that’s what you’ll end up doing,” said Khosrovian. “Don’t shortchange yourself or your possibilities because you don’t have to follow anyone’s footsteps in distilling. Grab your chance to be creative, and whatever you do will work and be satisfying. Some will like it, some won’t and that’s okay, but fakes usually don’t last. We’ve evolved over 18 years from helping restaurant, bar and hotel industries serve those who prefer to drink better outside of the home to helping customers drink better wherever they want to consume our products. We’ve learned things the hard way, but frankly, we got lucky on many business fronts as well. We are very good at manipulating and layering flavors to make our products delicious, flavorful and interesting to the consumer. In return, they appreciated and wanted more. Our love and passion come through in our products, so much so that as a loving gesture to my wife, Litty, there is a heart on nearly every one of our products, signifying how we got all of this started.”

  Khosrovian and Matthews also look for that same creativity, passion and willingness to play and learn in their employees. The freedom to express oneself and occasionally screw up is part of being a Greenbar Distillery employee. Khosrovian says mistakes happen and are okay because that learning experience will lead to improvements and ultimately result in happy customers.

Consumers Drive Future Goals

  “We will be going more towards the whole cocktail as our product versus only ingredients,” said Khosrovian. “This includes looking at RTDs in every format available, versus only base spirits. Our experience has opened our eyes to how much the customer is willing to embrace cocktails outside of the bar atmosphere, provided we can give them a similar experience and level of comfort. As happy as we are that the restaurant and bar world has returned, regularly going out to a bar can be inconvenient and expensive. We provide the best of the bar experience for consumers in every format possible, wherever they choose to drink better and more interestingly to enjoy our products”.

  Greenbar Distillery now makes the most extensive portfolio of organic spirits globally. Joining their TRU Vodkas are CRUSOE Rums, IXA Tequilas, SLOW HAND Whiskeys, FRUITLAB Liqueurs, CITY Gins, GRAND POPPY and GRAND HOPS Amari and BAR KEEP Bitters.

  “As a craft distiller, we always strive to meet the consumers where they are to ensure their craft cocktail experience is better, easier and more interesting.”

  For more product information, or to learn more about Greenbar Distillery, visit or call: Greenbar Distillery, 2459 E 8th Street, Los Angeles, CA  90021, (213) 375-3668, www.greenbardistillery.com

Carbon Dioxide & Nitrogen Play Important Roles in Craft Beverage Production

Cyndi
4 gas tanks

By: Gerald Dlubala

The production, delivery and packaging of beer and the use of gases like carbon dioxide (CO2) and nitrogen (N2) are inseparable. But because CO2 is also a natural byproduct of the brewing process, monitoring its levels during and in the delivery of draught beer is critical. Carbon dioxide has flavor characteristics that could cause your beer to undergo flavor changes if left unmonitored. Additionally, if pressures are left unchecked and become too low in the draught beer delivery system, the CO2 is allowed to leave the beer, causing the pour to be flat. Conversely, too high CO2 pressure results in over-carbonation, causing flavor flaws and a foamy pour. Either problem causes increased product usage and waste, increasing the brewery’s costs and decreasing an already thin profit margin.

Inline CO2 Sensors: Mettler-Toledo, LLC

  Dissolved CO2 sensors are inline sensors that continuously monitor dissolved CO2 in numerous applications, including the beer brewing process. Using dissolved CO2 sensors allows brewers to monitor key quality attributes of their product, ensuring a consistent product and all-important mouthfeel to their craft beers.

  Mettler Toledo offers its InPro5500i inline sensors, thermal conductivity sensors optimized for brewing quality control and monitoring the carbonation levels of the beer. The InPro5500i line uses digital technology to simplify handling, provide durable performance and offer increased product life, reducing lifetime sensor costs.

