Keeping an Eye on the End Game

Precision in Bottling and Canning for Craft Breweries

beer automated machine manufacturing

By: Cheryl Gray

Savvy craft brewers want problem solvers on their team, especially when it comes to bottling and canning products. 

Industry experts specializing in bottling and canning needs for breweries tout the equipment and technology to handle these tasks for operations of any size.

  One of those experts is XpressFill Systems, a long-established player whose clients, the company says, know to expect cost-saving innovations from its products and solid customer service, particularly after the point of sale. California-based XpressFill was founded in 2007 and began with the idea of solving a dilemma for small-scale wineries stuck with trying to bottle their wines by hand. It continues to service the wine industry, which surrounds the company’s facilities in San Luis Obispo.

  Today, XpressFill manufactures bottle- and can-filling systems in its San Luis Obispo plant, using top-quality components made exclusively in the United States. Its fillers come in several models, including volumetric, level fill and carbonated technology. With affordability, compact design and ease of use among its top priorities, the company continues forging ahead with new ideas to keep pace with customer needs in real-time.  

  The XFW200C is XpressFill’s latest addition to the line of filling products. Its weight-sensing technology is designed to ensure accurate fill volumes that will hit their mark every time. The importance of this precision, of course, is to avoid spills and underfills, which cost valuable production time and loss of product. 

  Rod Silver leads the company’s Sales and Marketing Division. He describes how the XFW200C is ideal for 12-ounce to 16-ounce cans. An industrial-grade touchscreen display allows the user to enter the desired weight and the technology installed keeps track of how much product fills the can. A larger flow path gives the user access to a smooth fill along with the flexibility of filling containers with almost any product of choice, including those with some level of particulates, such as flakes or small seeds. In addition to processing beer, kombucha, juice and RTD mixtures are among some of the other options.

  Twin Monkeys Beverage Systems, based in Denver, Colorado, is the brainchild of Josh Van Riper and Brian LeFevre. Their attention-grabbing moniker, along with the duo’s business model of customer-focused design, has earned Twin Monkeys a global presence in the craft brewing industry, with customers throughout North and South America, Europe, Australia, Africa and Asia.

  Both Van Riper and LeFevre have engineering backgrounds. They are focused on designing the kind of automated canning systems that didn’t exist when Van Riper was brewing craft beer.

  “I started a brewery and quickly found there were not good options for buying automated canning machines for craft breweries then (2013),”Van Riper said. “I got Brian to come to the brewery to discuss this opportunity and we then started Twin Monkeys to make affordable, high-quality automated canning systems for packaging beverages. We’ve grown to a 30-person company in a 14,000-square-foot facility, and we have over 500 canning machines strewn around the planet. I’m an automation engineer who does mostly controls engineering and mechanical concepts. Brian is a mechanical engineer. Between the two of us, we can design automated equipment from the ground up.”

  Twin Monkeys Brewing Systems offers a full range of can-fill-and-seam machines. The company offers craft brewers automation options that provide access to in-house, integrated canning lines equipped with three critical functions.

  “We are singularly focused on canning machines that do three things: fill cans, put lids on cans and seal cans. We rely on other expert companies to do things like labeling, depalletization and brewing, and we want to just perfect the three things we do over and over. We’re also creating a new customer service paradigm to provide easier and more efficient access to our knowledge for our customers.”

  Van Riper says that customer service extends to helping clients integrate their systems with a wide range of accessories.  

  “Although we only make canning machines, we consider ourselves to be systems integrators and that means we sell and support a wider range of equipment,” he said. “This provides more of a one-stop-shop model for customers to lean on us for a variety of their equipment needs. We plant 50 trees for every machine we sell, and in 2021 we became carbon neutral. We do serious work, but don’t take ourselves too seriously.”

  The process of canning and bottling craft beer also entails protecting the integrity of the product before it hits the market. That’s the role of Industrial Physics, which brands itself as the world’s leading test and inspection corporation. Armed with a global network of technical and support teams, the company’s 75-year history in quality control has guided the testing and inspection experience for some of the largest beverage corporations in the industry.

  Industrial Physics has a presence in 75 countries, with manufacturing facilities in 13 locations. Through its vast portfolio of more than a dozen testing and inspection brands, including CMC-KUHNKE, Quality By Vision, Steinfurth, Eagle Vision and TQC Sheen, test and inspection solutions are deployed to ensure premium quality control for beverage packaging, materials and products. At the same time, the company assures clients of personalized solutions for their product needs. 

  Whether a small start-up or a global name in the brewing industry, Industrial Physics says its

Testing and inspection solutions cater to every need and budget. Steve Davis, global product line director at industrial physics, has more than 20 years of engineering experience. He leads a team of experts who ensure that the equipment provided by Industrial Physics does its job.

  “When you’re dealing with bottles, cans and metal packaging, you’ll need reliable inspection machines to ensure the quality of your drinks,” Davis said. “With Industrial Physics, you’ll improve the efficiency of your processes and improve your product, saving yourself time and money and, ultimately, you’ll keep your customers happier. Through our leading brands, including CMC KUHNKE, Quality by Vision and Eagle Vision Systems, we’ve helped thousands of beverage fillers and breweries to taste success.”

  Davis went on to say, “From seam inspection and metal can testing to an inline inspection of empty and filled containers, our devices offer unmatched innovation and help you meet your quality needs. We protect the integrity of some of the biggest brands on the planet, as well as hundreds of emerging brands and everything in between. But how do we do this? By providing first-class test and inspection machines and products that check the quality of your packaging, materials and coatings.”

  Davis provides an example.  “Let’s take seam inspection. Our CMC-KUHNKE Auto XTS is a state-of-the-art, fully automated seam inspection solution. There’s nothing like it in the world, and it has the power to completely revolutionize seam solutions for your production line. We also have a wealth of smaller solutions to fit different needs and budgets.”

  The company offers instruments designed to provide functions that include double seam inspection, non-destructive seam inspection, bottle, keg and can vision inspection, abrasion testing and headspace and dissolved oxygen testing. Customer service, Davis adds, is a priority at every point of the client experience.

  “We understand that being fast, efficient and truly reliable is critical when it comes to servicing the instruments that keep your business running. And that’s why we’ve established a global network of dedicated service specialists to ensure you have an expert ready and waiting at a nearby location who can offer you support.

  Wherever you are in the world, our experts are on hand to support your needs, whatever they may be. We know that having the right people ready to help is critical. It’s critical to delivering quality and speedy service that ensures your instruments can get up and running as quickly as possible. From installation to calibration, repair and preventative maintenance, we’ve got you covered.

  We’re also passionate about being there for our customers in a more holistic way. We don’t just provide products. We’re there as a true partner. We have a wealth of solutions available across the beverage space, from metal packaging to bottles, our instruments test across an incredibly vast range of applications for many different manufacturing and laboratory needs.”

  Canning and bottling craft beer is a process that engages the expertise of filling, packaging and protecting products. Selecting the partner for one or more of these steps is not only based on budget but also depends upon which companies can accommodate the individualized needs of a craft brewery, no matter the size. Another important factor, experts say, is which company will stay with a brewery for the long run, ensuring that it can accommodate growth while not compromising on quality control. 

Pioneering Spirit

By: Tod Stewart

The warm afternoon sun is making late-September feel like mid-August. I’m here at Dillon’s Distillery with one of its pre-bottled Manhattans in hand. Sure, the busy Queen Elizabeth Way highway – a stone’s throw away – is adding some traffic noise to the serenity of the whole experience, but I can live with it. I mean, I’d rather be near the highway with a drink than on it, given how traffic can turn this whole stretch of the Toronto-Niagara pipeline into vehicular sludge.

  Located in Beamsville, Ontario, about a half hour’s drive (depending on the aforementioned road conditions) from Niagara Falls, Pure Spirits Distilling Corporation – aka Dillon’s Distillery (established in 2012) – is one of Canada’s pioneering small batch distilleries. Founded by Geoff Dillon and his father, Peter (both of whom hold degrees in biochemistry), the distillery appears to follow a philosophy that is both focused and fun…and guided by a real passion for distilling.

  “I grew up with a father who was passionate about single malt scotch whiskies,” confesses Geoff Dillon. “When it was time for me to go to university, I decided to follow in his footsteps by studying biochemistry. During my studies I fell deeply in love with the art and science of distillation. Brewing and winemaking were one thing, but when it came to distilling, I discovered that the possibilities were endless.”

  Like many distillers in Canada, Dillon was intrigued by the concept of creating an authentic Canadian rye whisky (i.e., one actually made from rye). But by Canadian law, whisky needs to be aged a minimum of three years, so, as with many other distillers, Dillon kept the wheels on by diversifying its portfolio…and it would appear there’s nary a spirit he hasn’t taken a run at.

  “We’re big into the experimentation side of things, so there’s always new spirits going into bottles,” Dillon enthuses. And rather than operating in a self-contained bubble when it comes to measuring the success of this experimentation, Dillon relies on external input.

