Category: Product Info

American Gin

Cyndi

Your how-to guide for developing world class gin

a glass of gin next to various small bottles containing herbs and spices and other ingredients

By Kris Bohm, Distillery Now Consulting

The process of developing a new gin can be a fun trip into the world of flavor and the many possibilities of flavors that can be extracted from unique botanicals through ethanol distillation. While at first the concept of developing gin may seem daunting to a distiller, the process of making a great gin can be simplified by following our handy dandy gin distillation guide.

  Before we jump right into the process let’s take a quick moment to go over what gin is and is not. In America gin is traditionally made from a neutral spirit that is redistilled with botanicals to create a flavored spirit that is gin.

  A typical gin will have juniper and coriander as its primary botanicals with many other botanicals also adding flavor to the spirit.

  In Europe and beyond gin is often a much broader term to define a spirit redistilled with almost any type of fresh botanical or ingredient. There are even some gins that taste more like fresh cucumber than juniper. I find it helpful for a distiller who is looking to make gin to understand the category of gin well, before beginning the endeavor of developing their own. This process of tasting some commercial produced gins made by other distillers is an excellent way to find inspiration for your own gin.

  With that said let’s dive right into the process of distilling with botanicals to start your journey with gin. It is important we take a moment to note that home distillation is not legal on a federal level in the United States. As always, if you intend to distill, we recommend doing it legally and that you secure the proper state and federal permits.

  For initial product development it is best to distill on a small scale and do concept trials. You can do good product development work with a small lab 1 liter glass still. Glass lab stills which utilize hot plates as a heat source and domestic water for condenser cooling are easy to work with and relatively inexpensive. Glass laboratory stills can be procured with a botanical basket for vapor infusion of botanicals.

many ingredients used to make gin are spilling out of glass bottles onto a table

  For the neutral spirit being redistilled, we recommend a sourced a clean neutral spirit (like vodka or grain neutral spirits) diluted to 40% ABV. It is unsafe to place any spirits in a still higher than 50% so we recommend 40% as a starting point for botanical distillation. It is critical to take detailed notes throughout this process to create replicable results.

  The only difference between science and screwing around is taking good notes. So, take good notes though the whole process and you’ll be better able to produce replicable results. Weigh all ingredients, take notes on yield. Take notes on flavors. This process of note taking will be essential as you move further into product development.

  The botanicals themselves are essential to the quality of your gin. Not everyone has fresh juniper growing in their backyard, so a distiller often must look to buy juniper from a commercial botanical supplier.

  Now, while you can find botanicals quick and easy on Amazon, it is important to talk about freshness and quality. The freshness and overall quality of a botanical is paramount in producing a good gin. Buying botanicals directly from reputable botanical companies will help to ensure you are working with high quality ingredients. Fresh juniper will be soft when squeezed, slightly sticky inside and very aromatic.

  If you buy juniper that is shriveled and bone dry, it will likely not make a good gin. Botanicals of all varieties are a seasonal agricultural product. Taking the time to understand the seasonality of some ingredients can help to make the best possible gin. For example, if you are making gin with citrus, it is helpful to buy it and distill it fresh during harvest season.

  Distillers frequently contemplate using many different botanicals when crafting a gin. Understanding how each botanical contributes to the flavor of gin is not easy to do.

  During product development the best way to develop your palate to recognize botanical influence is through single botanical distillation. This process is in essence placing neutral spirit in your still and adding a single botanical to the still, then distilling the spirit to extract flavor from the botanical. This will yield a spirit that is solely the single flavor of a botanical.

  By doing a single distillation of each botanical it will help you develop your product in two ways. First it helps in that you can taste each botanical individually to understand the essence of its flavor. Once you have gained an understanding of flavor you can then work on blending the spirits from your single botanical distillations to create a complete gin. As we get in more detail, we discuss quantities and ratios to give you a starting point for development.

  Now that you have a variety of flavored spirits you have distilled via Single Botanical distillation it is time to get into blending. The best starting point for blending is to understand common gin botanical ratios.

  In a glass while weighing out your distillates a simple starting point could look like…

60-grams juniper

10-grams coriander

2-grams Angelica

2-grams bitter orange peel

2-grams lemon peel

1-gram orris root

1 gram cardamom

1-gram cinnamon bark

1-gram grains of paradise

1 gram cassia

  After you have blended all these individual distillates into a jar, you should take a moment to make sure you have written down all the blending work that created this gin. This newly created gin will need to be diluted to bring the spirit down to a bottling strength. Add a bit of distilled water to reduce the concentration of alcohol.

  The ideal concentration is somewhere between 40-50% Alcohol by volume. Your gin is now ready to taste. Taste the gin and consider the overall flavor profile. If some botanicals are lacking, then add a bit more of that botanical distillate to the blend. If a certain botanical is overpowering, then create a new blend with different ratios.

  This process of blending and tasting can feel arduous and may take many tries to get just right. It is worth the work to do this blending process. It will not only ensure your gin is excellent but create a solid base to scale up your gin production. Once you have found a blend that you love it is time to scale up the recipe and make a big batch of gin.

  Scaling up production can be done in a few different ways. The most common way to scale up is to do what is known as single shot gin distillation. Single shot distillation consists of adding neutral spirits to the still along with all botanicals then redistilling the spirit to create a gin.

  After distillation the only thing added to the gin is water to dilute its strength. Determining how much of each botanical to add to the gin should be done using a multiplier based upon the quantities that went into your original blends. It is important to note that all stills behave a bit differently.

  You may find that your scaled up gin recipe may differ a bit in flavor from the lab scale recipe. As you have individual botanical distillates you can tailor the gin with the additional of single botanicals to adjust the flavor of the product if adjustments are needed.

  The development and creation of gin is a fun endeavor in the world of botanicals. Good gin takes work to create and has the potential to be a great product in your distillery lineup.

  How Aviation Gin is Made

Kris Bohm is the owner of Distillery Now Consulting and over 10-year industry distiller. When Bohm is not making gin, you can find him pursuing two wheeled adventures around the world.

Hop Trends & Delivery Methods Open Up New Possibilities for Brewers

Cyndi

With new delivery options, increased shelf life and enhanced applications hops are being recognized as a valuable commodity and marketing tool towards consumers.

close up photo of hop buds on the vine

By Gerald Dlubala

As growers try to regain the balance of supply and demand that was upended during the pandemic, some brewers are seeing hops as a marketing tool for more educated consumers. Is it time for hops to step forward and take a lead in craft brew marketing?

Civil Life Brewing, St. Louis, Missouri

  “I think it is,” says Dylan Mosley, Head Brewer of Civil Life Brewing in St. Louis, Missouri. “As a brewer, the world of hops is becoming increasingly interesting, even for those who use traditional, established varietals. Cascade Hops are synonymous with North American Brewing, and we use them in our historical-type beers. But the delivery method of adding hops has progressed, and that’s pretty cool. We use different delivery methods depending on the layer and level of aroma and flavors we’re after. For example, in our Merchant Ship IPA, we mostly use our bell hops in pelletized form. Some of the other hops are processed differently and isolated from the plant in methods like CO2 extraction or through hop oils.”

  Mosely says that brewers are increasingly able to get out of the hop whatever they are after by fine-tuning delivery methods and timing during production.

  “From a brewery perspective, it’s all about control,” said Mosely. “Deployment is key with hops, and it’s fascinating to pick and choose how, when, and where to add them into the brewing process. The newer packaging and delivery methods are really fascinating to me. And as a brewer, I love their shelf life, storability, and variability of what part of the hop you use. The only thing a brewer should remain aware of is their filtration methods and how some of these different hop choices will react with their filtration pads or membranes.”

  “It’s important to know that a little goes a long way with respect to replacing pellets with oils,” said Mosely. “But the more oils you use to replace traditional pellets, the more educated you have to be with deploying those oils. Education is key. It’s like a baker who uses exotic spices and clarified ingredients. A little can go a long way, and they must be used at the right times in the right amounts, or the layers of flavor will go haywire and become too pronounced or too specific. Drinkability can be reduced due to flavor profiles changing too rapidly. But having these types of contemporary hop products at our disposal is cool. It gives smaller breweries like us access to the same technologies and flavor profiles as the bigger breweries.”

  Mosely attributes the excitement over hops to consumers becoming more educated about what is in their glass or can.

  “I’m seeing some exciting things happening around hop use and choice, and the customers are driving those trends,” said Mosely. “So much so that I think we can expect more dramatic packaging highlighting the hops used in a specific beer. It’s something new for the consumer to learn and remember when they try new beers. If a beer shows the same hops or blend as something they’ve liked before, they’re more likely to try it. You know, wine drinkers look for wines from the same region or grape varietal, and I think you’ll see that with hop selection and marketing. Hops are an ingredient that the consumer can see, taste, learn about, and remember. More education about hops leads to excitement and conversation.”

  Mosely said that there is far more disinformation than factual information when it comes to craft brewing. Consumers are ready to learn about the process and talk about it, and brewers can make hops more exciting by labeling what hops are in the beer in their hand. A few years back, it was huge to see the Mosaic or Amarillo terms thrown around, but now, hop-centric beers have their hops listed on the label to push that fact.

