Bottling season is one of the most critical—and often stressful—times in wine production. Whether you’re managing a small or large winery, ensuring a smooth, error-free bottling run can save you from costly mistakes and inefficiencies. In our latest Expert Talks episode, we sat down with Melissa Hackett, owner of Wine Unfiltered Consulting, to discuss the keys to mastering bottling operations.
Melissa brings over 16 years of experience in winemaking and winery operations, having worked at 11 wineries across two states. Her expertise lies in streamlining production processes, adopting new technologies, and ensuring wineries run at peak efficiency. In this episode, she shares invaluable insights on how wineries can optimize their bottling runs for maximum success.
The Problem with a “Just in Time” Mindset
Many wineries approach bottling with a “just in time” mentality—ordering supplies, finalizing blends, and making last-minute adjustments right before the bottling date. According to Melissa, this approach leads to rushed setups, bottlenecks, and higher chances of errors. Instead, she advocates for a proactive approach, where all materials—bottles, closures, labels, and the wine itself—are staged well in advance. This ensures quality control and allows time to troubleshoot any potential issues before bottling day arrives.
A Timeline for Bottling Success
Melissa breaks down bottling preparation into three distinct phases:
- Long-Term Planning (8-12 Weeks in Advance):
- Edit labels and submit COLA approvals
- Order dry goods and packaging materials
- Finalize blends and stability adjustments
- Medium-Term Preparation (2 Weeks Before Bottling):
- Ensure wines are fully blended and stabilized
- Create the Bill of Materials in InnoVint
- Complete necessary adjustments for wine stability
- Short-Term Readiness (1-2 Days Before Bottling):
- Confirm wine stability and filtration needs
- Organize and stage dry goods
- Finalize QA/QC sheets and confirm bottling order
Building a Bottling SOP and Checklist
One of the most effective ways to prevent errors on bottling day is by developing a Standard Operating Procedure (SOP) and checklist. Melissa highlights key elements every winery should include:
- Wine Stability: Ensure heat and cold stability, along with proper chemistry parameters.
- Compliance: Verify label accuracy and COLA approvals.
- Quality Control Measures: Assign designated staff to oversee QA/QC checks.
- Equipment Checks: Confirm sanitation, nitrogen flow, and filter integrity.
Common Bottling Mistakes to Avoid
Mistakes on bottling day can be costly and time-consuming. Some of the biggest issues Melissa sees include:
- Unstable wines going into the bottle, leading to post-bottling issues.
- Last-minute adjustments to CO2, dissolved oxygen, and sulfur levels.
- Mislabeling or incorrect closure application due to lack of staging and order.
- Inadequate filtration, leading to wine quality concerns.
By running through a wine readiness checklist the day before bottling, wineries can catch and correct these issues ahead of time.
Preparing the Winery for Bottling Day
Beyond wine readiness, winery logistics play a crucial role in a smooth bottling run. Melissa advises wineries to:
- Clearly communicate the order of bottling so cellar teams can prep tanks accordingly.
- Stage materials in an accessible order to prevent last-minute scrambles.
- Ensure adequate space for glass storage and movement of packaging materials.
The Role of Technology in Bottling Efficiency
Technology can significantly reduce human error and improve bottling accuracy. Melissa recommends different tools for wineries of varying sizes:
- Smaller Wineries: Semi-automated bottling lines with inspection eyes to detect missing corks, capsules, or labels.
- Medium to Large Wineries: Fully automated monoblock bottling lines with camera systems for real-time quality checks.
- Essential Tools: FOSS, Admeo, InnoVint, Alcoholizer, Vivisely in-line DO monitors, and STARS stabilization systems.
Industry Trends in Bottling and Packaging
Melissa also touched on emerging trends in wine packaging, including:
- Growing popularity of smaller bottle formats (splits) in grocery stores.
- Increased demand for six-pack formats in premium wine markets.
- Continued dominance of large formats as status symbols in restaurants and high-end retailers.
Want more?
Connect with Melissa Hackett on her website: https://wineunfilteredconsulting.com/