  “We have a program at Dillon’s called the ‘Sipping Society,’” Dillon explains. “Through this program we bring together a group of like-minded spirit connoisseurs who have a chance to trial some of our innovations before they hit the shelves.”

  Of course, being a small pioneering entity in a world inhabited by much bigger players introduced a number of challenges to overcome. These included dealing with not only punitive taxation rates (since they lightened somewhat in Ontario, but still not to the extent as in a few other provinces) but some rather odd rules that were in place at the time Dillon’s was getting underway.

  “You needed to have a larger-than-5,000-liter pot still to be allowed to open an onsite distillery retail store,” Dillon recalls. In Ontario, if we didn’t have that, we would have had only one channel to sell into.” Dillon’s team came up with a pretty clever workaround. Having a 5,000 liter still in addition to separate mash tanks would have been a prohibitively costly and space-hogging affair. So, in cooperation with the German company, Carl GmbH, the world’s first 8,000-liter hybrid mash tank/pot still was developed to save space and money while eliminating the need for separate components.

  However, distilling requires more than just equipment. It takes dedicated and knowledgeable staff.

  “Building a team who believed in the concept and vision was our priority,” Dillon recounts. “We are in this incredible area of Niagara, which is not just surrounded by wineries and breweries, but winemaking and brewing education programs. There is a local distillation program at the Niagara College, where we are able to pull some of the most knowledgeable people from the beer, wine and spirits industry. Once we had a foundation of strong and passionate people, we had to determine what we were going to make and how we would source the ingredients.” To that end, Dillon availed himself of local ingredients largely supplied by local farmers.

  “It has always been a priority for us to work with local farmers,” he reveals. “I feel very lucky we made Niagara our home. We are surrounded by our farming community that grows fresh ingredients for us so we can make the best and most unique spirits.”

  Besides developing a close bond with the farming community to source local ingredients, Dillon’s stays clear of any artificial flavors. “So, if it’s a year when yields are lower or something didn’t grow, it can limit our production,” Dillon admits, adding, “We can’t make peach schnapps unless we can get our hands on the right peaches.”

  When it comes to actual production, Dillon’s “keeps things simple.”

  Dillon reveals that every spirit “…is made from one of two bases: rye grain or grapes. We work with a handful of local grape-growers to grow enough wine grapes annually to make our Unfiltered Gin 22 and our grape-based vodka. This grape base gives a unique viscosity and mouthfeel to the spirits that only grapes can provide. Just about every other spirit we produce comes from rye grain, grown locally by our friends in Brant County, about an hour’s drive west of the distillery.”

  “For flavoured spirits like strawberry gin, we begin with our rye base then finish by macerating fresh, ripe strawberries grown by our neighbors across the street,” he said. “We do something similar for our other fruit spirits, like peach schnapps, cherry gin or even the walnut amaro.”

  The garden in front of the distillery that began life to supply the ingredients for Dillon’s absinthe has grown over the past decade and now supplies botanicals to a number of spirits, ranging from lavender to hot peppers.

  Even the barrels Dillon uses for maturation are unique. While some ex-bourbon barrels are used, other casks are made by a local cooper. “He makes them just for us,” Dillon reveals. “We pick the trees, and then they are made locally just up the road.”

  Besides small-batch distillates, Dillon’s crafts an ever-growing range of premixed cocktails with the assistance of, in Dillon’s words, “…some superstar bartenders that work exclusively for us. They help us make unique, delicious and proper cocktails.” There’s also a mind-boggling range of bitters, with flavors ranging from rhubarb to wormwood, fennel and ginger. “At Dillon’s, we are all about cocktails,” Dillon maintains. “Most cocktails have some form of bitters in them. From the very first day we opened our doors, we knew bitters needed to play a big component in what we are doing.”

  Definitely a man with a vision, Dillon has watched  the distilling landscape evolve around him, with his distillery being at the forefront of many positive changes. The evolution has been rapid over the decade that Dillon’s has been in business, to the point where Ontario has 45 such establishments, with that number continuing to grow. If you factor in “contract” or “virtual distillers,” that number swells to over 150. He also has plans to introduce a handful of new products to market, including melon gin, a seven-year-old single-cask rye, a cask strength rye and, as of this November, the return of a brandy made from local grapes. 

  Distillers and spirit aficionados south of the border might consider visiting their northern neighbor and drop into Dillon’s for a professionally made cocktail or a spirit sampling. I was fortunate enough to try the following:

  Dillon’s Niagara Peach Schnapps (Batch 4, 24% ABV):  Lighter, drier and more natural tasting than what you’d typically find, with subtle, fresh peach aromas, a clean, balanced palate and a long finish.

  Dillon’s Cherry (Batch 28, 35% ABV):  A gin base infused with local cherries, then lightly sweetened. A distinctly juniper-scented gin base isn’t overpowered by the additional aromas of sour cherry/black cherry. The slight bitterness of the fruit harmonizes well with the sweetness/spice of the base spirit. Try in a cherry G&T or a French martini.

  Dillon’s Single Grain “Three Oaks” Rye Whisky (Batch 20, 43% ABV):  Geoff Dillon’s dream was to create an authentic Canadian rye whisky, and he’s done so admirably here. Made from a mash bill of 100 percent Ontario rye and aged (as the name suggests) in a combination of new Ontario oak, new American oak and first-fill bourbon barrels, it shows classic, spicy/dusty rye on the nose, with a hint of dried citrus peel. Warm, round and balanced in the mouth, with layers of fruity/spicy rye, vanilla and caramel, it’s quite gentle while remaining elegant and complex.

  Nearby Niagara-on-the-Lake is a quaint little town that’s definitely worth visiting. In fact, stay for a few days for some winery/distillery/brewery visits, great food, interesting shopping options and beautiful scenery. I’d highly recommend making the 124 on Queen Hotel and Spa your base because it has great amenities and is close to everything – like Treadwell, a can’t-fail choice for local “farm-to-table” cuisine and an outstanding local/international wine selection. Although “authentic Italian” has come to mean many things, Ruffino’s Pasta Bar & Grill is definitely your place if you’re looking for the real deal. Formerly the acclaimed Stone Road Grille, it was reimagined (due to COVID, of course) as something a bit less formal, but every bit as enticing. It’s about a 15-minute walk from 124 on Queen (though the walk home might be a bit slower).

  Cheers, and I hope to see you up this way soon!

The Design, Production and Manufacturing of Flavored Distilled Spirits

5 Ballotin alcoholic bottles

By: Kris Bohm: Distillery Now Consulting, LLC  

Take a moment the next time you are in your local watering hole. If you peer at the bottles of spirits behind the bar, there is a particular type of spirit you are sure to find. It is not whiskey, nor rum, vodka or tequila. The bottle you will almost certainly find is some type of flavored spirit. Whether it is a peanut butter whiskey or raspberry flavored vodka there is a variety of flavored spirits to be found behind every bar. If you look around at a liquor store, you will find dozens if not hundreds of flavored spirits on the shelf. The spectrum of flavors is massive and it is well worth giving the concept of flavored spirits some consideration. Many successful manufacturers have found that flavored spirits can be sold in volume. Let’s look closer at flavored spirits and then take some plain old vodka to flavortown.

The Appeal of Flavored Spirits

  There are literally thousands of varieties of spirits that are flavored. From spiced rums to honey whiskey, and vodka in a rainbow of flavors, there are flavors galore. The process of manufacturing flavored spirits can vary widely for the type of product being made. Some processes are expensive, labor intensive and can be subject to seasonality of ingredients. Other methods of manufacturing are very simple with merely the addition of a flavor before bottling. You might be asking yourself at this point. What kind of flavored spirits should I make at my distillery? This is a tough question because no two distillers have the same answer. Let’s start to answer this question by looking at the way flavored spirits are perceived by folks.

  The average consumer chooses flavored spirits because it is easy to make a mixed drink with. A person who enjoys a cocktail often has little to no knowledge of how to make a good cocktail. This demographic of consumer will view products like a lemon flavored vodka as a spirit that can simplify the process of making a cocktail. For this example, let’s explore the humble vodka soda. This popular drink is commonly served as vodka, plus soda water, with a lemon or lime added to it. If we substitute plain old vodka for a delicious lemon vodka this product can be combined with soda water and simplify the process of making a cocktail by not requiring fresh fruit to be added to the drink.

  For some consumers the appeal of choosing a flavored spirit over a traditional spirit is both flavor and drinkability. Drinkability can be a bit fickle so let’s define “drinkability” for the sake of this article. Some consumers of spirits believe they prefer to drink spirits that are labeled as “smooth” or “easy drinking”. Spirits even at 80 proof can be perceived as hot or labeled as a spirit that “has bite” or that it “burns”. These descriptors might not be terms used by producers of spirits as fair adjectives to describe their spirits, but regardless the adjectives are often used by the general public. Many flavored spirits not only have flavors added to them, they also have sugar or other ingredients added to them that mask the detectability of the alcohol in the spirits. The addition of flavor and sugar to a spirit can make the spirit taste more smooth or have less burn to it.