  “It’s like music albums with guest artists labeled on the cover,” said Mosely. “It’s an added name recognition boost. If you’re at the grocery store and one beer label does not mention hops, but the same style of beer from another brewery mentions the included hop varietals, that’s the one that will usually get chosen. Brewing looks so daunting and mysterious due to all the equipment, but it’s still only four ingredients. You drink it, and sometimes you don’t realize that it’s the hops you’re tasting over the other elements of the beer. If you at least have the name of the hop in front of you, you now have a mental record of that with the flavor profile. It’s your personal beer database of your likes and dislikes, and that’s pretty cool. We’re telling a story every time we put a can on the shelf or a glass of beer in front of a patron, and sometimes that story is just the name of the hops.”

Glacier Hops Ranch

  Montana-based Glacier Hops Ranch is a worldwide broker and dealer of premium processed hops sourced directly from hop growers and warehouses across the globe. President and CEO Tom Britz spoke with Beverage Master Magazine regarding hop trends in four primary areas of the industry.

1.    Economic Efficiency: “Traditionally, craft brewers just wanted to make great tasting beer, no matter the cost, and that included the hops,” said Britz. “That’s not so prevalent anymore. Cost containment and economic efficiency drive hop choices in both the varietals used and how they are used and delivered. Brewers want to squeeze the most revenue available out of every batch of beer produced. Pellets have become the go-to choice in hop delivery, but as any craft brewer will tell you, pellets also soak up product, which adds up over time. We commonly talk with brewers who lose 10- 25% of their product through simple pellet biomass and waste. Hops start with 75-80% moisture at harvest in the field and are dried down to 7-8% moisture content. By substituting half of the pellets with products like our Hopzoil®, brewers can gain up to 7 ½ % yield per batch brewed. Over 12 months, that equates to serious revenue gains without sacrificing flavor or aroma. We have an interactive worksheet that uses hard costs to estimate each brewer’s increased revenue per batch. Even small craft brewers can see their expected increased revenue by plugging in their numbers and getting their results in black and white.”

2.   Beverage Diversification:  Many breweries use various vessels, packaging lines, and means of distribution, so they’ve got what they need to produce and package different beverages,” said Britz. “We see business models moving breweries away from having beer as their singular product, and the same goes for hop usage. Hops aren’t only for beer anymore. Hopwater is a popular, refreshing, best seller with low cost of goods and high margins, and easy to produce in one day with Hopzoil®. We see it made with the addition of citric acid and simple sugars, but increasingly we see it produced using our Hopzoil® as the only ingredient. It can be made in small batches, making it easy to move from flavor to flavor. Hopzoil® comes in 22 different varieties and blends. Consumers notice that hop water made only with Hopzoil® reflects only the hop flavor and aroma with no bittering, biomass, or waste. Places looking for a great NA alternative are experiencing wider customer bases with Hopzoil® and hop waters. It’s a way to diversify into the NA world without much extra cost or waste. Additionally, we see the use of Hopzoil® in hard ciders, fruit purees, and other craft beverages.” 

3.   Functional Beverage Use:  “This is a huge area of growth for the hops industry,” said Britz. “Nutraceuticals are different applications for sure, and easier for some breweries to get into than others. When the hop compounds, or terpenes, are analyzed, you can cross-reference that analysis with their proven health benefits. We do with our pure hop oil what the marijuana industry does when analyzing the health benefits of their products. Our products provide calming effects just like CBD products, but without the lethargy that marijuana can promote. We’re seeing a steady growth of functional beverages that could use hops for conditions including pain relief, anxiety and depression relief, antioxidant properties, brain health, anti-microbial properties, and skin health, all kinds of benefits.”

4.  Return to Forward Contract Farming:  “Since late 2021-2022, there’s been an oversupply of some of the more popular hops,” said Britz. “Hop demand was going up, and then COVID knocked the bottom out of the market, leaving a large oversupply with no market. That’s finally beginning to balance out now, and because of that, we see an increase in contract farming to head off shortages in specific varietals. In the late 90s, up to 96% of hop farming was contracted. By 2020-2021, that number fell to mid 40% because of the excess in hops stored and readily available at discounted prices. So, from 2022 through 2024, 31% of acreage was pulled from hop farming due to these inventory excesses and increased production efficiency. After three painful years for hop growers, the supply and demand are starting to balance out. Contract farming ensures a predictable supply for all sides, but some smaller breweries may come up short or have difficulty finding what they need. The prediction is that for the 2026 harvest, forward contract farming will make a comeback, with those who did not get what they wanted this year leading the way to ensure their supply chain.”

Hop Favorites Remain Traditional While Delivery Method Evolves

  “The main hop trends we still see are the classics, like cascade, chinook, and centennial, or a blend using those three,” said Britz. “We also have demand for our citrusy and juicy fruit bomb series. No matter what a brewer uses, we recommend starting with 50% pellet replacement using Hopzoil®. One hundred percent will give a different flavor profile. Hopzoil® requires no refrigeration or freezing. It’s water-soluble, so it gets shaken into an emulsion. A 12-inch cube of Hopzoil® can go on a shelf and free up two pallets worth of shelving or floor space. As with most ingredients, we recommend keeping it away from excess light, heat, and oxygen. Our packaging is topped off with beverage-grade nitrogen and can be topped off with nitrogen or CO2 for resealing. When using Hopzoil®, brewers don’t get that drop off in some IPAs where the flavor is there and suddenly it’s gone. We’ve also gotten calls from brewers who have used our oils to rescue a batch of beer that didn’t turn out as intended, whether for sensory applications or something else. That’s a cool option and something for brewers to keep in their pocket should they need to rescue a batch of beer.”

  Britz says they have exported to over 50 countries and were awarded SBA’s Small Business Exporter of the Year in 2022.

  “Quite a few breweries have won prestigious awards using our products,” said Britz. “Hopzoil® is made from wet hops directly out of the field in a steam distillation environment, capturing the volatile oils released into the atmosphere through traditional field drying techniques. This method makes our product 8-15 times more concentrated than other suppliers, and brewers describe our product as more intense and brighter.”

Advice For Craft Breweries

  “I’ve seen a change over the last few years,” said Britz. “My advice for craft breweries is to focus on the service they deliver over the actual product they make, because the service will keep customers coming back as product trends and consumer desires change. Craft brewers are not in the beer industry as much as they are in the beverage industry. Recognizing the industry you are in allows much more creativity and out-of-the-box thinking.”

Packaging with Purpose

Cyndi

Balancing Brand, Function and Sustainability

bottles of beer with very colorfull labels on a very colorful background

By Alyssa L. Ochs

In today’s competitive craft beverage market, packaging involves much more than just putting your beer or spirits into a functional container. Packaging makes a powerful statement about your brand’s story, values and commitment to the planet.

  Modern craft beverage enthusiasts are drawn to products that evoke an emotional response and that stand out among the crowd in unique ways. Consumers have also become increasingly interested in supporting brands’ sustainability endeavors centered on recyclable and biodegradable materials in a circular economy.

  To learn more about current trends in craft beverage packaging, Beverage Master Magazine connected with NEENAH, a world-class manufacturer of premium printing, packaging, label and specialty papers.

close up photo of the label on a brewing bottle

Packaging & Consumer Perceptions

  Jennifer Dietz, NEENAH’s Label & Folding Board senior product manager, explained to Beverage Master Magazine how label design can be a powerful tool in shaping consumer perception. Headquartered near Atlanta, Georgia and with multiple U.S.-based manufacturing facilities, NEENAH’s offerings include label, box wrap, folding board and more. The company focuses on elevating brands through specialty and custom packaging substrates that demonstrate their uniqueness and communicate their brand ethos.

  “Color and texture can instantly communicate brand values such as authenticity, luxury, sustainability or innovation,” Dietz said. “Uncoated labels, for example, offer a tactile, natural feel that conveys uniqueness and craft, helping products stand out from mass-produced alternatives.”

  “Since most labels are a shade of white, introducing color or texture can dramatically enhance shelf appeal,” she continued. “NEENAH Label Papers can be manufactured in a variety of colors and textures, while offering consistent quality across production runs, ensuring brand integrity is maintained from run to run.”

  Dietz also explained how secondary packaging plays a significant role in elevating brand presence.

“For spirits and premium beverages, a well-designed box can create strong shelf impact, signal quality and make the product instantly giftable,” she said. “Uncoated papers in rich, deep tones, can evoke sophistication and intrigue while offering a premium end-product with no white edges. NEENAH® Folding Board offers a collection of 13 in-stock colors, including boards made from 100% post-consumer waste and pearlized finishes, as well as other options.”

NEENAH’s Craft Beverage Label Options

  NEENAH offers three label products, all of which are made to order and customizable.

  Dietz said that NEENAH’s ESTATE Label® is the market-leading trusted brand for uncoated wet-strength labels. It is most often used for wine and is manufactured in 60-pound text weight. The standard offering includes an expansive selection of 11 colors and five distinctive finishes.

  Secondly, there’s the BELLA® Label, which is a lighter-weight label but also manufactured with wet strength, with a 47-pound text weight. This label provides an authentic, hand-crafted look that is perfect for craft beverages.

  Finally, NEENAH’s CLASSIC® Label is a premium label without wet strength, making it ideal for red wines, spirits and jar labels. This label offers a crisp, clean and elegantly uncoated solution for a variety of label and packaging needs.

  Dietz elaborated on the concept of wet strength for labels and its importance for label stock. She said wet strength is a label’s ability to maintain its integrity and adhesion in moist environments such as refrigerators, coolers or ice buckets.