  Additional benefits and characteristics of Mettler-Toledo’s inline sensors include the following:

•   Helping the brewer maintain consistency and overall beverage quality control

•   Sensors are manufactured with a food grade, hygienic, intelligent design and diagnostics

•   The use of proven technology to accurately provide trusted CO2 measurement

•   Maintenance predictability

•   Process connection compatibility, available with three process connections: Variant Type N, TriClamp 2 inch and 29 mm with cap nut M42

For more information on Mettler-Toledo’s CO2 sensors, visit www.mt.com/analytical

Nitrogen Dosing for Shelf Life, Stability and Packaging Excellence: Vacuum Barrier Corporation

  While the applications for nitrogen dosing in the beverage industry have remained consistent, the products that benefit from being dosed have and will continue to grow. Cannabis-based beverages, the dramatic growth and variety of available RTD (ready-to-drink) cocktails and all nitro-style beers, coffees and teas benefit from nitrogen dosing in one way or another. Through its preservation and pressurization qualities, nitrogen dosing has allowed the explosion of new and flavorful RTDs to be distributed on a widespread basis to more markets. Pressurizing a can or PET (Polyethylene Terephthalate) bottle with nitrogen adds stability to the container, allowing for easier, more efficient and effective stacking and shipping. Additionally, the fact that nitrogen is inert and will not react with other substances or ingredients makes it ideal for use in beverage applications and industry because it doesn’t impact the aroma or flavor of the packaged liquid.

  “Adding a nitrogen doser to a filling line is a pretty simple process,” said Jim Fallon, international sales manager for Vacuum Barrier Corporation (VBC). “Our VBC dosers are designed to be bolt-on additions to a filler, with no requirement for complicated electrical or control integration. After determining the proper application for dosing, meaning pressurization, inerting or nitrogenating, the next step is to find the optimal location on the filler for installation. VBC application engineers also determine the appropriate dosing unit based on the available filler space, the brewer’s line speeds and the dimensions of the container that the brewer is using. Then, along with the doser, sensors and control panel, all that’s needed to start dosing is your power supply or compressed air supply, depending on the models used.”

  Fallon tells Beverage Master Magazine that the optimal amount of nitrogen dosing recommended for any application is found by looking at the associated needs.

  “In the beverage industry, these applications vary from pressurizing non-carbonated drinks for container rigidity to purging oxygen from the headspace for extended shelf life and nitrogenating a cold brew coffee or beer,” said Fallon. “VBC engineers collect necessary details about the container volume and dimensions, fill heights, line speeds and the brewery’s target specifications and goals. Equipped with that information, we can guide customers to the appropriate settings to ensure the dose is sized properly and, just as importantly, makes it into the container in a timely and consistent manner.”

  Fallon says that for many years, the only new advances in nitrogen dosing had to do with the availability of increased dosing speeds. But today, VBC dosing units can consistently and reliably dose up to 2,000 containers a minute, more than enough for most filling lines. Because of this achievement, VBC was allowed to shift its focus on advancing and improving the reliability and ease of adjustability of its dosers.

  “We’ve continued to build out the functionality of our Servodoser that we initially released in 2016,” said Fallon. “We’ve reduced the parts prone to wear along with maintenance needs of the long-life servo actuator, which has a cycle life into the billions. In addition, a servomotor on the valve stem allows for dose amount adjustment without changing any mechanical parts. These improvements reduce downtime and allow on-the-fly adjustment of dosing parameters. Vacuum Barrier’s modular aseptic dosing systems are quickly becoming the go-to design with OEM (Original Equipment Manufacturer) fillers integrating aseptic filling lines.”

  For more information on Vacuum Barrier Corporation and nitrogen dosing, visit www.vacuumbarrier.com

Gas Blenders for Draught Beer Delivery Solutions: McDantim, Inc

  To successfully dispense draught beer, you need pressure, and that necessary pressure generally goes unnoticed until something goes wrong. As far back as the early 1800s, that pressure was supplied by compressed air, but as all brewers know, oxygen doesn’t play well with beer. The solution to this dilemma was to use CO2, which was good unless you tried to use 100 percent CO2 in draught beer delivery systems that needed to push the beer over long distances from huge brite tanks that were only safety-rated for up to 15 pounds of pressure. Unfortunately, increasing pressure to push more beer only puts the tank over the intended safety rating or puts the brewer at risk of over-carbonating the beer.