  It has been proven in blind tasting panels that the addition of sugar to distilled spirits is quite effective at masking the perception of the alcohol in spirits.

This is a huge factor as to why flavored spirits are sold in such massive volume. Consumers who might not otherwise like to drink distilled spirits find flavored spirits to be more pleasant to drink.

How to Make a Flavored Spirit

Distilling with Real Ingredients:  Smaller craft distilleries will sometimes use fresh ingredients to produce a flavored spirit that is deemed “authentic” or “artisanal”. One example is a fresh lime vodka made by a distillery in California. This spirit is produced by macerating fresh locally grown limes in a neutral spirit then redistilling that spirit to produce a flavored vodka. This method is quite effective and the resulting lime flavored vodka is quite delicious. On the down side this method is labor intensive and subject to the seasonality of the fruit. This can create limitations in production capacity and in some cases be cost prohibitive to produce.

Extracts for Flavoring:  A method employed successfully by large distilleries to produce flavored spirits is the use of extract based flavors. Extract flavored products are built in a tank where a measured amount of neutral spirit has water, sugar and extract flavor added to it to create a flavored spirit. This method is simple, scalable and economical. There are several flavor companies in the US and abroad that manufacture extract flavors that are TTB approved and meant specifically for flavoring of distilled spirits. These extracts are easy to work with and can fast track the production of flavored spirits. This method is a very economical way to manufacture them, when compared to using real, fresh ingredients to add flavor.

Quality Assurance Process:  Quality assurance, also known as QA, is the testing of a product before it is released to the market. There are many pitfalls in this process that must be navigated prior to release. Once a concept has been created for the production of a flavored spirit it is essential that rigorous product development and quality assurance testing takes place. Testing of the spirits for faults, flaws or problems is essential to the success and commercial viability of the product.

  Let’s look at an example of a failed QA in product development. A distiller once hit upon the idea of a flavored vodka and quickly rushed to take the product to market. The product was a strawberry flavored vodka and it was made by soaking freshly picked strawberries in vodka, then filtering the vodka and bottling the product. The result of this process was a vodka that had a beautiful light pink hue and an aroma of fresh strawberries. The product was instantly a hit and the distiller sold lots of it through their tasting room and to distribution. Not long after the launch of this product the complaints began to roll in. Customers complained that their bright pink vodka turned an unsavory shade of yellow. Liquor store owners demanded refunds for the vodka. Upon tasting the ugly discolored vodka there were no flaws to be found in flavor or aroma, but the color was downright off-putting. In the end the distillery recalled and bought back the product and shortly thereafter discontinued the production of their strawberry vodka.

All of this could have been avoided if they had a better QA process

Legal Considerations:  There is some legal navigation required when it comes to manufacturing flavored spirits. The TTB requires a formula to be submitted and approved before that spirit is allowed to be sold.  Part of the TTB formula process is the review of the ingredients used in the manufacture of a flavored spirit. Ingredients used in a flavored spirit must be approved by the FDA as an ingredient that is on the GRAS (generally recognized as safe) list. It is important in product development that one makes sure the ingredients they intend to use are approved by the FDA and TTB for use in distilled spirits. In the case of using extract based flavors, these extracts should be TTB approved. Ask your flavor manufacturer in advance if the flavors they are providing are approved by the TTB. Some flavor companies have thousands of TTB approved flavors. This multitude of options afford a distillery the opportunity to make a flavored spirit of almost any flavor they can dream up.

Let’s Go to Flavortown:  Now you have a better understanding of a few methods used to make flavored spirits, along with some of the guidelines and restrictions around production. You have the basic tools you need to start working on producing flavored spirits at your distillery. There is a huge opportunity to sell flavored spirits and one that we encourage you to take. Flavored spirits are the gateway to flavortown and it’s a place many successful distilleries go. If you need some help making your own flavored spirits drop us a line.

A Closer Look at Celebrity Brands of Craft Spirits & Beer

By: Alyssa L. Ochs

Actors, musicians and other celebrities love craft beer and spirits just like the rest of us. Yet the difference is that they often have the means, resources and connections to make significant investments in the industry. An increasing number of famous individuals have been getting interested in the craft beverage business and putting their names onto labels of products they stand behind or perhaps have even helped create.

  Here’s what the celebrity craft beverage industry looks like right now, major players in this field and what there is to look forward to in the future.

Celebrity Involvement in the Industry

  Celebrities take a step away from their typical work to get involved with craft beverages for various reasons. Some have a true passion for the craft, while others are in it for the money or just looking for more exposure and additional ways to promote themselves. While some celebrities learn about the production process and engage in making beer and spirits themselves, others do little more than attach their name to a brand for cross-promotional purposes.

  Either way, celebrity-brand craft beverages are often unique because of their higher price tags and limited availability. Some celebrities use their beverage-related profits to benefit charities, and others use their star power to launch tasting rooms for VIP guests. However, there are unique challenges that come with producing, marketing and selling celebrity craft beverages that other beer and spirit companies may not encounter. For example, a beverage brand may suffer when an affiliated celebrity declines in popularity or is involved in a scandal. Meanwhile, a celebrity’s popularity may be affected if the beverage he or she promotes isn’t received well by the public. Some craft beverage fans believe that beer and alcohol belong to them personally and not the rich and famous. Therefore, they might be turned off by the concept of celebrity affiliations and avoid these products entirely.

  But for people who are loyal to certain celebrities or just curious to try celebrity-affiliated beverages, these are accessible products that can often be purchased in stores and online. More popular beverages are usually found in liquor specialty stores, such as Binny’s and Total Wine & More. But you might have to search for more obscure and exclusive celebrity-brand beverages online through sites like Cask Cartel and Sip Whiskey.

Examples of Celebrity Beverage Endeavors

  From musicians across all genres to television personalities and film actors, a diverse array of celebrities have been making their mark on the craft beverage industry in recent years. Some of these examples were limited editions that are no longer sold, while others are ongoing efforts that are changing the industry one bottle or can at a time.

  For example, actor and comedian Dan Aykroyd co-founded Crystal Head Vodka as a way to introduce additive-free vodka and bring more creativity to the vodka industry. Along with his business partner, artist John Alexander, Aykroyd envisioned a new kind of vodka without unnatural ingredients and has a true passion for the product.

  Several years ago, pop music star Justin Timberlake entered into a co-branded partnership with Sauza Tequila to create Sauza 901 silver tequila. The name 901 references the area code in Memphis, which is Timberlake’s hometown. Timberlake said that he developed a love for tequila after visiting Jalisco, Mexico and seeing the craftsmanship that went into each bottle of the spirit.

  Iconic hip hop legend Snoop Dogg partnered with his friend and co-founder of Trusted Spirits, Keenan Towns, to establish his own spirits brand. Known as the “King of Gin and Juice” because of his famous song of the same name, Snoop Dogg developed Indoggo Gin, which mixes seven premium botanicals with all-natural strawberry flavoring. In the past, the musician has also had marketing deals with the Corona beer brand, released his own rosé wine and made investments in the cannabis industry.

  Meanwhile, actor William H. Macy co-owns Woody Creek Distillers, which is based in Colorado and operates a distillery and tasting room just west of Aspen. Not only has Macy invested in the brand, but he has also rebranded himself as Willie Creeks, an alter ego who is a musician and offers life lessons that ultimately promote rye whiskey.

  Another celebrity who has been involved in the spirits industry is actor Ryan Reynolds. He teamed up with Aviation Gin in 2018 after falling in love with the spirit and investing in the company. Since then, Reynolds has become a co-owner of Aviation Gin and driven the creative marketing for the brand. In recent years, and staying true to the aviation theme, he and the brand have teamed up with businessman Richard Branson to serve the gin onboard Virgin Atlantic and British Airways flights.

  A financial success story in the celebrity spirits industry brings us to the actor George Clooney. The idea behind Clooney’s tequila brand, Casamigos, came about after he and his friend, Rande Gerber, were in Mexico and wanted to find a smooth tequila they could sip all day without the dreaded next-day hangover. This was back in 2013, but the friends still personally tasted every batch of tequila made four years later. The brand exploded in popularity, mainly through word-of-mouth and having Clooney’s name attached to it. In 2017, they ended up selling the brand to Diageo for $1 billion, which made Clooney the highest-paid actor of the year.

  Thus far, celebrities have been more involved in the spirits industry than in craft beer or wine. But to a lesser extent, those markets are also drawing the attention of the rich and famous.

  The late-1990s and early-2000s pop band Hanson, comprised of three brothers who love craft beer (now that they’re old enough to drink it), launched the Tulsa, Oklahoma-based Hanson Brother Beer. They created their own craft beer business in 2013 with their flagship beer, Mmmhops, a 7.5 percent English-style pale ale. Since then, the brothers launched the Hop Jam Beer and Music Festival, collaborated with other breweries to create unique beers and dedicated a portion of their beer-related profits to clean water wells in Africa through a nonprofit organization they created.