  “It is a critical performance feature for products like beer and white wine, which are frequently exposed to condensation or submerged in ice,” Dietz said. “While wet strength doesn’t alter the visual appearance of the label, it plays a vital role in the manufacturing process. Specialized additives are used to ensure the label resists tearing, wrinkling, or detaching when wet, preserving both brand presentation and product durability.”

  She also shared that NEENAH’s uncoated label stocks are engineered to perform just as well as the coated alternatives.

  “NEENAH Label Papers offer exceptional dimensional stability, ensuring precise registration for intricate designs,” Dietz said. “Uncoated papers also excel with embellishments like foil stamping and embossing, which tend to pop more vividly against their uncoated surface. Additionally, they work seamlessly with die-cutting equipment, making them a versatile and reliable choice for high-impact label applications.”

Sustainability in Craft Beverage Packaging

  Like many other brands serving the craft beverage market, NEENAH offers recycled and alternative fiber products to its customers as part of its focus on reducing its environmental footprint. Beyond just labels, there are various ways that breweries and distilleries can incorporate sustainability into their product packaging.

  Craft beverage packaging must be sturdy enough to protect the products during transport and visually appealing on store shelves. However, there is also an industry push to address concerns around single-use items that require extensive resources to produce and often end up in landfills. Options like compostable six-pack rings and fiber-based carriers provide beverage producers with more choices beyond traditional plastic, allowing them to minimize pollution risks without compromising strength or aesthetics.

Planet-Friendly Packaging Options to Consider

  There are biodegradable packaging materials available for the craft beverage industry, including plant-based plastics, molded pulp and compostable films. Beverage producers can also opt for packaging materials made from recycled materials to reduce their reliance on raw resources. Examples include aluminum cans with a high recycled content, recycled glass bottles and corrugated cardboard carriers.

  In addition to choosing packaging materials made from recycled materials, you can take your commitment one step further and prioritize packaging that can be recycled after use. Many municipal recycling systems accept aluminum cans, clear glass, paperboard cartons and certain types of plastic. It’s also helpful to label your beverage packaging with straightforward recycling instructions so that consumers instantly understand how to recycle it without confusion.

  An emerging concept to grasp is the closed-loop recycling model, in which packaging is designed with a mindfulness of circularity. Refillable glass programs and returnable aluminum growlers are examples of collection initiatives that keep packaging materials in continuous use, rather than discarding them. Technology is also aiding this effort with QR codes and smart labels that track the lifecycle of packages and add a sense of accountability and transparency to consumer exchanges.

  Not only is eco-conscious packaging a practical and responsible choice, but it’s also a marketing opportunity. By advertising planet-friendly practices on your beverage labels and website, you share your sustainability values with the public. These subtle stories will resonate with many of today’s beer and spirit connoisseurs, helping them to connect with your brand on a deeper level.

Looking Ahead to the Future of Craft Beverage Packaging

  This is an exciting time in a new era of craft beverage packaging innovation, particularly as technologies continue to improve and companies strike an optimal balance between functionality and environmental responsibility. Packaging has become a platform for brand storytelling and customer engagement. Meanwhile, researchers have been exploring the potential of next-generation biodegradable materials that leave behind little or no waste. 

  There are also specific design trends emerging in the craft beverage packaging industry, such as minimalist labels, lightweight bottles and reduced ink usage. These shifts represent further movement toward eco-friendly packaging choices and connecting with consumers who would like their purchases to align with their personal values.

  Meanwhile, we expect that some policy and regulatory changes will influence craft beverage packaging in the years ahead. Some state and federal governments have already introduced or are considering stricter requirements on single-use plastics. As a result, craft beverage producers may face heightened obligations and responsibilities to reduce their landfill waste, while also being incentivized to use recycled materials during production. By anticipating and adapting to these regulatory changes early on, beverage makers can avoid compliance headaches and position themselves as industry leaders in an increasingly competitive and mindful marketplace.

  If your beverage brand is looking for more from your packaging than just safely transporting products from one place to another, innovative companies like NEENAH can help. Your packaging choices will undoubtedly influence your customers’ perception of your brand and help people understand why making beverages is your passion. Crafting a delicious beverage is just part of the story, as packaging it in a memorable and responsible way ensures that your company will have a positive and lasting impact.

Cold Chain Logistics

Cyndi

How Craft Beverage Producers Can Protect Product Quality During Distribution

warehouse full of beer on pallets

By Nick Fryer, Vice President of Marketing, Sheer Logistics

Expanding into new markets is a major milestone for craft beverage producers, but it’s also when supply chain vulnerabilities tend to surface. Inconsistent storage conditions, longer transit times, and unfamiliar distribution partners can all jeopardize product quality and brand reputation.

  For today’s craft brewers, distillers, and ready-to-drink innovators, ensuring product integrity isn’t just about preserving flavor—it’s about having a cold chain strategy that can scale. From temperature-sensitive transit to final-mile delivery, success depends on reliable partners, smart planning, and the right equipment.

  In this post, we’ll break down the cold chain logistics challenges facing small and mid-sized beverage producers and explore the tools and strategies that can help them grow without compromising quality.

What “Cold Chain” Really Means for Craft Beverage Producers

  A “cold chain” is a supply chain that ensures temperature control from the moment a product is produced all the way to its final delivery. This includes any warehousing and storage, as well as transit time.

  Cold chain logistics involve the use of carefully managed refrigeration that can be adjusted to the specifics of whatever is being transported. For most craft beverage producers, 4-6 degrees Celsius has become the standard. Storing craft beer at 4 degrees has been proven to ensure flavor stability and meet food safety requirements. Anything above 6 degrees is associated with a reduction in the overall quality.

Why Craft Beverage Producers Benefit from a Cold Chain

  There’s a common saying that the minute you drive a car off the lot, it loses 10% of its value. Food and beverage products are fighting a similar battle. Every second they’re not in a controlled environment, they risk losing some of their quality and, in turn, their value.

  This is a major issue for craft beverages, which are generally less processed than their conventional counterparts. It’s what creates their unique taste profiles and keeps this industry so interesting. It’s also, however, what puts many products at risk of microbial growth and other chemical reactions that degrade the freshness and quality. The color can shift as the product is exposed to heat, as can the taste.

  Proper refrigeration and a cold chain that enforces it slows this process of degradation so that the product a brewery sends out tastes the same before and after delivery. The benefit of this is:

•     Fewer product recalls.

•     A stronger brand reputation. People feel more confident that they’ll get the same taste and quality, time and again.

•     Happier customers overall.

Spotting Temperature-Driven Quality Failures in Transit

  Experimental beers and spirits are what put American craft breweries on the map. Even with the variety that’s celebrated, there are a few common signs that something’s gone wrong.

  Here are some of the best ways to spot if temperature-related failures in transit are affecting the quality of a craft beverage:

•     Beverages appear cloudy when they shouldn’t be. This is often down to a microbial bloom that can happen with heat exposure.

•     The color of the product has changed. Oxidation is another common chemical reaction that happens when more natural brews are exposed to higher temperatures.

•     Beverages gush or are over-carbonated upon opening. This may even just show up in cans that seem to have expanded or suddenly have leaky seals. The issue comes down to fermentation, which is usually triggered by warmth. It’s something that craft beverages with live cultures in them (such as hard kombucha) have to be particularly wary of.

•   The beverage tastes different. It may suddenly be quite sour or “funky” when it shouldn’t be or develop a hop-forward profile that wasn’t there before. This can be from a combination of oxidation and microbial activity.

  If perfectly good beverages get sent out but then display the above issues upon arrival at their destination, it’s a sure sign that something’s gone wrong in transit. Another general red flag is when a product’s shelf span suddenly seems to be quite limited. That alone can point to issues in the supply chain.

From Tank to Taproom: Identifying Weak Links in Your Cold‑Chain

The best way to identify weak links in your cold chain is to check it, step by step:

•    The Production Facility: From the minute the beverage is packaged, it needs to be in a cold room that is continually monitored and handled carefully by staff.

•     Loading Areas: Docks and staging areas should be kept cold so that as the product is moved from one environment to another, it’s kept at a controlled temperature.

•     Transportation: No matter what method of transportation is used, some method of cooling has to be involved.

•     Distributor Warehousing: Products need to be labelled to indicate that they require cold chain storage, and warehouses should be vetted to ensure they have adequate experience and capacity for that storage.

•     Bars and Retailers: The cold chain isn’t over until the drink is being poured from the tap into a waiting customer’s glass. To ensure cold storage at this final point, retailers need to be educated and informed on how best to refrigerate the product.

warehouse showing pallets full of beer boxes

Cold‑Chain Gear That Works: Trailers, Packaging, & Storage

  There are a myriad of ways to approach cold chain gear. Here’s what actually works:

•     Long-distance cold chain transportation needs refrigerated trailers with insulated side walls, proper seals, and real-time temperature monitoring.

•     Shorter or local logistics can get away with insulated vans that keep portable cooling systems and ice packs stable.

•     Reflective, foil-lined pallet covers and thermal blankets can be used to maintain low temperatures when loading or unloading in unrefrigerated areas.

•     Packaging that keeps out heat and humidity is just as important as fridges and kitted-out cold chain trucks. Even simply making sure that everything is shrink-wrapped can prevent heat buildup.