  But by using blended CO2 and nitrogen gas technology in the appropriate amounts, breweries and taprooms can maintain and balance their beer storage and delivery systems to ensure the integrity of their draught beers glass after glass, maintaining product integrity without losing any quality of taste, aroma or mouthfeel, just as the brewer intended. However, premixed cylinders were found to be expensive and generally offered the wrong blend for the beer industry. McDantim Gas Blending Technologies was the first company to introduce a gas blender that was technically sound enough and appropriate for the beer industry. 

  “It started in the late 1980s,” said Kayla Mann, sales and marketing director for McDantim, Inc. “McDantim’s previous owner’s father was approached by Guinness to develop an on-site gas dispenser. Unfortunately, industrial blenders wouldn’t work well because they couldn’t handle low-flow needs. So, McDantim devised a blender optimized for low flow rates to ensure that the beer secured in your keg or brite tank is the same beer dispensed into the glass for your thirsty customers. Our goal is to improve draught beer consistently and continuously worldwide.”

  Mann said that McDantim Trumix® Blenders are generally maintenance-free, with a plug-and-play mentality that demands no electricity or cumbersome maintenance schedules.

  “The goal here is to set it and forget it,” said Mann. “Brewery or taproom managers already have enough on their plate without having to worry about gas blending. Trumix® Blenders are easy to install and set up with regulators and can be nestled in wherever a brewer decides to locate their gas storage. All our products are customizable for different CO2 and nitrogen blending needs, so no matter what beer you are brewing and serving, you’ll get what you need. We use six eager and local breweries as our testing grounds with our products, so we receive real-life and real-time situational help to ensure our blenders and products do what breweries need them to do. Our custom-configured blender solutions improve efficiency and decrease waste and are based on useable volume, including the length of delivery lines, the number of available taps and servers and the forecasted number of kegs per hour you can expect to use at any given time. It comes down to how many servers will be drawing out of how many taps simultaneously. Busy, large taprooms with several servers that stay busy for lengthy amounts of time will need a higher flow rate than the smaller craft breweries.”

  Mann tells Beverage Master Magazine that McDantim also offers a free downloadable app that can be used anywhere within the depths of a brewery because it needs no internet connection.

  “We’re all about education to improve the quality of the draft beer industry across the board,” said Mann. “The app is there for you to know what blend of gases is optimal for the beer you are producing or if you are struggling with pressure or specific lines. We can easily walk you through the app and teach you how it can help and improve your draught beer. It’s just another tool for everyone from the beginner through the seasoned professional, and it is valuable for those that may be hesitant to ask for help as well.”

Conditions included in the calculations are:

•    The beverage temperature in the keg.

•    The required keg pressure.

•    The CO2 content of the beverage.

•    Elevation above sea level.

•    The gas blend (CO2 percentage) of existing blender.

Your input conditions help determine the following:

•     The optimal CO2/N2 blend for your specific location and conditions.

•     What range of pressures you can safely apply to your beverages for optimal carbonation.

•     Easy U.S. and metric unit conversions.

•     The predicted CO2 content that will be maintained under unusual conditions, like high elevation production.

Additionally, McDantim’s free gas blend app includes helpful calculators for other areas of your draught beer process, including these:

•    The cost analysis calculator provides insight into how on-site gas blending with Trumix® blenders can save you money.

•    The gas usage calculator will forecast and determine how many kegs of beer you can expect to dispense using Trumix® Blenders or premixed cylinder gas.

•    The line restriction calculator helps brewers with their draught system design to get the correct restriction values to keep the beer from under or over-carbonation.

  McDantim’s Trumix® Blenders can be used equally well with all clean CO2 and nitrogen sources, including high-pressure cylinders, bulk tanks and separators. 

