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Napa Valley College Winery Procedures Manual 1

NAPA VALLEY VINTNERS ASSOCIATION TEACHING WINERY

NAPA VALLEY COLLEGE

PROCEDURES MANUAL

Fifth Draft 2007

Prepared by the Students

of Winery Fall Operations

December, 2001 December, 2002

May & December 2003

Acknowledgements: Thank you to: The Napa Valley Vintners Association for generously donating the money to build the teaching winery. The many wineries, suppliers and individuals who have willingly donated equipment, cash, knowledge and time. Stacey Hitchcock for collating some of the SOPs into this manual.


Napa Valley College, Viticulture and Winery Technology Standard Operating Procedure

Table of Contents

Vessel Gauging Procedures……………………………..……………………...4 Stainless Steel Tanks……………………………………………………………….......4 Kegs……………………………………………………………………………………10 Carboys………………………………………………………………………………...14

Sanitation………………………………………………………..……………..18 Three Cycle Wash……………..………………………………………………..….....19 Sanitizing with Quat………….…………………………………………………….....22 Sanitizing with SO2 solution………………………………………………………......23 Sanitizing with Alcohol……………………………………………………………......25 Barrels………………………………………………………………………………...26 Barrel Preparation………………………………………………………………….…27

Pressure Washing Procedure………………………………………...……….28

Ozone Sanitation………….…………………………………………………...30 Tank Cleaning Procedure…….………………………………………………33 Assessing Grape Maturation……….………………………………………...36

Pre-harvest Preparation………………………………………………………41

Picking and Sorting Grapes prior to Winemaking……….………………....44

Making Additions to Musts and Wines…………………..………………….46 SO2 additions to juice and must…………………………………………………….....46 Rehydration of yeast for Fermentation………………………………………………..48 Nutrient Additions………….………………………………………………………....50 Nitrogen additions …………………...…….…...…………………………………….52 Tartaric Acid additions to Musts and Wines…………………………………..……...56 SO2 additions to Wines………………………….……………………………..……..58 Enzyme Additions….…………………………………………………………………65 Tannin Additions...…………………..………………………………………………..66

De-stemming and Crushing Grapes……………….…..……………………..70

Bleeding (Saignée)..……………….………………….……………………….73 Cold Soak………………………………….…………………………………..75 Cold Settle…………………….……………………………………………….77

Alcoholic Fermentation……………………………………………………....81


Punchdown……………………………………………………………………….85 Pumpovers………………………………………………………………………..89 Rack and Splash………………………………………………………………….91 Barrel Heat Exchanger……………………………………………………….…93 Extended Maceration Procedure……………………………………………….95 Pressing off from a Picking Bin…………………………………………………97

Malolactic Fermentation…………………….……………………………….....99

Pressing Operations-Bladder Basket Press for White Grapes………………101 Pressing Operations-Ratchet Basket Press for Red Wines……………….…104 Topping…………………………………………………………………………107

Stirring………………………………………………..…………………..….…108 Barrel Racking with a Wand…………………………………………………..109 Barrel Racking with a Bulldog Pup…………………………………………...113 Tank Racking………………………………………………………………..…117 Wine Filtration (mini scale)…………………………………..….…………….121 Wine Filtration (small scale)…………………………………..….……….…..124 Wine Filtration using a Pad Filter…………………………………..….……..126


Napa Valley College, Viticulture and Winery Technology

Standard Operation Procedures

Gauging Procedure For Stainless Steel Tanks Developed by Graham Baskerville and Richard Wolf November 2003 I Introduction Gauging of containers used to store and process juice and wines provides a fast means to estimate the volume of juice, must or wine in the container. This facilitates the accurate estimation of juice volume for the calculation of additives during processing and for record keeping. To avoid contamination of the juice/wine by the measuring device it is better to measure the height from the surface of the liquid to a defined reference point, usually the rim of the top opening, rather than measuring the depth of the liquid directly. This is why this method of determining wine volume is sometimes referred to as taking a: “dry measure.” The tables in the following section are for the NVC tanks. The procedure for gauging varies depending upon the type of container. This procedure is for vessels with a bottom outlet/valve, such as a stainless steel tank. II Equipment Vessel to be gauged 500 mL measuring cylinder 2L or 4 L jug 20 L bucket Marking pen T square graduated rule to reach close to the bottom of the container Tape measure Flashlight Straight edge to bridge the tank opening/frame Spirit level Step ladder to safely read levels through top opening Notebook to record results III Procedure 1. Place the container to be gauged on a stable, level surface. If there is not sufficient room

beneath the bottom valve outlet to accommodate the bucket then raise the tank on a forklift and ensure it is level using a spirit level.