Smart Monitoring Tools: Tracking Temperature, CO₂, Humidity, & Shock

  Cold chain gear works best when it’s paired with smart monitoring tools and IoT sensors. The technology can track key variables in real time and send alerts if anything changes, so that businesses have time to intervene before quality degrades. The data collected can also be used later to further optimize the cold chain and make more energy and financially efficient decisions.

  Here are the main aspects worth tracking in a craft beverage cold chain and why:

•     Temperature: This is important no matter what kind of craft beverage you’re transporting, as any heat exposure can cause oxidation and spoilage.

•     Humidity: High humidity often leads to mold growth on packaging or the rusting of metal kegs. Anything transported long distances, especially in warmer months, should have humidity levels monitored.

•     C02: Build-up of this gas can accelerate fermentation in craft beverages and lead to bursting cans and bottles, especially if a product has active cultures in it (such as the yeast in a hazy IPA).

•     Shock: Too much shock during craft beverage transportation risks packaging and product integrity and can also damage cooling systems.

  By monitoring all of the above, especially through centralized tracking and logistics platforms, craft beverage companies can maintain a controlled environment for their products. The result is then improved quality control.

Conclusion:

Keeping It Cool from Production to Pour

  There is so much work that goes into creating craft beverages. Investing in cold chain gear, technology, and logistics strategies ensures that none of that work gets lost in transit. Instead, breweries can rest assured that they’re always putting their best product forward and, in doing so, building a brand reputation that keeps people coming back.

Nick Fryer is the Vice President of Marketing, Sheer Logistics. Nick has over a decade of experience in the logistics industry, spanning marketing, public relations, sales enablement, M&A and more at 3PLs and 4PLs including AFN Logistics, GlobalTranz, and Sheer Logistics.

Crafting the Perfect Fill

Cyndi

Filling Equipment Insights for Brewers and Distillers

By Alyssa L. Ochs

In the craft brewing and artisanal distilling industries, every detail matters – from the meticulously curated ingredients to the final presentation and every step in between. One of the most crucial yet often overlooked steps in the production process is filling.

  Whether you’re filling a bottle of whiskey or a can of IPA, the filling step affects product integrity, shelf life, operational efficiency and regulatory compliance. Fortunately, modern filling equipment has advanced significantly, offering brewers and distillers advanced features that cater to the specific needs and styles of beer and spirits. 

  In this article, we examine how filling equipment has evolved and what it looks like in today’s forward-thinking breweries and distilleries. To gain further insights, we also connected with Tony Saballa, the owner of Fillmore Packaging Solutions, which offers affordable beverage packaging for craft beverage makers.

Types of Filling Equipment Available

  The ideal type of filling equipment for your operations depends upon your product’s carbonation level and viscosity. For example, gravity fillers work well for thin and free-flowing liquids, such as craft spirits. They use the force of gravity to move non-carbonated liquids from holding tanks to cans and bottles. You’ll often use gravity fillers for vodka, gin and whiskey.

  Piston fillers are commonly used for liqueurs that have a high viscosity. Using mechanical pistons, these fillers draw a specific amount of spirit into a cylinder before pushing it into your container. Cream-based spirits and syrups with a thick consistency often incorporate piston fillers. 

  Volumetric fillers help beverage makers achieve a consistent fill volume, allowing you to stay true to your brand while also ensuring legal compliance. Distillers often use volumetric fillers to make ready-to-drink (RTD) cocktails, as they provide high accuracy control and help maintain precise brand consistency. These fillers operate by dispensing a volume of liquid using a rotary pump or flow meter to measure and control the flow of fluid.

  Isobaric or counter-pressure fillers utilize specialized machines that fill beer and other carbonated beverages into bottles with consistent pressure, thereby preventing the loss of carbon dioxide. With isobaric fillers, you’ll achieve equal pressure inside the can or bottle during the filling process, thereby preserving the carbonation. In addition to beer, sparkling wine, cider and carbonated RTD cocktails often use this filling method.

Fillmore’s Equipment Offerings

  Based in St. Louis, Missouri, Fillmore Packaging Solutions helps improve packaging processes for overwhelmed and underserved small craft beverage makers worldwide.

  This company focuses on the mechanical side of the small beverage trade. It has beverage packaging machinery available for both carbonated and non-carbonated beverages, including beer, wine, cider, kombucha, sparkling water and RTD cocktails. 

  Tony Saballa from Fillmore told Beverage Master Magazine that his company offers automated packaging machinery for filling cans and bottles with multiple sizes and formats.

  “Our filling machines are primarily engineered for isobaric filling, also known as counter pressure filling, a method used for filling carbonated beverages under pressure to minimize foaming,” Saballa said. “Our fillers can also be used for filling non-carbonated beverages.”

  Saballa explained that Fillmore’s machinery doesn’t require any complicated installations and is designed to be easily moved into the workspace and rolled away when not in use.

  When asked about the type of electrical connections Fillmore fillers require, he said, “Our fillers are engineered to operate from a standard 120-volt, single phase power outlet, so there are no specialized electrical connections required.”

  Saballa shared that Fillmore products’ packaging fill rates are always dependent on product temperature, carbonation levels and package size.

  “So, the typical fill rates our fillers range between 12 to 16 containers per minute,” he said.

  Fillmore’s equipment is designed to fit in a space of about three by five feet, or 15 total square feet. Its machinery can also be operated by just one or two people in a brewery or distillery, resulting in minimal labor requirements.

Precision Filling for Accuracy & Compliance

  Since the beer and spirits industries are heavily regulated, filling equipment is also relevant to legal compliance. Accuracy is of paramount importance when filling beer or spirits into cans or bottles. Regulatory organizations, such as the Alcohol and Tobacco Tax and Trade Bureau, require that containers meet volume declarations with minimal variation.

  Fortunately, today’s advanced filling equipment prioritizes precise and repeatable fills so that every can and bottle meet the appropriate volume requirements. For example, there have been significant technological advancements in sensor-based fill level detection, piston controls, digital flow meters and programmable fill settings.  

  This level of accuracy helps prevent product loss from overfilling, saving craft beverage makers money and resources. It also prevents underfilling, which can lead to compliance issues and customer dissatisfaction. When your bottles and cans are filled precisely, it shows that you pay attention to the details and run a professional operation that prioritizes quality control.

Automating the Beverage Filling Process

  In general, automated filling systems reduce your business’s need for extensive manual labor and help prevent employee mistakes. However, compact automation solutions like those offered by Fillmore are a game-changer for small craft beverage makers with limited production space.

  Small and mid-sized beverage producers are consistently seeking ways to balance efficiency with their space limitations. With an automated filling system, you can maximize the space you have while streamlining labor demands and achieving high throughput. Every square foot matters if you operate in tight quarters, such as a shared co-manufacturing environment or converted warehouse.

  Gone are the days when automated filling solutions were only reserved for high-volume-producing mega breweries and distilleries. Now, craft beverage producers of all types and sizes are embracing automation technology and working smarter on a smaller scale.

Flexibility & Seamless Integration

  When it’s time to invest in new filling equipment, consider automated systems with a user-friendly setup to get up and running promptly. Another priority might be plug-and-play simplicity that doesn’t require costly upgrades or infrastructure expansions.

  As some modern craft beverage makers now produce multiple types of beer and spirits, flexibility is another priority for filling equipment. Distillers and brewers often look for filling equipment that can work alongside their existing systems and accommodate various bottle and can sizes. Pieces of filling equipment aren’t isolated machines but rather one of many pieces in a broader production ecosystem.

  Universal compatibility is top of mind for companies specializing in filling equipment as demand increases for variable speed settings, modular designs and adjustable container guides. It is now possible to fill carbonated and still beverages with the same filling equipment line, easily switching between cans and bottles with minimal adjustments.

Scalability for Future Expansion

  In the fast-evolving world of craft beverage production, it’s essential to plan not only for today but also for future growth. Filling equipment should support your current needs and your goals for the years ahead.

  It’s often advisable to start small with your filling equipment, such as with a compact and entry-level system that allows you to build capacity as demand hopefully increases. For instance, you could launch with a two- or four-head filler and then upgrade later to a six- or eight-head model, provided the electrical infrastructure and base frame will support the expansion.

  Scalability involves increasing both speed and versatility, as many beverage makers are starting to explore new products that deviate from their original creations. If you choose a flexible filling machine, you will be able to accommodate various fill volumes, types of products and multiple containers.

  Another goal of scalability is to minimize downtime, so you never have to shut down your production line to install a new system based on new needs. Automation modules, adding additional filler heads during scheduled maintenance and software upgrades can help you achieve this goal. Keeping these factors in mind will help you protect your filling equipment investment and help your business evolve with the times and shifting consumer demands.

What’s Next for Beverage Filling Equipment?

  Looking ahead, next-generation filling equipment promises even greater precision, adaptability and efficiency than ever before, benefiting breweries and distilleries.

  Emerging technologies include remote equipment access, allowing operators to control and monitor filling equipment from their mobile devices. There has also been progress in AI-powered diagnostics and monitoring, which can automatically adjust regulate carbonation, viscosity and temperature.

  Meanwhile, some innovators have been perfecting automated clean-in-place systems and adjusting machine design to improve production speed further and ensure legal compliance. Fully integrated beverage packaging lines that handle filling, rinsing, closing and labeling are also in demand as equipment-makers take smart technology and automation to the next level.