To contact McDantim or get more information on gas blenders, visit www.mcdantim.com

More Than a Pretty Face

Cyndi

Image Is Important, but so is Safety and Productivity

beer can lying on a flat surface

By: Cheryl Gray

While attractive packaging can draw new business for craft brewers, protecting what’s inside that packaging can make or break the bottom line. The same detailed attention is required to move products to store shelves swiftly. Fortunately, there are companies with specializations in each of these production areas.

  Among them is Industrial Physics, a test and inspection company considered to be a global leader in its field. Industrial Physics operates across a wide range of testing brands, each cornering a specialty. Those brands include CMC-KUHNKE, Steinfurth, Quality By Vision, Eagle Vision and TQC Sheen. Although it offers its customers multiple options, the company has a singular purpose: to guard the integrity of brands and products for manufacturers, production lines and laboratories across multiple industries worldwide.

  Steve Davis is the global product line director at Industrial Physics. He leads a team of experts who ensure that the company’s equipment protects the integrity of its customers’ metal packaging. Davis brings more than 20 years of engineering experience, with particular expertise in designing and developing metal packaging testing systems. He describes how Industrial Physics provides practical solutions for breweries large and small.

  “From seam inspection to label inspection, leak detection, code reading and abrasion testing, we’re here to protect the integrity of our customer’s beverage product.”

  Industrial Physics offers 40 testing applications and 2,500 products for a vast array of manufacturers, including breweries. Davis explains how the company leverages industry leadership to benefit its brewery clients:

  “The power and versatility of Industrial Physics allow us to support a broad range of breweries all over the world. And that really sets us apart from any other test and inspection provider. No matter the size of your brewery or the type of test you need to conduct, we can support you.

  The equipment allows organizations to test across a multitude of applications. Whether that’s ensuring that a can containing a fizzy drink won’t leak or that a cardboard box is strong enough to survive the turbulence of transit, the solutions are extremely diverse. We have a wealth of solutions available for the beverage space. From bottles to cans and kegs, we support beverage manufacturers of all sizes.

  But we don’t just provide equipment. At Industrial Physics, we’re equipped with some of the world’s finest minds within the world of beverage packaging and metal packaging. With an unrivaled portfolio of products that span so many specialties, we speak with our customers to ensure they’re discovering a solution that is suitable for their unique needs. With our equipment, we can help customers take their production and testing to the next level by investing in an instrument that will allow them to enhance their current setup and ultimately grow their offering by reducing waste and costs significantly.

  We also offer service solutions for our instruments, supporting customers with installation, calibration, preventative maintenance and repairs. No matter where you are in the world, we have local experts on the ground who can support your needs to ensure your instruments are operating efficiently.”

  One of the Industrial Physics brands is CMC KUHNKE. Davis describes its versatile options, all designed to save time and money:

  “Whether you’re a small brewery needing a compact and cost-effective solution like our useful CMC-KUHNKE seam saw, or a global giant within the world of beer looking for a more advanced, automated solution such as our CMC-KUHNKE Auto XTS, we can help you with this and everything in between!”

  Safeguarding the integrity of brewery products requires thought in every step of production. When it comes to keeping production lines moving swiftly and efficiently, Custom Conveyor Concepts promises to meet the needs of virtually any brewery. Matthew Gill, a co-founder of the company, has been in the packaging industry for some 40 years, working various floor positions before moving into management, sales and consulting. Gill explains how Custom Conveyor Concepts evolved:

  “In terms of the number of years in business, we are relatively new, as we were founded in 2015. However, Custom Conveyor Concepts (CCC) was formed after having been producing conveyors for more than 10 years for Exchange Team Advantage (ETA) and their customers. ETA was founded in 2005 as a used equipment supplier and OEM rep for virtually all aspects of liquid and powder packaging – depalletizing/unscrambling, filling, capping, labeling, coding, case packing and palletizing – literally, start-to-finish, turn-key applications. In doing so, we were requested to provide the connecting, often challenging, conveyor. After years of producing it for specific applications, the decision was made to make it available as its own commodity, and Custom Conveyor Concepts was born.”

  Gill emphasizes that his company’s products are designed to solve problems confronting breweries, whether accommodating tight spaces or tight deadlines.