  Another celebrity beer collaboration involves The Grateful Dead and Dogfish Head Brewing, based in Milton, Delaware. The psychedelic rock band has been involved with the brewery since 2013 and has worked together since then to create a third version of American Beauty HazyRipple IPA. The band’s “American Beauty” album and famous track “Ripple” inspired the beer, which features the iconic Grateful Dead dancing bear image on the label. However, the band’s involvement with other aspects of the beer production process is limited.

  To show how diverse and widespread the celebrity beverage industry has become, here are some additional examples of celebrities and their affiliated beer and spirit brands:

•    Kenny Chesney – Blue Chair Bay Premium Rum

•    Kendall Jenner – 818 Tequilla

•    Marilyn Manson – Mansinthe

•    Dwayne ‘The Rock’ Johnson – Teremana Tequila

•    Mark Wahlberg – Flecha Azul

•    Curtis ‘50 Cent’ Jackson – Effen Vodka

•    Bryan Cranston and Aaron Paul – Dos Hombres Mezcal

•    Sean “Puff Daddy” Combs – Cîroc Vodka

•    Channing Tatum – Born and Bred Vodka

•    Drake – Virginia Black Whiskey

•    George Strait Código – 1530 Tequila

•    Bob Dylan – Heaven’s Door Whiskey

Considerations and Looking Ahead

  The celebrity-brand beverage industry continues to be exciting because there’s always something new in the works to look forward to. There is always a strong public fascination with rich and famous people, and that trend is not likely to disappear anytime soon. As an increasing number of celebrities enter this industry, the competition increases and drives the demand for superb product quality that goes beyond just a popularity contest of celebrity status.

  Yet there are significant legal considerations that celebrities must keep in mind as they venture into the beverage industry for the first time. Collaborative efforts between celebrities and spirit-makers can take on various forms. These include development deals that give celebrities greater control over the final product and endorsement deals that offer little more than using a celebrity’s name. Other deals involve simply using a famous person’s image to promote an existing brand all the way up to full ownership, in which a celebrity owns both the brand and the means of production.

  Specific state and federal laws separate the roles of beverage producers, distributors and retailers, which can make it challenging for celebrities to navigate if they want to be involved in more than one part of the business. Other issues that celebrities must consider before diving into the beer and spirit industry are background checks needed to obtain alcohol beverage licenses, the age of their target audience, morals clauses in their contracts and endorsement disclosures required by the Federal Trade Commission.

  Alcohol production is proving to be an enjoyable and profitable side gig for numerous celebrities interested in connecting with their fans in new and unique ways. But to get beyond the initial hype and keep craft beverage customers coming back for more, it is time to embrace the spirit of innovation and achieve long-term growth with products able to stand on their own, even without a familiar name and face behind them.

Enhanced Single-Serve and Ready-to-Drink Markets Need Updated Point-of-Sale Systems   

By: Gerald Dlubala

Whether online ordering for pick up, requesting additional items to-go or purchasing single-serve containers from a local market, these options reflect the alternative and increasingly essential revenue streams for craft beverage producers. Additionally, they have proved to be a popular and effective way for craft producers to get their products into the hands of new and potential consumers. According to data supplied by Arryved, a leader in Point-of-Sale (POS) systems for food and drink businesses, many of the consumers that participate in the online and to-go craft beverage markets are different than those that choose to frequent brewpubs, tasting rooms and taprooms in person.

  The good news for craft beverage producers is that participation in the single-serve, ready-to-drink and to-go markets continues to grow. Consequently, it makes sense to nurture those relationships and make the off-premises consumer experience an event that provides value and enjoyment while enhancing your bottom line. The proper POS system can do that.

Your Business, Your Point-of-Sale System: Arryved

  “Of course, there was a sea of change beginning with the pandemic,” said Nancy Trigg, chief people officer for Arryved. “It seemed like, over the course of one night, the brewpubs, wineries and taprooms all had to scramble and pivot business models to come up with a functioning online and to-go ordering system, as well as a safe and viable delivery or customer pickup option. Point-of-Sale systems had to evolve and quickly match that change in direction. In haste, many businesses simply installed a separate system for this newfound revenue stream. It all seemed good until the businesses realized that, in reality, they were using two separate systems pulling out of a single inventory base, causing supply confusion and accountability problems. Point-of-sale systems, like Arryved, that looked at the situation and responded in a more business-sensitive, proper way were the ones that not only helped their clients survive but also helped them grow their consumer base during the uncertainty and shutdowns.”

  Trigg says that a proper POS system is one of the most crucial tools a craft producer has to understand and analyze for how they are doing business, and she urges owners to approach their businesses with that exact mindset.

  “If you have the proper POS system set up for all of your revenue streams, including on-premises, single-serve purchases and online ordering with customer pickup, you will immediately receive valuable insights into what you are selling, when you are selling it and how your products are being used,” said Trigg. “Are some products more popular at certain times, like lunch or dinner? Are some being consumed more with food? Which beverages are more popular at which times? Are they being sold in smaller pours? Larger pours? Are certain products more popular for carryout over in-house consumption? For flight purchases? So much data related to your specific craft products concerning single-serve and online-ordering revenue streams can be harvested from the right POS system.”

  Trigg told Beverage Master Magazine that the applicable laws about these types of sales will generally stick around because of the great work from the guilds, communities and cities to help food and drink businesses remain afloat during the height of the pandemic. Now, craft beverage producers must have a POS system that integrates these transactions into their daily business practices by highlighting and providing data tailored to their specific products, customer profiles and unique business situations.

  “When craft beverage producers start packaging their products, the inherent level of their risk rises, if only based on the costs of packaging,” said Trigg. “That little extra risk can be just enough to inhibit the creative experimentation that makes up the backbone of what a brewpub, taproom or tasting room is supposed to be. But with the right information derived from an inclusive and detailed POS system, that risk is minimized. Now they can offer the right products to the right consumers at the right time, including single-serves, ready-to-drink varieties or a wide range of to-go flight-type options or mix-and-match packs tailored to specific tastes. Unfortunately, not many POS systems properly provide these types of flight tools or pick-six options within their makeup. Arryved does just that, providing the craft producer meaningful insights into what is and isn’t working, and when.”

  Trigg said that Arryved is a POS system genuinely built to care for an all-inclusive beverage program, including those that, either now or in the future, want the option to offer food sales. In addition, Arryved enhances brewpub or tasting room atmospheres by allowing its customers to order drinks to-go, online or in single-serve, ready-to-drink options.

  “There are always developing options within the single-serve and ready-to-drink markets that craft beverage producers need to stay aware of,” said Trigg. “This includes the growing popularity of flight options and different sizes of mix-and-match take-home packs that the customer can customize. Craft producers need a POS system that recognizes these trends and supports mobile guests just as well as it does with on-premises guests. Arryved supports craft beverage producers in all facets of their revenue streams, while featuring unmatched support for the industry. In addition, we stay engaged in the business sector and always have someone available to speak with directly.”

Ready-to-Drink, Single Serve and To-Go Markets Thriving

  The ability to try and enjoy craft beverage products off-premises was, and still is, a game-changer for many craft brewers, winemakers and distillers. For the past couple of years, these markets have helped many establishments remain open and proved they could be a robust, new revenue stream. Breweries have traditionally offered their products in growlers and crowlers so their consumers could enjoy the beer at home. Additionally, the popularity of individual can seaming devices, like those offered by Oktober Can Seamers, gives craft beverage producers more flexibility in to-go offerings and allows consumers more flexibility in how and where they choose to use the beverage.

  In its primary function, can seamers allow craft beverage producers to get their product out the door and into the hands of consumers for off-premises enjoyment. But Dennis Grumm, CEO and lead engineer for Oktober Can Seamers, told Beverage Master Magazine that many clients realize additional untapped revenue possibilities by canning beer, mixed drinks and specialty cocktails for to-go orders. Brewpubs, distilleries, and wineries can all use a can seamer to offer their beverages, unique brews and house cocktails on a to-go basis. It’s an economical and very effective way to get new customers to try your products while satisfying your current customer base. Distillers have had great success canning their best-known, ready-to-drink cocktails, but canning is also an effective way to offer seasonal or limited-release drinks and cocktails.

  Pouches are another way to get your product in the hands of consumers that would not normally spend time in your place of business or would just like to take your crafted offerings with them on the go. Pouches range from those in the refrigerator for individual pours of wine to the single-serve cocktail and wine pouches that resemble the child-friendly juice pouches. The benefits of using pouches include offering a resealable, portion-controlled package that reduces packaging weight by up to 94 percent and can be shipped and packed using fewer resources.

Enhancing the Single-Serve and Ready-to-Drink Market: O-I Glass

  O-I Glass, based in Perrysburg, Ohio, is looking to elevate the single-serve, to-go and ready-to-drink markets to better reflect the on-premises, brewpub and tasting room experience. Megan Henry is the global marketing communications business partner for O-I Glass. She told Beverage Master Magazine that they are transforming the to-go, single-serve and ready-to-drink markets by offering a new glass packaging alternative called the Drinktainer™ for these markets.