Beyond the Container

Cyndi

Understanding Packaging and Its Subproducts for Modern Breweries

Earthrings showing 3 six pack carrying containers for beer cans

Photo Credit: Earthrings

By: Alyssa L. Ochs

In the modern brewery, packaging is more than just a finishing touch or an afterthought at the final stage of production. Rather, it is a vital part of a brewery’s brand strategy, a way to improve operational efficiency and a mechanism for achieving sustainability goals.

  Innovative packaging technologies help breweries grow and adapt to changing consumer demands. Settling for what used to work in the past to package beer is no longer an option for forward-thinking producers. From wrap-around case packing to shrink sleeve application, side loaders and compact palletizing,  new packaging solutions are redefining what it means to be ready for production and attract a strong consumer base.

  This article explores various aspects of brewery packaging and its subproducts, driven by real-world insights and companies that are setting new standards for aesthetics, efficiency, and sustainability.

Primary Packaging Basics: Core Components for a Strong Foundation

  Simply put, the foundation of all brewery packaging operations is the containers holding the beer. Whether you pour your beer into cans, bottles, or kegs, this is the cornerstone of your primary packaging and the basis for which all subproducts must complement.

  Cans now dominate the craft beer industry because of their logistical advantages, recyclability, and durability. For cans, many breweries have begun to embrace shrink-sleeve application technology with full-wrap, high-impact branding.

  Producers like Mother Earth Brewing (Vista, California and Nampa, Idaho) have used automated cartoners to streamline the process of erecting and packing cases and trays. Modern cartoners allow easy changeovers between 12-ounce and 16-ounce cans and help breweries keep up with growing demands.

  Meanwhile, a sizable number of breweries still favor glass bottles for specialty beers or to celebrate nostalgia and beer-drinking traditions. Packaging bottles requires careful consideration for handling and shipping weight.

  Stainless-steel kegs remain efficient vessels for on-premise distribution, events, and international export. However, PET plastic, one-way kegs are trending as a sustainable and cost-effective alternative to stainless steel because of their lightweight, compact, high-oxygen barrier advantages.

  Closures, whether in the form of cap ends, swing tops, crown caps or keg fittings, are also primary packaging products critical to maintaining freshness and the necessary pressure.

Packaging Subproducts: Behind-the-Scenes, Yet Crucial

  However, there is enormous potential in the best uses of secondary and tertiary packaging materials, also known as subproducts. These materials play essential roles in protecting and presenting beer, as well as in distribution coordination and sustainability.

  For example, combined cardboard and film packaging are hybrid materials that offer excellent visibility and strength to a packaging strategy. Shrink-wrapping helps bundle beer multipacks and pallets. There are breweries that are moving towards biodegradable films and reduced-gauge materials to improve the eco-friendly qualities of their shrink wrapping.

  Wrap-around case packing systems are high-speed systems that can limit downtime and reduce the strain on machinery. Wrap-around cases that operate in continuous motion provide a precise and fast way to create and seal boxes around beer products, thereby improving line efficiency and speeding up the packaging process.

  For example, Summit Brewery Company (St. Paul, Minnesota) has achieved virtually no downtime and no needed repairs using an InvisiPac® Tank-Free™ Hot Melt System. Graco worked with the brewery to boost production efficiency by reducing hot melt adhesive waste and stabilizing the rate of glue consumption.

  Shrink sleeve applications are popular because of their 360-degree branding opportunities. They are ideal for cans and specialty bottles, conforming to unique contours better than pressure-sensitive labels. Breweries love this trend because of the vibrant, high-impact branding that does not require pre-printed containers. Shrink sleeves enhance brewers’ branding flexibility and are ideal for seasonal brews and limited releases.

  Other essential packaging subproducts include tray packs, dividers, and side loaders. Corrugated trays and side loaders help maintain line efficiency and prevent damaged products. This is especially critical when packaging beer in glass or mixed-format packs.

  Cardboard carriers and dividers protect units and enhance their visual presentation for consumers. By combining cardboard and film packaging, a brewery can use less material than it would with traditional cartons while ensuring visibility and protection.

  Other aspects of packaging are the inks and adhesives used on beer labels. At a minimum, these materials must stay affixed to the product and be readable. However, you can use water-based inks and adhesives that are low in volatile organic compounds to tap into eco-minded consumer preferences and support your brewery’s sustainability initiatives.

Evolving Automation: Equipment Innovations for All Sizes of Breweries

  In the past, automation was only considered relevant for large, well-established breweries with extensive packaging needs. However, even smaller breweries are embracing automation because of the compact packaging systems now available.

  For instance, breweries can find compact palletizing solutions that are designed for small spaces. You don’t need a warehouse-sized space to automate your brewery with a compact palletizer.

  Breweries of all sizes can also automate their packaging with side loaders and tray packers. These investments help brewery packaging lines move at high speed and overcome labor concerns. Side loaders efficiently place cans and bottles into cartons and are often used alongside wrap-around case packers to reduce manual labor.

  Advanced machinery solutions like wrap-around case packing can streamline operations with minimal stop time. The result is faster throughput and reduced wear and tear on machinery components. Shrink sleeve applicators can accommodate various container sizes and shapes, even allowing for late-stage customization if design ideas change over time.

Brewery Packaging with Sustainability in Mind

  Eco-friendly brewing is no longer a niche — it is a requirement for modern beer producers. Breweries must weigh the pros and cons of the materials they use for beer packaging considering where they came from, how much they strained natural resources to produce and their recyclability.

  Fortunately, breweries can boost their sustainability and lower their carbon footprints in many ways. Lightweight materials, such as thinner bottles and cans, can help reduce vehicular emissions from trucks used to transport products. If you package and label your products onsite rather than outsourcing this work, you can maintain greater supply chain control and produce beer sustainably.

  Meanwhile, using recyclable and compostable beer carriers is a fantastic way to reduce landfill waste and release fewer planet-overheating gases into our environment. Film-cardboard hybrids help breweries reduce plastic waste while still being visually appealing and durable. Eco-friendly carriers perform well and can now often be recycled or degrade naturally once discarded. 

  To prioritize sustainability, breweries can also work with their packaging suppliers to develop eco-friendly formats tailored to their unique needs. Customization is now commonplace in this industry, as breweries do everything they can to stand out from the competition in a crowded marketplace.

  There are also reusable and refillable bottle and keg return programs that breweries can investigate. These types of programs are expanding throughout North America and Europe, making them legitimate options for many modern breweries. Exploring all available sustainability options can help brewers align their business with their environmental values and comply with changing legislation.

  Multiple innovative companies are now working in the sustainability space to give breweries more options.

  UniKeg offers PET plastic kegs as a lightweight, cost-effective solution to traditional steel kegs. Earthrings is a company that offers 100% recyclable and compostable beverage rings constructed from sustainable cardboard.

  Another company, WestRock, offers paper-based brewery packaging solutions, such as cartons and multipacks, to help brewers reduce their plastic use. DS Smith collaborated with Martins Brewery to develop a custom, sustainable six-pack handle packaging product for glass bottles.

  These are just a few examples of companies that have identified a need in this space among breweries and risen to the challenge to help promote sustainable beer production.

Final Thoughts and the Future of Beer Packaging

  Although brewery packaging subproducts might seem like minor factors in the overall production and sale of products, they collectively have a significant impact. Subproducts can either make or break a brewery in terms of shipping efficiency, regulatory compliance, labor demands and carbon footprint.

  Looking ahead, the craft beer industry has a lot to look forward to with regard to smart and sustainable packaging. Technology companies have made QR codes and smart labels accessible and enticing as a way to market content directly to consumers.

  There has been a trend towards even small nano- and microbreweries investing in compact and mobile canning solutions to reduce their reliance on third-party companies. With sustainability now top-of-mind for breweries worldwide, eco-design integration is increasingly important. Now, breweries must not only think about how their products are packaged but also where they will end up after they are used — ideally recycled, reused, or composted.

How to Elevate Your Products with the Best Flavorings

Cyndi
a man and two women around tubes and bottles

By: Alyssa L. Ochs

There will always be something appreciated and cherished about beer that tastes like beer and spirits that remind us of what we’ve always known and loved about them. However, there’s also significant value in the unique and creative additions of flavorings to our favorite craft beverages.

  Flavorings have the potential to help breweries and distilleries stand out in a crowded market if they are willing to experiment with classic flavors and emerging trends. Whether you use fruits, spices, herbs or aging techniques, flavorings offer endless possibilities to cater to consumer tastes and help beverage brands establish distinct, memorable identities.

To learn more about the possibilities of flavorings in the modern craft beverage industry, we connected with two prominent leaders in this field: Beck Flavors and Mother Murphy’s Flavors.

The Evolving Role of Craft Beverage Flavorings

  With thousands of breweries and distilleries operating across the country, distinguishing your business from the competition has never been more crucial. These days, running a successful craft beverage operation requires considerably more than just making a great product. Customized flavors offer brewers and distillers opportunities to create a unique identity while showcasing regional tastes and catering to a local customer base.

  Nick Palank, marketing manager for Beck Flavors, told Beverage Master how his company’s primary focus is collaborating with brewers to develop tailor-made flavor profiles that align with their brand identity, resonate with their target audience and leverage emerging trends.

  Beck Flavors is a family-run business that has been around since 1904, creating custom flavors for over a century. Based in Maryland Heights, Missouri, Beck Flavors serves various food and beverage sectors and prioritizes environmental sustainability and community engagement in the local St. Louis area.