  “We provide solutions. Whether it is space limitations, the need to expedite size changes or how to increase output, the only essentials required are your needs. Tell us what you want to do, and we will work with you to make it happen. We have worked with many startup companies, as well as very large, universally recognizable companies, and helped them grow. Our conveyors are versatile and expandable, as you can easily add, remove or re-route them. We only offer stainless steel, and our conveyors are constructed out of 11 ga., providing solid, durable equipment that will stand up to the harsh cleaning chemicals and offer ease in cleaning.”

  Gill adds that Custom Conveyor Concepts understands how to help breweries maximize their equipment investment while, at the same time, staying within budget.

  “We have worked with 600 cpm breweries down to 3 hd. fillers and manual crowners, when bottles were more prevalent. Our defining quality, in addition to the quality product we provide, is the attention we give to our customers and helping them achieve their needs, often providing options to help them stay within or define their budgets. We provide specialty equipment and service at ‘regular’ pricing. We don’t charge extra for non-stock items or detailed line layouts for placing the equipment. 

Our entire team’s product knowledge and industry experience are irreplaceable for providing application solutions. We do where others say it can’t be done. Many of our competitors don’t want to be bothered with small, low-dollar projects or small projects that require you to seek a solution. We excel at those.”

  Among the most popular products from Custom Conveyor Concepts are its serpentine conveyor and accumulation tables. Gill explains that while space is at a premium in most production facilities, it is more so in smaller operations. These two items, he says, offer ready solutions.

  “Utilizing a serpentine conveyor can convert the space a 5-foot conveyor consumes into 15 feet. The ability to make a roll change on a labeler without shutting off the filler makes the ROI for inline accumulation tables worth every penny.”

  Creating the bottling for breweries worldwide is the role of BPS Glass, a company based in Panama City, Panama, with its U.S. office in Atlanta, Georgia. As a family-owned business that began some 60 years ago, BPS Glass now boasts a reputation as one of the leading suppliers in the glass packaging industry. At its core is an emphasis on investing time, resources and effort in training its team members to create viable, innovative solutions for clients. Isidoro Cherem, a spokesperson for BPS Glass, says that the company works with breweries and distilleries that range from small craft operations to large commercial facilities. Cherem adds that dedication to optimal customer service sets the company apart from its competitors.

  “Thanks to our amazing team of experts and our commitment to excellence and creating long lasting relationships with our customers, we have grown to be the largest packaging supplier in the South and Central American region. We are constantly working towards expanding into the USA, and we are sure that we can replicate our success in the North American region.”

  BPS Glass offers more than 150 types of glass bottles for multiple industries, along with custom bottle designs. It also promotes services that include client-specific packaging and assistance with logistics to ensure timely, secure delivery of orders at the most cost-effective rates.

  Label design is another service BPS Glass provides its clients, with a focus on label colors and shapes, materials, textures and other aesthetic components. The company adds that it equips its clients with real-time marketing analysis, keeping an eye on marketing trends to help clients choose the right bottle, label and packaging for a product.

  Multiple choices in bottle closures are also on the company’s product roster. It points to its decades of knowledge in the chemical processes, physical considerations and industry safety standards to help clients safely package a product for consumers.  

  Whether using cans or bottles, breweries must factor in how best to protect the integrity of their product, both in terms of taste and safety of consumption. In addition, the efficiency of a production line depends upon investment in the right equipment that can move products swiftly and safely to store shelves. These considerations require the expertise of companies that know how to help breweries achieve these goals on time and within budget. 

Good Beer Makes Great Whiskey

Cyndi

By: Kris Bohm, Owner of Distillery Now Consulting

The idea to start a craft distillery can come from many places. If you talk with almost any brewer they will tell you the idea of a distillery is one they have considered. The tools needed to start a distillery are so similar to a brewery that much brewery equipment is identical to the equipment found in a distillery. Brewers who want to jump into making distilled spirits have most of the knowledge, tools and skills needed to manufacture spirits. One skillset brewers lack is in the art of operating a still but have no fear we are here to help. Let’s talk about selecting the right still for a brewery to make amazing, distilled spirits. Afterall good beer makes great whiskey so if you have a brewery why wouldn’t you do it?

