WINEWORKS KEG FILLING GUIDE

Transcription

1 WINEWORKS KEG FILLING GUIDE VERSION 1.0 FEBRUARY : Introduction 02: RETURNABLE KEGS 03: ONE-WAY KEGS Key KEGS (Slimline & BaseLine) Eco KEGS, Boxkeg & MiniKegs 04: Keg Checklist 05: Other Keg Types

2 Introduction Interest in delivering wine in a large-volume format that does not require large amounts of glass disposal is rising, as the recycling of kegs means that carbon emissions are lower, given the smaller amount of packaging, ease of handling at the point of sale, and potential recyclable nature of some kegs. Keg delivery systems can be broken into two basic types returnable stainless steel kegs (just like the breweries) and one-way kegs, which remove the problems of return. Returnable Kegs: Stainless steel kegs are a robust, familiar and effective way to distribute your product to your customers. The three major issues to consider are how to fill the kegs, then how to collect the kegs and return them to WineWorks or your winery for cleaning and refilling, and the third is how to actually keep the kegs from being lost and conglomerated with the massive keg pools of Lion and DB, or even stolen. There are two ways to use stainless steel kegs to do this. The first is to supply and manage your own kegs. This requires an up-front investment, and a system of keg collections, as well as an investment in a washing, cleaning and sterilization station. An easier system to supply kegs to your customers is to use a keg hire service; in NZ an effective supplier is Kegstar. The main benefit to the Kegstar system is that there is no need to buy kegs, your capital can be utilised elsewhere, and that they collect your kegs from venues regularly so you don t have to. The data about where and how long kegs have spent at a particular location is available through your App, and this can assist in product rotation and improving efficiencies. The process is as follows: Winery forecasts and orders kegs Customer informs Kegstar when kegs are ready for collection via smart phone Empty kegs are delivered for cleaning and filling Text informs customer that full Kegstar kegs are arriving Winery organises distribution of full kegs to customers

3 Key Keg Key Kegs are available in two models the Slim Line, and the Base Line. We have filled several hundred of these now, and are finding that they are the most commonly accepted amongst the wine Industry, both for the domestic market and the export market. Initially there have been supply chain issues with agreed lead times not being met. This is appears to be due to several importers, and oversubscribed manufacturing capability, resulting in long lead times and orders being pushed out with minimal communication from the supplier. These issues have been improving, but they are still difficult to source. Geisenheim Univesity in Germany was commissioned to conduct an analysis of the differences between glass bottles, KeyKegs and Bag-in-box for various wines in The points they tested were colour intensity, sulphur loss and sensory difference, and after 12 months, and then a further 6 months after opening, KeyKegs were found to exhibit only small differences to glass bottles, while bag-in-box performed poorly in the same tests. For the full report click here. Base Line Slim Line PALLETISING: WineWorks stacks the 30 litre keykegs 6 per layer, with a layerboard between each, 3 high. 18 per pallet, with a layerboard on each layer, including on top and on the pallet itself. This clarifies the volume loaded in a container. Kegs are stacked with flat panels to flat panels also, to minimise movement. It also shows the WineWorks printed carton label placed on the blank panel of the keg. This will be something that you should decide, whether or not you identify the keg, as without a label the keg is indiscernible from any others. We generally show alc % and standard drinks, etc etc. Of course this is your decision and will depend on market requirements. Eco Keg Box Keg Mini Keg There are other kegs I the market that are not so commonly used, but the purposes of your knowledge, they are: EcoKeg BoxKeg Mini Keg

4 Keg Check-list 1. Carbonation vs. Still: If the product going into keg is to be carbonated, then the maximum carbonation level for any of the kegs to be filled is 6.0g/L of CO₂. Customers must be made aware of this. 2. Keg Coupling Types: There are many types of keg coupling in use through-out the world. The Australian and NZ markets use predominantly the same types of coupling, D & G. WineWorks has filling equipment that uses these couplings, which cover most of New Zealand s markets: Beware of kegs with couplings that are not of these types. 3. Filling Efficiency: It is far more efficient to fill the Stainless Steel and Ecokeg Kegs as they are intended for wet use and do not have to be inverted. They can also be filled on a load cell if required. The Keykegs are labour intensive and slow to fill manually. 4. KEYKEG Liners: If you choose Keykegs, extra kegs must be ordered. We have seen the liners fail with pin-hole leaks out of the bottom seam. Order an extra 5%. 5. Filling Method: In order to preserve the bottling line efficiency it is better to fill the kegs separately in a complete and integral process. This utilises a pump, and dedicated filter housing which is completley independent of any filling line. WineWorks Hawkes Bay has a dedicated 30 cartridge housing available for sterile filtration as kegs are filled. For further information contact Andrew Condon or Paul Botha. 6. Fill Volume: If Stainless Steel or Ecokeg kegs are chosen, then fill these kegs on a scale and use the calculation for wine density to establish the correct tare weight. 7. Traceability: Makes sure that keg caps are supplied with the kegs prior to filling. These need to be placed on the coupling post filling for hygiene reasons, and act as tamper evidency. WineWorks ensures a filling log is kept, and that each keg is identified and numbered as per filling sequence with a label. This can be placed on the cap or the keg. Try to source waterproof varnished label stock. 8. Post Filling: It is good practice to allow the kegs to settle for at least a week before transportation to make that full pressurisation is achieved when the liquid warms to ambient temperature. This can prevent CO₂ loss and leakage.

5 WineWorks has also Researched Other Options in the Keg Market: Petainer Best option from a logistics point of view as the lead time is going to be potentially shorter. Brief findings summary - Potentially to be manufactured in Australia - Options 15, 20 and 30 litre - Optioned with both a cardboard outer and a polypropylene option - Barrier is by the way a of scavenger - Shelf life depends on key size 15 litre = 6months litre 9 months - Has fittings that are compatible with both flat and well type (S and D) - HDPE is recyclable in New Zealand through Replas our current slip-sheet provider - Cardiff Group We recommend this as the best option of the non-standard kegs after the Petainer and in some cases will be a better than above. We have requested further details on all sizing this includes pricing. Brief findings summary: - 2 types of unit eco draft re-usable and expo draft one-way - Keg sizes 5,10, 15, 20 and 30 - Long shelf life (up to 2 years for beer) - The 5 litre version is shelf drafting (maybe good for HBIB) - HDPE is recyclable in New Zealand through Replas - Containers can be customised - Up to 10 bar pressure - Dolium Keg - Again another European designed keg available in 20 and 30 litres. Brief findings summary: - Available in a Type A flat fitting or a Type S well fitting (so we are not sure if it will work here and Australia (flat and well type). - Sits in a frame - FDA and EU approved - Pub Keg - Great concept but not really an option as the exterior portion of the keg is designed to be returned, but is an interesting concept. -