Palank referenced recent Brewers Association statistics showing that fruit-forward beers account for a 25 percent increase in new craft beer releases. This indicates an increasing demand for refreshing, bold and complex flavors. He also pointed out how breweries are interested in creating desert-inspired beers with nostalgic and indulgent flavors while also pushing boundaries with tea-based fermentation and botanical infusions. Meanwhile, there is substantial interest in seasonal flavors and limited-edition releases, perhaps even collaborating with local chocolatiers, spice companies or coffee roasters. These efforts have the potential to boost taproom traffic as consumers embrace the changing seasons lean into shifts in their drinking preferences. 

  “With 65% of craft beer consumers actively seeking new flavors, breweries that embrace this trend have the potential to drive significant engagement and brand loyalty,” Palank said.

  “Our strategy combines market research, sensory testing and expert formulation to help breweries develop beers that aren’t just flavorful but also commercially successful,” Palank shared. “The craft beer industry thrives on creativity and innovation, and with the right custom flavors, microbreweries can craft not just a great beer, but a signature drinking experience that sets them apart from the competition and keeps customers coming back for more.”

  Beyond just traditional beer, Beck Flavors is also working with breweries in the ready-to-drink (RTD) and non-alcoholic (NA) spaces.

  For example, flavorings add depth and richness to NA beers so they don’t fall flat or taste undesirably simplistic. Lower-alcohol, session-style beers can incorporate flavors to entice casual drinkers looking for 4 percent ABV or less options. Meanwhile, hard seltzers, hard teas and kombuchas with added flavorings can expand RTD offerings and give consumers more choices based on their curiosities or wellness goals.

Current Flavoring Trends

  “We have been creating a lot of indulgent profiles, such as pumpkin cheesecake, and unique fruit profiles, such as clementine flavors,” Al Murphy, the CEO of Mother Murphy’s, told Beverage Master Magazine. “We are always trying to create new flavors for spirits that have never been used in the alcohol and beverage industry.”

  Mother Murphy’s is a family-owned food flavoring business that has been operating since 1946. Murphy family members still own and run the company, which is headquartered in Greensboro, North Carolina. From humble beginnings as a two-man side business, Mother Murphy’s has expanded to employ over 150 people and ship its flavorings to more than 30 countries.

  Murphy said that sweet, indulgent and fruit flavors are all trending right now, based on his company’s experience working with breweries and distilleries. As gathered from consumer preference research, he said their top 10 flavors were the following: mimosa, prickly pear, cucumber, blueberry, sour, rosé, ginger, mandarin/tangerine, blood/red orange and pear.

  To keep up with trends, Palank from Beck Flavors said that his company leverages market intelligence and consumer insights through comprehensive research, trend analysis and data-driven reports utilizing resources like Mintel, Innova, and Tastewise.

  With regard to 2025 trends shaping the beer industry, Palank said, “In the U.S., citrus remains a leading flavor in craft beer, with tropical flavors also showing high growth momentum. These flavors are approachable and familiar, making them a safe yet exciting choice for consumers. Microbreweries can experiment with combinations like pineapple and orange peel to create refreshing, vibrant beers. With consumers seeking globally inspired experiences, flavors like yuzu, calamansi, prickly pear and lychee are giving beers a fresh twist.”

  Palank also said that dessert-inspired flavors reminiscent of doughnuts, chocolate, or gelato invoke a sense of indulgence and nostalgia for childhood memories in consumers. Examples of these “special treat” beers include caramel pecan porters and cereal milk IPAs.

  “In Europe, the use of herbs and spices in craft beer is on the rise,” Palank said. “This trend is driven by the desire to enhance sensory experiences and flavor intensity. Pairing herbs with citrus flavors is particularly popular, offering a refreshing twist that appeals to consumers seeking novel taste experiences. Ingredients like cinnamon, hibiscus and Sichuan peppercorn are adding complexity to beer profiles.”

  Another interesting trend is hybrid beverages, which includes unique creations like tea-inspired beers, cocktail-inspired brews and coffee-infused lagers that push flavor boundaries to the next level.

How to Create Custom Products with Flavorings

  The process of getting started with flavorings involves reaching out to an expert company like these two highlighted here to discuss your motivation to try flavorings and devise a customized solution based on your company’s unique beverages. Both Mother Murphy’s and Beck Flavors offer the opportunity to request flavor samples to help you narrow down your options.

  “We don’t just create flavors — we help breweries craft memorable drinking experiences that set them apart in the industry,” said Beck Flavors’ senior applications manager and technical sales representative, Adam Berge. “By combining data-driven insights, expert formulation and meticulous testing, we partner with brewers to bring bold, innovative flavors to life, ensuring that every beer tells a story and captivates consumers.

  Berge went on to explain how his company conducts market intelligence and sensory research to identify trends and emerging consumer preferences before diving into flavor development. Once they identify a flavor direction, the research and development team takes over to develop a formulation that integrates with the company’s beverage style.

  “Once a flavor is developed, we offer breweries a sensory testing process to ensure that the final product delivers the intended aroma, taste and mouthfeel,” Berge said. “Sensory testing allows us to fine-tune intensity levels, identify any unexpected interactions and make necessary adjustments before full-scale production.”

  He emphasized the importance of ensuring a flavor is scalable and consistent across every batch. Successful flavors must perform reliably during all conditions to maintain a signature taste without confusing fluctuations from one drink to the next.

Considerations About Using Flavorings

  Al Murphy from Mother Murphy’s shared with us that one important consideration is to decide between natural or artificial formulations of flavorings for your beer or spirits.

  “Most companies use natural because they would like to have ‘natural’ on the label,” he explained. “Typically, artificial is cheaper, and you can use less but many companies don’t want ‘artificial’ on the label.”

  Murphy also mentioned a common mistake craft beverage producers make with flavorings.

  “Some distilleries don’t know how to use flavors in conjunction with acids and sugar,” he said. “They might know how to distill a spirit or blend a spirit, but they need a flavor partner that can help them create a flavored spirit product.”

  Beck Flavors’ principal flavor chemist, Rick Gibson, emphasized that craft beverage producers must integrate new flavors into their recipes to ensure balance, compatibility, stability and consumer appeal.

Gibson has nearly 50 years of flavor experience and is one of only around 400 Certified Flavored Chemists in the world.

  Gibson explained the importance of achieving the right balance between a beverage’s existing profile and a new flavor. For example, too much of any ingredient can overpower a beer, making it overwhelming or one-dimensional.

  “To prevent this, breweries should consider how flavors interact at different stages of the brewing process, including fermentation and conditioning,” Gibson said. “A well-integrated flavor should enhance rather than dominate, allowing drinkers to experience a harmonious blend of flavors with each sip. Our team at Beck Flavors works closely with brewers to fine-tune intensity levels, ensuring that every ingredient plays a complementary role in the final product.”

  There is also the crucial issue of pairing the right flavors with the right style of beverage. Some flavors naturally complement beverage profiles or are better suited to them, such as a bright citrus flavor paired with a hazy IPA or a coffee flavor paired with a porter.

  “Additionally, breweries should consider how flavor perception changes based on factors like alcohol content, body and carbonation levels,” Gibson said. “A highly carbonated saison may amplify herbal or floral notes, while a high-ABV imperial stout can support rich, dessert-inspired flavors like chocolate and maple. At Beck, we help breweries identify the best pairings based on their beer style and brand vision, ensuring that new flavors feel intentional rather than forced.”

  Beverage producers should consider how flavors impact shelf stability and product performance over time. Gibson noted that certain fruit extracts lose their vibrancy after a while, yet cinnamon and nutmeg become more pronounced as beverages naturally age.

  But ultimately, beverage producers must keep consumer preferences in mind at all times when implementing new flavors. Requesting in-person feedback and online reviews from loyal customers is an effective way to gauge interest in new flavored beverages and assess consumer behavior.

  “Understanding what drinkers are looking for — whether they’re adventurous craft beer enthusiasts or casual consumers seeking familiar, approachable flavors — is key to developing a product that sells,” Gibson said.

Consumer Awareness Shows an Emerging Regenerative Market

Cyndi
barista pouring beer into a glass mug from a brass tap with wooden handles

By: Erik Lars Myers

The beer pours a rich amber color, crystal clear, with a stark white fluffy head. Warm caramel-sweet malt aromas greet your nose from the glass, counterpointing the earthy hedgerow bouquet of East Kent Goldings hops. It is Reset ESB, a drinkable, classic, English-style ESB. It is also the world’s first Regenfied™ Certified Beer.

  The vast majority of the malt in this beer brewed at Fullsteam Brewery in Durham, NC is Regenfied™ Southern Select, a 2-row base malt created Riverband Malt House in Asheville, NC, the first – and currently only – malt house in the world to malt Regenified™ Certified barley. This particular batch of barley is Avalon, a malting barley created at Virginia Tech’s Small Grain Breeding Program specifically for farms in the South. It was grown at Harbor View Farms, a Tier 3 Regenified™ Certified farm in Rock Hall, MD. That traceable pathway is one of the main considerations toward Fullsteam’s use of the Regenified™ seal.

Becoming Regenified™

  Regenerative farming is a philosophy that covers a wide range of farming practices. At its base, regenerative agriculture is a method of farming that focuses on practices that are meant to create and maintain healthy ecosystems and preserve sustainable farmland for future generations. It prioritizes soil health, reduces reliance on synthetic herbicides, pesticides and fertilizers, and nurtures the land as well as the people who use it.