2. Identify the reference point from which measurements are to be made, usually the top of the top flange if a stainless steel tank type container.

3. Close all valves and doors except the top and fill tank with water. 4. Place the straight edge across the frame or tank opening if the opening is larger than the T

square bar. Measure the reference point and record. (It may not be zero if a straight edge is used to support the T-square.)

5. To provide adequate resolution, water should be removed from the container in such increments that the container’s water level drops about 0.5” for each measurement. For the

Napa Valley College Winery Procedures Manual 5 tapering top or bottom sections of a tank, 2L or 4L is an appropriate volume to remove for NVC’s tanks. For the straight section 20L is appropriate.

6. Use the measuring cylinder to add 2L of water to the jug and carefully mark the water level on the jug. This mark will be used for subsequent filling of the jug.

7. Similarly measure 20L into the bucket and mark that level. 8. Drain 2L of water into the jug from the bottom valve. Throw away this water. 9. Record the height of the surface of the water and the volume of water removed. 10. Repeat steps 8 and 9 until the water level in the container reaches the top of the straight side

of the container. If the height change becomes < 0.25” then increase the volume of water removed for each measurement.

11. Once on the parallel section of the tank increase the amount of water removed at each measurement to 20L.

12. At the bottom of the parallel section reduce the amount of water removed at each step to again maintain a measurement approximately every 0.5”

13. When the tank being measured has been drained, open all drain valves and doors to allow the tank to drain and dry. Leave the top cover loosely in place to prevent debris entering the tank while still allowing air to circulate and the sealing gasket to be free.

14. Tabulate the results, showing the height from the surface of the liquid to the reference point, together with columns showing the volume of liquid in both liters and gallons. Ensure that the reference point is clearly identified on the table.

15. Examples for a 190 gallon/722 liter self emptying stainless steel tank and a 307 gallon/1164 liter flat bottom stainless steel tank are attached.

16. In using these tables to measure the volume of juice or wine in a container, ensure that the measuring device has been thoroughly sanitized before use, in accordance with the Sanitizing Procedures in this manual.


Tanks FS03 and FS04Kent Italian Tanks 20.9L per inch 5.525 gals/inch plus 25 L in the sloping part of the floor