  “In an increasingly common world of to-go packaging, we feel that it’s time for craft beverage producers to elevate that part of their business and the consumer experience,” said Henry. “Growlers and crowlers are great, but they have limitations. As soon as you open them, you’re under a time constraint as to how long that product will be good. Using our wide-mouthed Drinktainer™, you’re promoting a sustainable packaging option with the recyclable glass and RipCap® closure, and you’re allowing the consumer to enjoy your products as if they were in your brewpub, taproom or tasting room.”

  Henry said that capacity and shortage concerns still affect many industry players, but those worries are not an issue with Drinktainer™, which is currently available in inventory.

  “We know that many beer aficionados prefer to consume their beer out of a glass, straight from the tap,” said Henry. “Offering to-go, single-serve options in a recyclable glass container is just a naturally better way to enjoy beer and craft beverages in general. Glass packaging provides great flavor retention in any environment and allows producers to feel more comfortable offering their consumers different types and combinations of products without the fear that alternative packaging, like plastics or pouches, will taint their beer, cocktails or wine. In addition, with the wide mouth (42mm), consumers get the deeper flavor and more robust aroma experience as if they would be drinking from a glass on premises.”

  Sustainability is a significant issue of consideration in every phase of craft beverage production, and the Drinktainer™ is a fully sustainable product, available in clear that is customarily used for beer and in a flint tone that highlights the color combinations of cocktails and other beverages. It’s sealed using a RipCap®, an easily applied and highly secure closure that O-I Glass believes brings a nostalgic feel to the products. Drinktainer™ has been successfully used to offer pick-six trial packs and beer flights, and it requires no other glasses or barware to enjoy as the beverage maker intended.

Find more information on the Drinktainer™ at www.o-i.com

TANK & TANK SYSTEMS: Streamline Production and Maintenance

2 huge brewing machines

By: Cheryl Gray

The tanks and tank systems that support the production of the brews and spirits of the craft beverage industry work to keep the quality and safety of those beverages on target.

  No matter the size or brand of the tanks involved, craft brewers and distillers want optimal results and a minimalistic cleaning and maintenance routine to ensure productivity goes uninterrupted. Some companies cater to the industry to provide multiple options.

  Among them is Quality Tank Solutions (QTS), headquartered 35 miles outside of Milwaukee. The company, founded a decade ago, is a stainless-steel tank manufacturer. Jimmi Jean Sukys is the

company’s owner.

  “We are about 100 employees in size and we serve the brewing, food and beverage, dairy and pharmaceutical industries,” Sukys said. “Aside from manufacturing, we also install and repair stainless steel vessels. Our talented engineering team helps you refine your process by increasing efficiency, quality and cleanability.”

  QTS provides a wide range of complete stainless-steel tanks and tank systems for craft breweries, whether it is a start-up or an established brewery. This includes custom-built brewhouses with two to four vessels of 3-1/2BBL to 100BBL in size. The systems are configured to accommodate any height or space restrictions. Standard construction offers features that include either manual or fully automated operation and either steam or direct fire. QTS also supplies brewhouse equipment, such as boilers, chillers, keg washers, bottling lines and walk-in coolers. Sukys explains what additional innovations set QTS apart, including the top-priority use of high-quality materials, efficiency and cleanability.

  “Our QTS cellar tanks are versatile and are completely customizable to meet your specific needs,” Sukys said. “The tank system industry has been around for some time now. What QTS has brought to the table, in just 10 years of service, is consistent and trustworthy results with emphasis on quality standards. Our tanks are engineered and manufactured in Wisconsin, USA using only U.S. stainless steel. Tank longevity is a priority. QTS is with you every step of the way. Even after you receive your tanks, we can help you install, repair or expand. Our expert team members offer amazing customer service.”

  Solid customer service and buying American-made products are among the reasons behind Potomac Distillery’s decision to buy tanks and tank equipment from Idaho-based Corson Distilling Systems, Inc. The Washington D.C.-headquartered distillery is the home base for Thrasher’s Rum, which takes its moniker from owner Todd Thrasher.  “I worked with Corson because I wanted to source American-made products,” said Thrasher.

Corson Distilling Systems is a family-owned business founded a little over a decade ago by brothers Josh and Tory Corson. Today, the company hand-builds each system from materials that include raw stainless steel and copper. The firm also turned to SOLIDWORKS Premium 3D design software to boost its output, streamlining the process of creating models and drawing files while supporting automatic configurations of equipment designs within the SOLIDWORKS products family. Combining the productivity of SOLIDWORKS with another technology solution, COUNTERPART ERP, shaved off a considerable workload and further streamlined processes for the team of draftsmen responsible for the products sold by Corson Distilling Systems, Inc.

  Breweries count on a variety of tanks and tank equipment to get their products out. That includes brew kettles, lauter tuns, mash tanks and more. 

  QTS brew kettles feature what the company describes as a steam-driven Omega Heat Transfer Surface Jacket. The company touts this feature as one that allows precision boiling designed to eliminate over-boiling, which can negatively affect the final product. In addition to some of the other features that are standard on QTS products, its brew kettle standard features include a vent stack with DMS drain, flanged and dished top head, shallow cone bottom and a vortex breaker. 

  Options include a combination brew kettle and whirlpool, so-called “China-hat” assembly, direct fire and vent stack installation. The company’s whirlpool tanks can either stand alone or be combined with other functions. They are customized to handle a brewery’s system capacity. Standard features incorporate many of those offered in other products by QTS, along with a feature known as Trub Guard. The whirlpool tanks can be customized to combine the functions of a whirlpool tank with a brew kettle.

  The company also offers steam-driven calandrias designed to achieve boiling point temperatures without using a heat transfer surface jacket. The calandrias are made of a cylindrical shell and a tube design that is custom-sized to meet the requirements of breweries of virtually any size. The calandrias feature an insulated shell and tube design, accessible flanged ends, a square tube frame with adjustable feet and an optional flexible design to fit a brew house.

  Mash tanks by QTS include standard features such as flanged and dished top head, turbine agitation, glass stop manway, tank light, side wall baffles, shallow cone bottom, NORD gear drive, removable CIP assembly, steam jackets and, of course, 3-A standards. Options include a combination mash and lauter tun, a hydrator and a knife gate.

  The company’s lauter tuns incorporate a tight wedge screen wire fit at the bottom of the vessel, which is designed to eliminate the possibility of the screen bending under the pressure of a heavy mash bed.

  This tight tolerance design prevents excess grains from seeping through the screen. Features of the QTS lauter tuns include gear drive and agitation, which are configured based on the size of the vessel. Other standard construction features include a freeboard above grain bed depth, flanged and dished top head, shallow cone bottom, rake assembly with plow bar, glass top manway, tank light, removable CIP assembly, rectangle side entry manway and wedge widescreen false bottom. Optional features are a combination mash and lauter tun and underscreen CIP.

  Lager tanks designed by QTS feature a horizontal design that the company touts as more efficient since the tanks have more surface area coverage. The lager tanks feature flanged and dished heads, an insulated vessel design, a heat transfer surface jacket, a quarter-inch thick formed saddle with adjustable feet and an oval swing-in manway. They also have a removable CIP assembly with a “whirly spray” device and come fully equipped with a PRV, sample valve, butterfly valves and a CIP accessory. Available options include a stacked tank design and a visual sight gauge assembly.

  For distilleries, QTS offers custom-made hot and cold liquor tanks with features that include flanged and dished top heads, an insulated vessel, a round cross-arm manway, a heat transfer surface jacket, overflow control, F&D and flat-pitched bottoms.

Options include a visual sight gauge and an immersion heater. 

  One QTS product used for adding ingredients during the brewing process is the QTS Q-Bot. It can be used as a dry hop or slurry vessel. The tank’s flexibility helps in the work of adding ingredients at different points in the production process. Among its features are a shallow cone top head, a 24-inch round pressure manway, interchangeable perforated baskets in sizes of one-eighth, one-fourth and one-half inches, a tangential side inlet, a rolled push ring and caster wheels.

  Cleaning tanks and the accompanying equipment are very important, not only for protecting the investment in production, but also for protecting the distillery products. At Potomac Distillery, Thrasher favors a non-chemical approach to cleaning his tanks, which he says are all jacketed.

  “We clean the still and fermentation tanks about once a month. We typically use a combination of water and citric acid and then clean again with distilled water.”

  Experts say that designing, manufacturing, installing and maintaining tanks and their accompanying equipment is done with a combination of craftsmanship, innovation and ever-evolving technology. The aim, of course, is to preserve the products that craft brewers and distillers pour their time and resources into making and getting ready for market.

Inviting Sustainability into The Vodka Industry

a lone white flower

By: Tina Karras, Founder & Owner — Tina’s Vodka

As a founder and owner of a vodka distillery, I regularly contemplate our industry’s sustainability. I want people to have what they enjoy, but I also want a future for our planet.

  The process of sourcing, making, and packaging alcohol has environmental implications that we can no longer afford to ignore. It varies by the liquor and production method, but the Beverage Industry Environmental Roundtable’s research reveals that each 750-milliliter bottle of liquor produces an average of 6.5 pounds of carbon dioxide into our atmosphere. This cannot continue.