  Over time, farms that use regenerative practices have shown a long-term increase in yield benefits in their farmland. These farms reduce their carbon footprint, conserve water, and grow healthier food. They also safeguard the long-term viability of their farmland in the form of improved biodiversity, reduced erosion, and a reduction in local water pollution. This is achieved through careful cover-cropping, rotational grazing of livestock, no-till farming, and a wide variety of other practices.

  But it isn’t easy. The short-term switch from conventional farming to regenerative farming can mean investment in different tools, practices, and labor. It can also mean a reduced yield while the switch is being made, a daunting proposition in an industry with already razor-thin margins.

  That is one of the reasons that the Regenified™ certification works a little differently than other certification programs. Rather than simply working to meet a target – the “if you meet these documented conditions then you qualify as Certified” method – Regenified™ exists in progressive tiers in a way that helps farmers build toward a regenerative farming future, setting goals over years to work in new processes, increasing their regenerative practices while building a better and stronger future for their farmland. In turn, the Regenified™ Seal helps manufacturers and end consumers identify the products made with these farming practices.

  A 2024 consumer product report by Regenfied™ shows an ever-increasing consumer awareness of “values-based shoppers.” Their report shows an “Emerging Regenerative Market” whose consumers are willing to pay more for regeneratively farmed products and seek them out when they can, noting that they are “especially interested in supporting regenerative agriculture across core product categories such as fruits and vegetables (83%), eggs (60%), dairy (56%), meat (52%), and grains (48%).”

  For companies like Riverbend Malt House and Fullsteam Brewery, it means putting their money where their mouth is.

Regenified™ Manufacturing

  “Regenified™ malt is crucial to our triple bottom line approach,” says Brent Manning, one of Riverbend Malt House’s founders and Chief Strategy Officer. “We’ve always prioritized people, planet, and profits. When we started over a decade ago, we really wanted to focus on organically or sustainably farmed barley. At the time, mother nature had other plans for us. After an early difficult growing season we had to choose between conventionally farmed grain and keeping the business open, but now we have the opportunity to refocus on a mission that, at its core, is vital to who we are.”

hand holding a handful of grain

For Fullsteam Brewery, it was a no-brainer. “It really fits into our core values and mission statement,” notes Jon Simpson, Fullsteam Brewery’s Director of Brewery Operations and Innovation. “Supporting Southern agriculture and what we think of as ‘the Southern beer economy’ through our purchases has been at the heart of Fullsteam’s mission since its beginning. Investing in a specifically southern grain created by one of our local partners that supports the future of farming in the South is a perfect fit.”

  Over the past 15 years, Fullsteam has acted on its mission to the tune of approximately $1 million of locally sourced ingredients. Riverbend is one of their primary local partners, and so the opportunity to create a series of beers centered around this malt was serendipity.

  For both of them, fitting Regenified™ certification into their process isn’t very much of a disruption and in many cases flows directly with how their operations are designed, which is primarily based around traceability and lot tracking. Traceability, something that larger breweries or maltsters may have to create specific processes for, is often just business as usual for small- or mid-sized breweries.

  “We still receive all of our grain in super sacks,” Manning says, referring to the 2000 lb totes that bulk grain is shipped in. He notes that lot tracking to a farm, or even a field level, might be something that larger maltsters might have an initial issue with, but that it’s part of Riverbend’s normal operations. Since the outset, part of their process has been tracking individual strains of barley from different farms and regions because those different strains and regions have significant flavor profile differences. They pass along that information to their brewery and distillery partners to help govern ingredients choices but also as a means for differentiation.

  Similarly, at Fullsteam, tracking the use of local ingredients in each beer has been a mission for so long that for Simpson, keeping this particular supply chain separate is just a normal day-to-day operation. “The biggest change has been making a more detailed note in our brewing logs noting the exact lot number and source of the grain.” Of course, making a well-balanced beer often means using more than one type of malt, but for the Reset line, 100% of the base malt for the beer is Regenified™ making up 80%+ of the grist. The rest of the malt is sourced locally from one of North Carolina’s three malt houses.

Regenified™ Value

  For both Fullsteam and Riverbend, the decision to use Regenified™ malt is one of prioritizing their own values and recognizing that some purchasing decisions are not driven solely by price but by the greater impact it might have in the world.

  “They’re small steps,” Simpson says, “But they add up. You take all the small steps you can and know that at the end they’re having a larger impact together.”

  Manning notes that for larger businesses – he specifically mentions large distilleries – locally grown, regeneratively farmed grains are way to significantly impact their supply chain-based carbon emissions. But the same is true for every size of food or beverage manufacturer. Whether it bears out to more sales in the market or not is still up in the air, but for these producers it’s all part of their larger strategy anyway.

  “Does it get traction?” Simpson mused, “Hard to say. But it’s definitely attractive to certain customers that are important to us. Retail partners like Whole Foods, among others, are more apt to focus on environmentally conscious manufacturing and ingredients. The Regenified™ Seal makes it easier for customers to recognize that value on the shelf. And that’s worth it as far as we’re concerned.”

Fullsteam Brewery’s Reset ESB: https://www.fullsteam.ag/beer/reset-esb

Riverbend Malt House’s Regenified™ Southern Select: https://riverbendmalt.com/malt/regenified-southern-select/

Regenified™ 2024 Consumer Report: https://regenified.com/2024consumerreport/

About the Author

  Erik Lars Myers is an award-winning professional brewer and lover of beer. He has written two travel guides about beer and written and edited multiple books about homebrewing.

Make Your Own Ready to Drink Cocktails

Cyndi
cans of different ready-made cocktails

By: Kris Bohm: Owner of Distillery Now Consulting LLC.

Canned cocktails are the largest growing category in sales of spirits in the past 4 years. Canned Cocktails also known as RTDs (Ready to drink cocktails) are hot right now! The sale of drinks classified as RTDs grew 24% from 2022 to 2023. (Neilson) There are many ways to create canned cocktails and an abundance of variety in flavors of canned cocktails.

  Starting with a product concept all the way to creating a finished product is an immense and difficult adventure but well worth the work, when done right. This article will discuss in detail one particular way of producing RTDs and cover all aspects of creation and manufacturing. Along the way I’ll also share the lessons learned from launching ready to drink cocktails. Let’s learn about canned cocktails!

  As a beverage alcohol producer if you are struggling to grow it may be time to go on the lookout for the next trend in beverages to grow your business. If growth is a good measure of new trends then RTDs are the answer. When distilleries first started producing RTDs several years ago there was a sense of uncertainty as to whether RTDS would be a short lived trend. This uncertainty came from several places. There were horror stories of recalled products from cans exploding (Trust me i was there). Distributors said the price point was too high for canned cocktails compared to beer and retailers were not willing to give RTDs space on their shelves.

  Flash forward to today and canned cocktails are thriving and selling at a much higher price point per unit than beer. Now we do not want you to have to recall a product or having exploding cans so before you jump right into making your own RTDs let’s talk about how to develop a product.

  When it comes to manufacturing RTDs there are hundreds of aspects that must be given consideration in preparation to create a successful product. If your goal is creating an RTD then start first with answering all the questions we have outlined before you commercially package your product. Below is a list of canned questions that you should answer.

•  What type of cocktail do you want your RTD to taste like?

•  How boozy do you want it to be?

•  Is the product highly carbonated, lightly carbonated or noncarbonated?

•  What ingredients will be utilized to flavor the RTD?

•  If the product is sweetened what kind of sweetener will you use?

•  Will you use juice or other natural ingredients and are they readily available?

•  Is the formula for the product shelf stable?

•  How long will the product last before it expires?

•  Is refrigeration needed to store the packaged product?

•  How will the product be branded and marketed?

  It is essential to answer these questions before you get ahead of things and package a product. RTDs are not the same as beer or distilled spirits. It is essential to be diligent and give careful consideration to the product formula, flavor, cost, packaging process and shelf life before a product is released. Spending a considerable amount of time in product development and quality assurance testing will save you money and headaches. Good product development can avoid problems as your project moves from concept to a finished ready to drink product. 

  One of the critical steps in product development is selection of the packaging itself. Once a product formula is developed one must give consideration to the container the product will go into. Whether canning boxing or bottling selection of the packaging and material the packaging is made from is key. The package will dictate the equipment needed, the label on the package and many other factors that will require big expensive decisions. Cans are the most common and affordable choice for packaging. Cans come in a variety of sizes, shapes and different liner types. A second option for packaging a product is aluminum bottles. Aluminum bottles cost more than cans but they are unique and can provide differentiation to stand out in the vast sea of canned beverages. The actual volume of the packaging must be selected early, as part of the TTB formula and label approval process must include this information.

  There are a multitude of options for packaging, it is essential to make sure the container and the equipment are suitable for a product before you buy those items and start manufacturing products.

  When it comes to making an RTD one of the biggest expenses is the packaging line. This is the equipment that rinses, fills and seals the containers holding your product. If you do not already have a canning or bottling line there are numerous vendors who build equipment for packaging RTDs. Lets cover the key components of equipment that are must have tools to take distilled spirits and transform them into canned cocktails. Below we will discuss all the equipment and steps needed to produce a carbonated canned vodka soda.

  The first essential tool is water filtration. A water filter critical to produce clean and sterile water that tastes good. Water which will make up the largest ingredient in an RTD so it must have excellent flavor and a water filter will help control the flavor.

