Issue link: https://read.dmtmag.com/i/670021
w w w. v w m m e d i a . c o m M a y - J u n e 2 016 | V I N E YA R D & W I N E RY M A N A G E M E N T 5 3 AUTOMATION Jordan produces approximately 105,000 cases each year. At 120 bottles per minute, the fully auto- mated MBF bottling line it pur- chased through Scott Laboratories is out of reach for most wineries. However, Matt DiDonato of Pros- pero Equipment assures smaller wineries can package affordable equipment to make investing in their own line possible. "There are a number of ways to do it based on the company's budget, how much labor it has available and how much financing it can get." Simplistically, bottling equipment is referred to as semi- or fully auto- mated. A semi-automated bottling line consists of separate mecha- nized components requiring manual labor to move bottles from one com- ponent, or station, to the next. "It's labor-intensive, but there is a cost savings," says DiDonato. A semi- automatic line operated by three to five workers can reasonably pro- duce 300 to 400 cases per day. on one line. Each machine can do multiple things just by changing the parts on it," he says. DiDonato says wineries now typically purchase their first bot- tling equipment using two strate- gies. Like St. Julian, they start with all semi-automatic machines then upgrade to one or both monob- locks at a later time, or they start with a single monoblock, add semi- automatic machines for the other operations and eventually upgrade with a second monoblock. "We see the switch to a fully automated line around 5,000 to 5,500 cases per year. That's typically the break- ing point where owners can make the numbers work. Smaller produc- tions would probably have to mix and match." But even mix-and- match components have plenty of options that affect wine quality, production efficiency and packag- ing options. Remember, the more complex the machine, the more expensive it will be. BUYING VS. LEASING Generally, "a semi-automatic line is going to cost around $30,000; a fully automatic line starts at $75,000 to $80,000; and a half line, A fully automated line produces a completely finished bottle and, if it includes pallet-handling and case loading equipment, can pro- duce finished cases. These lines require four to seven very fit people and produce, at minimum, roughly 1,000 cases per day. They can be created by creatively linking semi- automated equipment together, purchasing separate automated components and combining them or, more commonly, purchasing a prepackaged series of equipment made by the manufacturer, called a monoblock. There are typically two standard monoblocks. One combines the rinser, sparger, filler and corker; the other combines the capsuler, heat shrinker and labeler. Both monob- locks may be purchased together or one at a time and assembled with semi-automatic components to complete the line. "Our next dream machine is a combination corker and heat shrink- er monoblock," says John Fifer of southwest Michigan's St. Julian Winery. For now, he works with St. Julian's fully automated line assem- bled from mixed components, most of which were purchased in 1995. "We now do 60 different products The GAI 2401 at David Coffaro Vineyard & Winery in Geyserville, Calif., features a deaeration station, 12 spits gravity filler, gas injector and corker closure. It can handle up to 3,000 bottles per hour. [Photo courtesy of Prospero Equipment] + It's important to budget, understand your needs and do your research before purchasing a bottling line. + You can begin by purchas- ing parts separately, then adding more and making adjustments toward full automation as your business grows. + Leasing may seem attrac- tive, but can prove more expensive over the long haul. + Ongoing maintenance and knowledgeable employees are imperative for success. + There are advantages to employing mobile bottlers, but it requires careful planning. AT A GLANCE