Sourcing Sustainable Ingredients Through Regenerative Agriculture

  I’ve always been disheartened by the nagging fear that nothing I did as a single business owner would impact the global environment. However, after watching the documentary “Kiss the Ground,” I am hopeful at last. This film asserts that if we commit to changes that regenerate our planet’s soil, we will simultaneously balance our changing climate, replenish the Earth’s water supply, prevent species extinction, and raise more abundant crops. Here, at last, is a film with solutions that leaves me optimistic about our planet’s future.

  The documentary inspired me to embrace regenerative agriculture in my vodka production process and spread the news to others. This type of farming is not new by any means. Instead of industrial farming methods that deplete the land with a lack of biodiversity, pesticides, and fertilizers, regenerative agriculture applies traditional farming methods to maintain healthy soil, plants, and water. It seeks to reverse environmental damage through no-till systems, crop diversity, planned livestock grazing, and biosequestration (the method of trapping and storing carbon in plants, microbes, and other organisms).

If We Implement These Solutions, We Will See A Rapid Shift In Our Planet’s Health

  Regenerative agriculture is the simplest way to heal the soil, and soil health is the key to solving the climate problem. If every alcoholic beverage producer sourced grain from fields farmed with regenerative agriculture and bio-sequestration, massive amounts of CO2 would be drawn down into the soil and out of the atmosphere. Tilling fields for corn, wheat, barley, rice, and other ingredients we source for our products releases massive amounts of CO2 into the atmosphere. No-till plows can plant those seeds without allowing CO2 to escape. The healthy soil that resulted would capture carbon and reduce runoff. If we keep the soil covered and healthy, CO2 remains in the ground where it belongs.

Resistance to Regenerative Farming and Organic Ingredients in the Liquor Industry

  Leading scientists and soil experts claim that capturing atmospheric carbon and replenishing the Earth is possible with the technology we already have. Unfortunately, this type of farming faces strong opposition, and many remain resistant to change. I haven’t yet seen regenerative agriculture become a significant part of the spirits industry. Perhaps this is because organic, non-GMO corn is simply more expensive to produce than GMO corn.

  Today’s farmers are able to keep the cost of industrial agriculture low through the extensive use of harmful chemicals. These become necessary because their way of farming creates an ecosystem centered around only one crop. Over time, it depletes the soil of nutrients and throws the environment out of balance. Natural ecosystems are filled with a variety of plants and animals, each designed to keep the others in harmony. When massive amounts of one plant cover an area, it is natural for predatory insects and weeds to move in and take advantage of the surplus. In an effort to protect their crops, farmers spray tons of poisonous pesticides and herbicides on the fields. To replace nutrients in the soil, they turn to harmful fertilizers. 

  For example, glyphosate has had a major impact on the production of corn for vodka. For over four decades, this chemical has been the leading tool farmers in the United States used for killing weeds before planting their corn. According to the United States Department of Agriculture (USDA), glyphosate — the main ingredient in Roundup — has become the most widely-used herbicide in the US since 2001.

  The problem was that this chemical killed all plants indiscriminately. In response, scientists created “Roundup-Ready” crops in 1996. Genetically engineered plants were then able to tolerate the herbicide. After this, farmers could spray their entire cornfield without worrying about being selective. Today, farmers who grow Roundup-Ready GMO crops use glyphosate as a desiccant to speed up their harvesting timetable. Spraying their plants with the herbicide kills the crop, causes it to dry out sooner, and produces more consistent yields. This allows them to harvest crops as much as two weeks earlier than they could have otherwise, which proves to be an advantage in colder climates.

  Exactly how glyphosate impacts long-term human health is still being debated, even though its use has increased almost 20-fold during the last two decades. The World Health Organization’s International Agency for Research on Cancer (IARC) declares that glyphosate is a carcinogen. The IARC also claims that Roundup is linked to Parkinson’s disease, Alzheimer’s disease, and autism.

  Regenerative farming employs biodiversity to control weeds and pests. It is more expensive, but the cost is worth it. When spirit brands embrace this way of farming, they discover exciting benefits. In addition to the environmental gains, they will also be pleasantly surprised by a vast improvement in the quality of their product. Vodka made with organic corn and without added sugar simply tastes better, since it has its own natural sweetness. There are no additives — just organic corn and water.

  The best way to ensure the corn and grains sourced for the production of spirits are organic and farmed sustainably is to purchase them locally. Eliminating the need for transporting large volumes of grain over long distances is also a way to reduce the liquor industry’s carbon footprint.

  Despite the cost, a growing number of farmers are looking into the possibility of producing their crops with sustainable farming methods and regenerative practices. Because of the damage that has already been inflicted on our planet and the harmful practices still going on today, regenerative farming requires commitment. Some of these farmers have to spend up to three seasons restoring the soil in their fields. On top of this, many are forced to plant a 25-foot buffer crop to block the overspray of pesticides from neighboring farms. It is time for the liquor industry to show these farmers our support.

  Farming is inherently risky, and farmers are resistant to change. When you ask them to do something they have never done before, especially when neighboring farmers aren’t doing it, you are asking a lot of them. It’s hard for farmers to learn new techniques because so many of them are already working another job to avoid losing their farm. Greater education is key to getting more farmers to adopt regenerative practices.

  The best means of persuading large farms to commit to regenerative agriculture is by demonstrating that it makes financial sense. If large distilleries can work out long-term contracts to source grains directly from the farm, it could be a win-win scenario for both parties. The distillery could share a regenerative story about the farm and about their product. Likewise, if a farmer knows there is demand for sustainable ingredients, they will be willing to meet it. There are so many positive stories that can come out of these partnerships.

Reducing Waste in the Distilling Process

  Sourcing quality ingredients is paramount because it offers us a chance to restore our planet’s health. However, the most unsustainable part of liquor production is distillation. It leaves us with waste products that are harmful to the environment if not disposed of properly.

  Inspired by shortages during the Covid-19 pandemic, some distilleries began turning these waste products into hand sanitizer and are still doing so even after the commercial producers restocked the shelves. I have known certain distilleries to give away a bottle of sanitizer with every purchase.

  Distilleries are also forming partnerships with industries such as fish farms, livestock farmers, and bakeries to put waste grain and water products to good use. At TimberFish Technologies, spent grain is converted into fish food and pumped into growth tanks brimming with speckled trout, Atlantic salmon, and shrimp. Distilleries also send waste products to farms that raise livestock — often the same farms where they purchased their grain initially. Upcycled waste products are not just for animals. Bakeries use mash to make sourdough bread and grain byproducts to make flour.

  Other distilleries are exploring ways of reusing their waste products to keep the machines running. Converting waste into energy can be achieved by an anaerobic digester system that uses waste to produce methane. Cyclically, this methane helps to fuel the very distillation process that produces it.

Reducing The Impact Of The Liquor Industry’s Packaging Materials

  After distillation, packaging is the second most significant environmental challenge in our industry. A 2019 assessment finds the carbon footprint of glass vodka bottles accounts for 43 percent of the product’s carbon footprint. Recyclable PET plastic bottles account for around 27%.

  Ideas for making the packaging of our products more sustainable include recycled glass and cork. Larger distilleries are funding research into biodegradable bottles, recycled paper-plastic hybrid bottles, and plastic bottles made from wood pulp.

Hope for a Sustainable Future in the Liquor Industry

  As more and more of our consumers become aware of climate change and its implications, they are adopting a new understanding of what it means to drink responsibly. Today, people are reading labels. They are aware that their purchases have an impact on our planet and want to know where their food and beverages come from. We should give them the opportunity to make a difference with the products we provide.

  There is a new climate story that is optimistic and simple, and the liquor industry can be part of it. If we learn how to support sustainably-farmed ingredients, manage our waste products responsibly, and package our products in environmentally-conscious ways, we don’t have to live in fear.

The Most Important Opportunity for Brewery Owners

Why So Many Are Missing It

employee retention tax credit

By: Catherine Tindall

The Employee Retention Tax Credit (ERTC) is one of the best ways for those in the beverage industry to regain their footing in a post-COVID age. Unfortunately, according to current estimates, many eligible businesses are missing out on this historic opportunity. For those who received or may otherwise be familiar with the Paycheck Protection Program, also known as the PPP, the concept is similar, but there are key differences that make the ERTC a much more generous program overall.  To understand why I will outline some of the key provisions and eligibility parameters, explain the process for claiming the credit, and answer some common questions I encounter in my own practice, such as “why haven’t I heard of this before?”

  The ERTC is a tax refund credit entitling employers to up to $26,000 per employee, depending on the number of quarters a business qualifies for. Eligibility is determined by either revenue disruptions or government orders on a quarterly basis. Many breweries are unaware that they are eligible for the ERTC due to the capacity and operation restrictions on their indoor dining and/or tasting rooms that occurred during the pandemic. Financial disruptions to that aspect of the business trigger ERTC eligibility for all the divisions of the brewery, not just the restricted segment.  We routinely see businesses qualify for six or seven-figure credits under these parameters.