Designing a Distillery

  As the dream is put down on paper and planned for the specifics start to come into play. Are you going to make whiskey, vodka, gin , rum or do you plan to make all of them? What do you want your still to look like? Will it be a shiny copper showpiece or a stainless economical work horse? What ingredients you plan to utilize to produce distilled spirits is very important to consider when selecting the right still design. The equipment for distilling potato vodka is very different from that used to distill malt whiskey. If you are unsure where to start here, this may be a good point to bring in an expert to help you make these choices.

Selecting the Right Still Size

  The first question many folks ask when selecting a still is something like how big of a still should I get? Should I get a column still or a pot still? What is more important to consider about how big is how small is too small? A common issue with many new distilleries is that they start off far too small. In fact some distilleries start so small that they outgrow the capacity to produce enough product within a year. The opinion held by most whiskey distillers is that a still any smaller than a 250 gallon will hinder your distillery from growing. Depending on the configuration of a still and the ABV of the wash a 250 gallon still can produce a single whiskey barrel per day. This key number is important to consider. Why this matters is that a larger still only costs slightly more than a smaller still. Secondly the larger your still is the less you will spend on labor per gallon of spirits produced.

Key Considerations

  It can be easy to underestimate the real quantities of spirits a distillery needs to produce to be successful. This is especially true if you plan to distill any spirits like whiskey or brandy that need to age for years before they are ready to bottle.

Some of the best whiskies from around the world like bourbon, or single malt whiskey spent years in the barrel before they were bottled. If the products you plan to make are going to taste as good as other products on the market they will need to age as well. There are no proven shortcuts to age spirits faster, but there are plenty of examples of so called “rapid aged” products that were not successful. The point of all this is that you have to plan years into the future. If you buy a still that can only produce enough spirits to meet the demand you are planning for today this still will not be able to make enough spirits to age to meet your demand several years down the road. The more whiskey you are putting in barrels every day the more potential you have to grow. To put a cap on growth by selecting too small of equipment can be a costly mistake.

  Selecting the perfect size still or stills is not an easy decision to make. There are a multitude of  factors that must be carefully considered to make these decisions with confidence.

Budget is the critical factor. Budget not only for the cost of the still but also other equipment needed to support the still is important.  A budget for operating expenses is also helpful as once you get the still it takes capital for raw materials, labor and overhead to operate the equipment.

  Another consideration to take in is the size of the facility.. If you only have 500 square feet of space for your equipment, then it is unlikely that a 500 gallons still is going to fit well into your building and still leave room for the operation to function. You should not select your equipment until you know the amount of space you have for the equipment.

  Production Goals are a critical factor that must be given thought and planning. If you want your distillery to be producing 1000 barrels of whiskey every year then there is no way a 250 gallon still can get the job done. Sizing the still for the long term production goals of a distillery will help you stay ahead of your growing pains. The size of the still will directly determine the quantities of spirits you can distill.

  Skilled labor is an essential part of the equation. For a brewery to make the best spirits possible it is a wise investment to bring in an experienced distiller to help guide the process and handle the distilling. Although there are many similarities between the brewing and distilling, there are also vast differences in the process and in the regulation of the industries. A skilled distiller will bring the knowledge and experience to the table to help you make the best whiskeys possible and also ensure it is done in a way that is compliant with regulations.

Lets Make Whiskey!

  Building a brewery is an expensive endeavor and most brewhouses in a brewery are not run constantly. The addition of a still can create the opportunity for a brewery to run its brewhouse more often to create distillers’ beer to be distilled into whiskey. This is good for the business as it can create greater economies of scale. To do this effectively is it paramount to select the right size still to meet your goals. This is a huge opportunity for most breweries and one that can create immense new value and also open new markets for a brewery. If your brewery is ready to take the leap into distilled spirits now is the time to do it. After All most brewers love a good whiskey and good beer can be transformed into great whiskey.