  The second tool needed is a brite tank and a chiller. The brite tank is used to store the product before it is packaged. The chiller provides the cooling capacity to reduce the temperature of the product down to ideal carbonation temperature in the brite tank.

  To carbonate a beverage effectively it must be cold, once the product is cold carbon dioxide is added to create carbonation. From the brite tank the product is transferred to a packaging line to be put into cans or bottles. A packaging line is a complex piece of equipment that handles the movement of the liquid and packages in sequence to clean the package, purge it to remove oxygen, fill with liquid, then place a lid or cap on the package and then seal it.

  Packaging lines can vary in speed from producing a few units per minute to hundreds of units per minute. Selecting the right packaging equipment first requires that the packaging be selected and tested, only then can the packaging line be picked out.

  If buying a full set of packing equipment is not the right step for you there are alternative options to consider for producing RTDs. The alternative path to producing a RTD is to partner with mobile canning companies that can package your product for you. Throughout North America there are several companies who offer mobile canning services.

  A mobile canner will come to your facility with all of the equipment needed to quickly and efficiently package your RTD. Mobile canning is an excellent route to take if your business is looking to test out a concept but might not have the space and or resources to install packaging equipment. When working with a mobile canner it is critical to still put a product through quality assurance testing before packaging and selling the product. It is important to note that with mobile canning it can add significant cost per unit and consideration in how the product is priced will play a role in working with a mobile canner.

  The upside of utilizing mobile canning is reduced initial investment. With a mobile canner there is no major capital investment in equipment required to get started which means you can start canning cocktails sooner rather than later, with less money invested.

  There are many reasons RTDs are taking the market by storm.Consumers have become more health conscious of what they drink and low calorie spirit based drinks fit that bill. RTDs are convenient and the perfect choice for those who want an easily accessible drink alternative to beer or wine. RTDs are far more portable than glass bottles and the accessories needed to make cocktails. Creating canned cocktails and selling them can be a challenging endeavor.

  Without question there is strong potential for your RTD to succeed if done well. Developing a successful RTD will certainly be a challenging and serious project but with good equipment and knowledgeable people your concept can be brought to life. Sales of canned cocktails are growing tremendously year over year.

  Take the leap and join the revolution by producing your very own RTD. Canned cocktails are opening doors to serve cocktails in places that spirits cannot be found and a RTD can become the key product to grow your beverage business.

Kris Bohm - Owner of Distillery Now Consulting

Kris Bohm is the owner of Distillery Now Consulting where he is the head unicorn wrangler. Bohm has also developed some mighty tasty and successful RTDs. He can be reached at distillerynow@gmail.com

Sourcing Grains for Craft Distilled Spirits

Cyndi
two men standing at bag with grains in their palm

By: Becky Garrison

According to Michael Swanson, co-founder, farmer and distiller for Far North Spirits (Hallock, Minnesota), craft distillers have an excellent opportunity to highlight the difference between a crop grown for flavor compared to a crop grown solely for yield. This distinction affords them unique opportunities to explore how to source the specific grains that will produce a spirit with a particular desired flavor profile.

  Swanson cites rye as an example, as that’s the primary grain he utilizes in his whiskeys, and he observed how this scenario plays out similarly to many crops. As he observes, historically and across multiple countries, winter rye has been grown and sold as a commodity. There are exceptions to this, particularly in pre-prohibition Pennsylvania, where rye was grown specifically for use by the many distilleries across the state. But for the most part, rye was and still is treated as a commodity. However, when they started growing rye to distill into whiskey, they realized that their particular variety had a distinctive flavor profile.

  So, Swanson and his team conducted a three-year crop research study that was the first of its kind. In this study, they grew 15 different varieties of rye and then milled-mashed-fermented-distilled them individually. From this, they could determine that all other things are equal, the variety of rye alone affects the flavor of the whiskey. Also, after barrel aging the whiskey, they found that the aging process amplified the differences in flavor between the varieties. In particular, the open-pollinated varieties showed a much broader flavor spectrum than the hybrid varieties.

  Despite the increase in flavor in the open-pollinated varieties, the hybrid varieties have been quickly gaining acreage across the U.S., Canada and Europe because of their much higher yields. These high yields enable farmers to increase their gross revenue to the point that growing hybrid rye can be almost as profitable as a corn/soybean rotation, with much lower input costs. But growing the majority of open-pollinated varieties at this price point isn’t profitable. Hence, mass producers of whiskey aren’t willing to pay more for open-pollinated rye due to the massive number of bushels that they consume in a year.

Talking About Terroir

  Swanson has observed that craft producers who focus on producing products based on flavor rather than yield are willing to pay more for grains with a broader spectrum of flavor. To this end, craft distillers have started conversations about terroir that are very similar to defining a wine by taking into account factors such as the vineyard where the grapes came from and the AVA where this vineyard is located. Simply put, place matters, with regional differences emerging among whiskeys produced by craft distillers based on where the grains are grown.

  Miles Munroe, master blender for the Portland, Oregon-based Westward Whiskey, views barley similar to how a winemaker considers different wine styles, the different grape varietals and the various climates in which they’re grown.

  “We know that barley types, soil, and climate bring diversity and complex flavors to whiskey. The shape of our custom pot stills and the way we approach distillation allows for the most amount of grain character to come through, so we’re focused on high-quality barley that has a sense of place,” he reflects.

  In recent years, the Skagit Valley in Western Washington State, situated along the same latitude as the Scottish Highlands, has emerged as a major agricultural hub. This distinction led to Copperworks Distilling Company (Seattle, Washington), Westland Distillery (Seattle, Washington) and Westward Whiskey emerging as leading players in the evolution of the creation of American Single Malt as a new spirits category.

Sourcing from Malthouses or Direct to Farmers

  Except for a select number of distilleries that malt their grains in-house, distillers work with a malt house to source and then malt the grains according to the distiller’s particular specifications for a given spirit. These malt houses can ensure that the grain meets minimum specifications so that it can be malted.

  Some craft distillers follow the model of distilleries like Westward Whiskey, where they work with malt houses that source local barley, which gives their spirits a sense of where the grain is from. Miles Munroe, master blender for Westward, chooses two-row barley because it meets the standards of what craft brewers also expect. So, they select their malt houses with these criteria in mind.

  Others, like Tyler Pederson, master distiller at Westland Distilling, work with a network of local malt houses and brokers to source their malted barley. These partners work with regional farmers to select and procure the raw barley they malt to their specifications. Pederson describes this process, “It’s a very involved effort, and we collaborate with everyone throughout our supply chain, even going so far as funding a barley breeding program to develop new varieties for the whiskey industry.”

  Westland’s Colere editions were created specifically to reflect how different varieties of barley offer different flavors. To date, they’ve released three expressions: Colere #1, made with Alba, #2, made with Talisman and their current expression and #3, made with Pilot. How Westland sources its grains was one contributing factor to its achieving B-Corp Certification in 2024.

  A small but growing number of distillers like Far North Spirits purchase their grains directly from the farmer. According to Jason Parker, co-founder of Copperworks Distilling Company, “This represents a new way of doing business where a customer is getting better flavor, sometimes at the expense of a good yield.” He cites his experience sourcing a barley variety named Alba as an example. After they created a delicious whiskey using Alba, they found their local malt house had encouraged their supplying farmers to quit growing it because they found another barley that was easier to malt and produced a higher yield. But it didn’t taste like Alba, and now the flavor it produced is no longer possible to produce.

  To convince farmers to grow specialty grains like Alba that may yield fewer bushels per acre or perform less efficiently in the malthouse, they put the word out to farmers that they were willing to pay the farmers per acre instead of per bushel. Once they contract with farmers to bill by the user rather than the bushel, thereby sharing the risk with the distillery of planting grains for flavor rather than yield, they will contract with a local malt house, such as Link Foods, to malt the barley.

  Before contacting farmers, Swanson recommends doing research into the specific varieties of grains that grow best in one’s particular area. This knowledge will help ensure that the farmer can grow this particular grain variety in a large enough quantity without sacrificing quality such that the farmer can make a profit and the distiller can produce a quality spirit.

  Gabe Toth, lead distiller for The Family Jones (Loveland, Colorado), describes how working with Olander Farms/Root Shoot Malting, which is less than five miles from their production distillery, affords them multiple opportunities. “We can develop local, unique flavor, keep our dollars local and support local businesses. We can also reduce our supply chain footprint, reducing both our vulnerability to disruption and our carbon usage via transit and work directly with our farmers to experiment with new grain varietals. This helps us support on-farm sustainability initiatives or collaborate on other projects that are a result of having direct relationships and even friendships with them.”

Challenges in Sourcing Grain Directly from Farmers

  In Toth’s estimation, price is probably the major factor working against this approach, followed by uniformity. As he reflects, “Commodity agriculture over the last several decades has increasingly squeezed small farmers out of the market, and the relatively small farms we work with don’t have the economies of scale to leverage for competitive pricing. Local grain can also be more prone to variability compared to a large processor that can over-contract and be more selective or blend away variation.”

  However, Parker reminds craft distillers that focus on making value-priced whiskeys, as opposed to flavor-driven whiskeys, that they can’t compete with the big producers on price. Big companies have economies of scale and contracts that are not available to craft distilleries. “So, you might as well chase the one thing you can control, which is good, unique flavor. To do that, you probably don’t want to be putting the cheapest ingredients in but rather use grains and other products that make a real flavor difference.”