  There are a number of features that set this credit apart from other programs designed to aid businesses affected by the pandemic, like the PPP. Unlike the PPP, the credit itself comes back as paper checks from the IRS, and also unlike the PPP funds, which were restricted to certain uses, a business owner is free to use the ERTC however he or she sees fit. This is because the credit is actually a refund of wages and payroll taxes your organization has already paid. A consequence of this is that there is no overall program limit on the funds to be disbursed through the ERTC, in contrast to the PPP which had a limited fund pool. Businesses affected by government orders are entitled to every cent they qualify for. Taken together, all of these factors are what gives this program its power. The only limitation is time. This credit will begin to be phased out in April of 2023, meaning that business owners need to ensure they submit their claim as soon as possible. 

  Given the tremendous upsides, every business owner in the beverage space should try to see if their business qualifies, even if it seems doubtful. There is no need to become experts in the credit’s provisions, which can often be nuanced. The important thing is to find the right professional, and, to this point, one must be careful. There are unfortunately a lot of bad actors in this space looking to make a quick buck, and many of them are very good at seeming legitimate. 

  The following are some of the most asked questions associated with the ERTC.

  Should I get a second opinion? Because of the substantial nature of these credits, it’s often worth speaking to multiple providers for the credit to get a sense of the relative merits of each, and to look to the expertise and experience of those working on your case rather than fancy marketing or smooth sales tactics.

  Why haven’t I heard about this before? There are several reasons why many business owners have not heard of this important credit. One is that, in contrast to the PPP program, the ERTC has not been well advertised by the government (after all, since when did the IRS advertise refunds you’re entitled to). Another is that many tax practitioners are hesitant to pursue it given the sometimes complex nature of the claims, if this isn’t their area of expertise. Finally, we commonly find that too many CPAs mistakenly believe that their clients do not qualify for the credit, and so never bring up the possibility of claiming it with them.

I would encourage all brewery owners to actively explore eligibility. The potential benefits of qualification, hundreds of thousands of dollars in obligation-free money from the IRS, is one of the highest value things you could do for your business in the current environment of economic uncertainty.

  There are certain pitfalls to avoid, such as dishonest companies operating in the space, but if you choose the right firm or professional to partner with, the process is remarkably painless. Just be mindful that this is an opportunity with a time limit attached. With less than a year before it begins to phase out, now is the time to claim the credit you’re entitled to.

  Catherine Tindall is Partner & CPA, Dominion Enterprise Services (DES), a full-service CPA firm providing tax planning and consulting alongside specialty tax credit processing. The firm has more than 50 years of collective experience and recently announced the launch of its Employee Retention Tax Credit (ERC) Division to help restaurants assess their eligibility for the ERC and properly secure the maximum refund allowed. Learn more at…

Back on the (Rye) Ranch

whisky bottle and glass

By: Tod Stewart

Just close your eyes…“You can see Faith, Hope and Charity as they bank above the fields….” – Al Stewart, “Flying Sorcery,” from the album “Year of the Cat.”

  Stewart was likely referencing the nickname of the three Gloster Gladiator fighter planes flown during the Siege of Malta in WWII in that line. From 10,000 or so feet, I was looking down at a different, though similarly named, trio as my Bell 407, flown by Alpine Helicopters Inc., banked languidly port-side. Referred to as the “Three Sisters” (Faith, Hope, and Charity – or Big Sister, Little Sister and Middle Sister, respectively), their peaks jut skywards as part of the South Banff Range of the Canadian Rockies.

  The breathtaking flight was just one of the many memorable activities arranged by my host, Alberta Distillers Ltd. (ADL), as part of the “Rye Ranch” experience. Over the course of four days, I was to get an intimate look at all facets of Canadian whisky production. I would also have the honor of being one of the first “civilians” (i.e., not a member of the Bean Suntory, ADL’s parent company team) to taste ADL’s latest rye whisky expression. Both of these would go a long way in helping answer the question: what makes Canadian whisky unique?

  Founded in 1946, ADL has risen to become perhaps the most respected and significant distiller of rye whisky on the planet today. In fact, its Alberta Premium expression is the top-selling rye whisky in the world. Davin De Kergommeaux (DDK), who, as I mentioned in my previous Beverage Master Magazine story, literally wrote the book on Canadian whisky, doesn’t mince words. “I think ADL is my #1 Canadian distillery right now for quality whisky and straight-shooting staff. [It’s] the best rye distillery in the world, and they make so much else besides.”

  Seeing as how I had DDK on the line, I thought this might be as good an opportunity as any to get an expert’s opinion on what, precisely, makes whisky from Canada unique.

  “The key to making great Canadian whisky is blending many components to make a whisky with consistent flavor from batch to batch,” he began. “Each component is made to emphasize specific qualities which blenders then integrate batch by batch. The amount of each component used can be adjusted as needed for each new batch, to even out any differences in the grain from different growing seasons, and any differences among barrels.”

More about barrels in a bit. Carry on DDK….

  “Making individual components also allows distillers to tailor maturation to the specific distillate – charred oak for corn, toasted for rye, for example. Spirits aged in a variety of barrels and for different lengths of time give noticeably different whiskies and blenders are able to use just the right amount of each in the final blend so they get exactly the flavor profile and texture they are looking for.”

  He simplifies the concept this way: “American whisky-makers blend the grains together in mash bills, while Canadian whisky makers blend them as mature spirits. Each has its advantages, and each gives the resulting whisky its own personality, so one approach is not better than the other, just different.”

  While at the Rye Ranch (and before a truly superb dinner prepared by Chef Corinna Murray from Personal Thyme), I managed to corner George Teichroeb, ADL’s general manager, into one of those unprepared for, unscripted and (likely for him), totally annoying one-on-ones to pepper him with similar questions. Dressed in my awesome boots and Stetson from Lammle’s Western Wear (if you wanna look like cow-poke, this is the place), I brashly asked questions like, “Did I hear you say earlier in the day that making bourbon is easy, but making Canadian rye whisky is more challenging?” (Teichroeb has spent time in Kentucky – at distilleries, not in prisons, as far as I know –  so, he’s up on the ins and outs of both whisky styles.)

Beverage Master Magazine: Did I hear you say earlier in the day that making bourbon is easy, but making Canadian rye whisky is more challenging?

George Teichroeb: Well, to be clear, I didn’t say making bourbon was necessarily easy.

BM: Okay, fine. It was a bit loud on the distillery floor. But you said something along those lines, right?

GT: What I said was that with bourbon, there are guidelines set out for its production that remove some of the complexities of the process that we, as Canadian whisky producers, face.

  We can use continuous distillation, batch column distillation or kettle, and we can determine how much of each style make up the final blend with a fair amount of flexibility. If we were making bourbon, we would be much more regulated. With Canadian whisky, the distiller can decide which spirit and at what strength can go into a specific type of barrel. At ADL, we use ex-bourbon, new Canadian and multi-use barrels – and we have the advantage of deciding which option to choose.

BM: It would seem that Canadian whisky is “a thing” again. Why, from your point of view, is this happening?

GT: I read an article about three years ago that said from 2009 to 2019, there was a 230 percent increase in global distillers’ use of rye grain in their whiskies. Consumers and distillers have started to understand that the use of rye creates a flavor profile that is very unique, and this has led to a refocusing on the country that’s been a pioneer in rye distillation—namely, Canada.

BM: So, it really is a ryevolution!

GT: [Deadpan glance].

BM: Um, sorry. What, then, from your perspective, sets Canadian whisky apart from all others?

GT: I think there are certain historical standards that play a large part. Canadian whisky has to be matured for at least three years. It has to be aged in wood and on Canadian soil, but these are requirements that are similar to those of other countries. It’s in the blending process where Canadian whisky makers’ expertise comes to the forefront, and consumers are really starting to understand the value of skillful blending.

BM: Anything about the Canadian whisky industry you’d like to see changed?

GT: You shouldn’t be able to call a whisky “rye” if there isn’t, in fact, any rye in the blend! [In my previous Beverage Master piece, I mentioned the somewhat strange situation that distinguishes “rye whisky” as a category rather than a reflection of what is distilled.]

BM: Where do you see ADL, and the Canadian whisky industry in general, heading into the future?

GT: It’s been great that ADL has always been seen as a pioneer rye distiller, but this doesn’t mean we won’t continue to try new things in the future. We will continue to consistently use prairie rye as a main whisky ingredient, and I think this association with specific, regionally-grown grains will take hold in other Canadian distilleries. You might see different strains of corn being used in the eastern Canadian provinces. The prairies will likely remain heavy on wheat, which is a great base for vodkas.

  While touring ADL’s barrel warehouses a few days back, I noticed another unique feature of many Canadian distilleries: the use of pallets rather than racks for barrel maturation. While this is common in the majority of Canadian whisky distilleries and significantly improves efficiency, the verdict is out on whether it has any negative effects on the aging of whisky. To play it safe, ADL incorporates both rack and pallet warehouses. Racking barrels increases airflow around them and gives the liquid greater exposure to the barrel heads, both of which have a beneficial impact on development.

  Other features that are unique to ADL’s whiskies are the use of predominantly unmalted rye and (because of this) the reliance on in-house reactors that yield one of the two types of enzymes that make up the “enzyme cocktail” used to convert rye starch to glucose.

  One aspect that’s unique to all Canadian whiskies, and the one that stirs up the most consternation, is the “controversial” 9.09 regulation, which, in reality, is much ado about nothing. I won’t go into a long dissertation on how this regulation came about (there has been plenty written about it), but the upshot is that a Canadian whisky distiller is permitted to add up to ten percent of another liquid to every 100 liters of mature whisky. So, for example, ten liters added to 100 liters brings the total volume to 110 liters, and ten percent of that volume works out to one-eleventh or 9.09 percent). This “other liquid” is typically un-aged whisky or wine.

  While purists like to rant about this, think of how much “non-scotch” winds up in Scottish whiskey finished in casks that once held sherry, port or Madeira. Teichroeb sees this regulation as beneficial in that it adds a degree of flexibility to the generally ridged requirements whisky makers are governed by. And it allows blenders to introduce subtle flavoring elements to a final blend, the result of which I was about to taste.

  As the sun dipped low behind the majestic Rockies in the distance, and as the embers of the campfire contributed to the glow of our already-somewhat glowing group, Teichroeb poured us drams of ADL’s latest whisky: Reifel Rye. Named in honor of the distilling family that helped establish ADL, it is a 100 percent Canadian rye whisky showing distinctive, dusty/spicy rye on the nose, with subtle hints of vanilla custard and dried fruit. Smooth, warm, mildly fruity/spicy and beautifully balanced, it was the perfect nightcap to wrap up with what had been a pretty much perfect stay in Canadian whisky country.

Slowly Sipping Premium Sake

bottles of sake

By: Hanifa Sekandi

You have most likely sipped on this subtle, smooth spirit at your favorite sushi restaurant. Sake is a drink that warms up your soul and shockingly excites your senses. Some would say it brings the same joy as tequila. But you do not see it coming. Sake is a humble beverage that does not announce its presence immediately on the palette. Its balanced flavor profile satisfies the desire to sip and dine without overpowering the experience. Alas, a few sakes in, there it is, a feeling unlike any other alcoholic beverage you have sipped on before. It does not hit you in the chest or burn the throat. That tipsy feeling comes later, even for those who don’t consider themselves lightweights.

  Sake has enchanted North American imbibing culture. So much so that it has transitioned from the beautiful Japanese restaurants where most people first experienced it to liquor stores across the US. As of late, luxury sake brands are making headway, creating an alcoholic beverage niche just like wine and other high-end spirits and liquors. Like premium tequila, it is becoming a staple on bar carts for those who value a selective drinking experience where just anything will not do. It is about quality and the story that makes the alcohol they drink meaningful.

What is Sake?

  Sake is a Japanese alcoholic beverage. The word sake in Japanese describes all alcoholic beverages. Nihonshu is what sake is called in Japan, most likely something sake enthusiasts in the West are unaware of since this designation is rarely used in western Japanese restaurants. For most people, their first experience with sake is at a Japanese restaurant. While dining on seafood dishes, sake is served and an excellent pairing for this type of cuisine. So, what is sake? Sake is a translucent rice wine. It is often served in a small cup called an Ochoko. It is made with rice and water and brewed by converting starch to sugar. From the sugar, alcohol is produced. The brewing process of sake involves several steps.

  The sake brewing process starts with polishing the rice to remove the outer layer. Once this stage is complete, the rice is soaked to ensure that any leftover bran is removed. Next, the rice is steamed to cultivate koji cultures, an imperative component of making sake. While one batch of rice steams, Koji mold is added to the steamed rice. The steamed rice and rice with added koji mold are mixed in a tank containing yeast to create a starter. Next, the mashed ingredients are transferred to a tank with steamed rice, water and koji, frequently added during the alcohol fermentation period of approximately one month. The fermented mash is then pressed and stored.

  As you begin the at-home sake experience, you need to buy the appropriate cups since the size of the cup, the shape and the material it is made with influence the fragrance of sake. There are several vessels that one can use to serve sake. For example, a masu container is a small wooden box with a shot glass placed in the center. Another vessel is a Sakazuki, a flat wide-mouthed cup used for Shinto ceremonies and rituals. Small shot glasses are another option for serving sake since thin glass supports a rich tasting experience. It is also suitable for high-quality sake. Shuki is a commonly used vessel. Shuki is a term generally used to describe all sake vessels. Wooden shukis are favorable since they enhance the aroma of sake and provide a milder aftertaste.

Sake Beginnings

  To truly appreciate an alcoholic beverage, it is essential to understand its beginnings. These stories over a warm meal with friends bring us together. Further, history demonstrates that bridges and communities have been built simply by sharing spices and drinks with people from different cultures. Sake has its own story. Although the birthdate of sake is hard to determine, its roots are intriguing. The Book of Wei in the Records of the Three Kingdoms contains Japan’s earliest record of alcoholic beverages. It is believed that sake dates back to the Nara period (710–794). Initially, sake was used during religious ceremonies. During the Heian period, sake was consumed as part of games and festivals.

  In the earlier stages of sake, before it became a viable commodity. The Imperial Court during the 8th and 10th centuries governed and controlled its production. The types of sake that people could drink were also determined by the rank they held in court. For example, clear, robust-flavored sake was reserved for those in high-status positions. People viewed as a lower class could only consume unrefined, cloudy brews. During this time, people drank sake for festivals and offerings to the gods.

  In the 12th and 14th centuries, shrines and temples became sake brewers and the central producers for over five hundred years. It was at the temples where the brewing process was perfected into three stages. Sake’s longevity, stronghold into the future and availability to the general public are due to these efforts that ushered in the production of sake at a scale. It is important to note that the upper-class nobility only had access to sake during this time. A move into commerce created a demand for this once-exclusive drink.

  Once specialized brewers entered the market in the 14th and 16th centuries, temples and shrines no longer held a monopoly on production. Innovations for serving sake made headway during this sake rebirth. New sake vessels offered an easy way to purchase sake to-go, a departure from the wooden pails. Fast-forward to present-day sake production, where technological advancements that commenced years prior and continue to improve brewing methods have allowed sake producers to distribute it globally. New avenues opened the door for the sale of refined luxury sake. It is no surprise that premium sake brands are finding a space among elite alcoholic beverages.

What Is Premium Sake?

  So, what is premium sake? Is it worth the price? Does it stand out among other luxury beverages? Luxury sake brands are just getting started. It will not be long before such brands are found next to top-shelf wines and spirits on bar menus in North America. Premium tequila has reigned supreme in recent years. It is now sake’s turn.

  Sake has an average ABV of 15% to 16%, quite compelling for those looking for an alternative to high alcohol content spirits. Not bad for a rice wine! Sake Hundred, a high-end sake developed by Ryuji Ikoma, a sake connoisseur who also founded Japan’s Saketimes, is gunning to shake up the fine wine and high-end Japanese whiskey terrain. Ikoma aims to “expose drinkers to the most outstanding examples of Japan’s national drink, showcasing its many styles and sophisticated complexities that allow it to pair with a myriad of cuisines well beyond that of simply sushi.” While developing his brand, he visited hundreds of Japanese breweries to learn about the techniques and art of making sake from those who have gained expertise through their lineage. In 2018, he launched Sake Hundred, a new portfolio of sake for a new generation of sake drinkers. He partnered with select breweries to help him produce his new line of high-end sake.

  “Our collection of sakes will take drinkers through a journey of both culture and taste, two elements that are closely intertwined in sake making. You can taste the personality of the sake brewer in our sake, just as you can taste the terroir of a fine wine,” noted Ikoma. He added, “Each part of Japan has its own culture and there is no better way to get to know that culture than through sake.”

  Sake Hundred released the limited edition Gengai with an eye-opening price tag of $3,100. Their flagship sake, Byakko Bespoke, made from the “king of sake rice,” Yamadanishiki retails at $380. Of course, other premium sake brands are eager to enter the U.S. Kikuhime ‘Kukurihime’ Ginjo Sake, produced by Kikuhime Brewery, is a top-shelf sake named as a tribute to the Goddess of Hakusan Mountain. The water near this mountain is used in this renowned, slowly aged sake for approximately ten years. Some retailers sell it for $650. Another notable high-end sake is Shukondeinoshiro Kamutachi. Producers of this sake only make 60 bottles a year. Luckily, the price tag on this sake is not as shocking. Getting a taste of this premium slow-matured rice wine is a possibility for those who do not mind splurging just a little. It retails at $229.

  Those in the know do not mind lower-priced sake while dining at their favorite sushi restaurant. Even if it sits at a lower price point, it is a great accompaniment to your meal. For many, this led them to explore the world of sake. Its rich cultural roots and the unique brewing process bring each bottle to life. Do not be surprised if it also becomes a member of the new-age beverage trend for individuals seeking wheat-free and gluten-free alcoholic drinks. For now, sipping on warmed sake feels just right.