1000L DRY MEASURE First 2.25inches of the tank are taken up by the lid

Ins Gals Ins Gals Ins Gals Ins Gals

2.25 263.37 14.5 195.73 26.75 128.08 39 60.44

2.5 261.99 14.75 194.35 27 126.70 39.25 59.06

2.75 260.61 15 192.97 27.25 125.32 39.5 57.68

3 259.23 15.25 191.59 27.5 123.94 39.75 56.30 ins Gals

3.25 257.85 15.5 190.20 27.75 122.56 40 54.92 Tank Base - 6.61

3.5 256.47 15.75 188.82 28 121.18 40.25 53.54 Door Top 12 63.66

3.75 255.09 16 187.44 28.25 119.80 40.5 52.16 Jacket Bot. 19 100.80

4 253.71 16.25 186.06 28.5 118.42 40.75 50.78 Jacket Top 30 159.15

4.25 252.32 16.5 184.68 28.75 117.04 41 49.40

4.5 250.94 16.75 183.30 29 115.66 41.25 48.02

4.75 249.56 17 181.92 29.25 114.28 41.5 46.64

5 248.18 17.25 180.54 29.5 112.90 41.75 45.26

5.25 246.80 17.5 179.16 29.75 111.52 42 43.88

5.5 245.42 17.75 177.78 30 110.14 42.25 42.50

5.75 244.04 18 176.40 30.25 108.76 42.5 41.12

6 242.66 18.25 175.02 30.5 107.38 42.75 39.74

6.25 241.28 18.5 173.64 30.75 106.00 43 38.36

6.5 239.90 18.75 172.26 31 104.62 43.25 36.97

6.75 238.52 19 170.88 31.25 103.24 43.5 35.59

7 237.14 19.25 169.50 31.5 101.86 43.75 34.21

7.25 235.76 19.5 168.12 31.75 100.48 44 32.83

7.5 234.38 19.75 166.74 32 99.10 44.25 31.45

7.75 233.00 20 165.36 32.25 97.71 44.5 30.07

8 231.62 20.25 163.98 32.5 96.33 44.75 28.69

8.25 230.24 20.5 162.60 32.75 94.95 45 27.31

8.5 228.86 20.75 161.22 33 93.57 45.25 25.93

8.75 227.48 21 159.83 33.25 92.19 45.5 24.55

9 226.10 21.25 158.45 33.5 90.81 45.75 23.17

9.25 224.72 21.5 157.07 33.75 89.43 46 21.79

9.5 223.34 21.75 155.69 34 88.05 46.25 20.41

9.75 221.96 22 154.31 34.25 86.67 46.5 19.03

10 220.57 22.25 152.93 34.5 85.29 46.75 17.65

10.25 219.19 22.5 151.55 34.75 83.91 47 16.27

10.5 217.81 22.75 150.17 35 82.53 47.25 14.89

10.75 216.43 23 148.79 35.25 81.15 47.5 13.51

11 215.05 23.25 147.41 35.5 79.77 47.75 12.13

11.25 213.67 23.5 146.03 35.75 78.39 48 10.75

11.5 212.29 23.75 144.65 36 77.01 48.25 9.37

11.75 210.91 24 143.27 36.25 75.63 48.5 7.99

12 209.53 24.25 141.89 36.5 74.25 48.75 6.61

12.25 208.15 24.5 140.51 36.75 72.87

12.5 206.77 24.75 139.13 37 71.49

12.75 205.39 25 137.75 37.25 70.11

13 204.01 25.25 136.37 37.5 68.73

13.25 202.63 25.5 134.99 37.75 67.34

13.5 201.25 25.75 133.61 38 65.96

13.75 199.87 26 132.23 38.25 64.58

14 198.49 26.25 130.85 38.5 63.20

14.25 197.11 26.5 129.46 38.75 61.82


Tank FS02

Tank FS05

Gauging Table for 307 Gallon Santa Rosa Stainless Steel TankSerial # 3184

Height from surface of liquid to Contents Height from surface of liquid to Contents Notestop edge of upper lid flange top edge of upper lid flange

Inches US Gallons cm Liters

0 307.50 0.0 1164 Top of upper lid flange3/8 306.97 1.0 11623/4 306.44 1.9 1160

1 3/16 305.91 3.0 11581 5/8 305.38 4.1 11562 1/16 304.86 5.2 11542 1/2 304.33 6.4 11522 15/16 303.80 7.5 11503 5/16 303.27 8.4 11483 3/4 302.74 9.5 11464 1/8 302.21 10.5 1144 Bottom of upper lid flange4 1/2 301.69 11.4 11424 3/4 301.16 12.1 11404 15/16 300.63 12.5 11385 1/8 300.10 13.0 11365 5/16 299.57 13.5 11345 1/2 299.04 14.0 11325 5/8 298.52 14.3 11305 3/4 297.99 14.6 11285 7/8 297.46 14.9 11266 296.93 15.2 11246 1/8 296.40 15.6 11226 1/4 295.87 15.9 11206 3/8 295.35 16.2 11186 1/2 294.82 16.5 11166 5/8 294.29 16.8 1114 Top of straight side section7 1/2 289.01 19.1 10948 3/8 283.72 21.3 10749 3/16 278.44 23.3 1054

10 1/16 273.15 25.6 103410 15/16 267.87 27.8 101411 13/16 262.59 30.0 99412 11/16 257.30 32.2 97413 9/16 252.02 34.4 95414 3/8 246.74 36.5 93415 1/4 241.45 38.7 91416 1/8 236.17 41.0 89417 230.89 43.2 87417 7/8 225.60 45.4 85418 11/16 220.32 47.5 83419 9/16 215.04 49.7 81420 7/16 209.75 51.9 79421 5/16 204.47 54.1 77422 1/8 199.19 56.2 75423 193.90 58.4 73423 7/8 188.62 60.6 714 Top of upper door24 3/4 183.34 62.9 69425 5/8 178.05 65.1 67426 1/2 172.77 67.3 65427 7/16 167.49 69.7 63428 5/16 162.20 71.9 61429 3/16 156.92 74.1 59430 1/16 151.64 76.4 57431 146.35 78.7 55431 7/8 141.07 81.0 53432 3/4 135.78 83.2 51433 5/8 130.50 85.4 49434 9/16 125.22 87.8 47435 7/16 119.93 90.0 45436 5/16 114.65 92.2 43437 3/16 109.37 94.5 41438 1/16 104.08 96.7 394 Bottom of upper door38 15/16 98.80 98.9 37439 13/16 93.52 101.1 35440 11/16 88.23 103.3 33441 9/16 82.95 105.6 31442 7/16 77.67 107.8 29443 5/16 72.38 110.0 27444 1/8 67.10 112.1 25444 15/16 61.82 114.1 23445 3/4 56.53 116.2 21446 9/16 51.25 118.3 19447 7/16 45.97 120.5 17448 5/16 40.68 122.7 15449 3/16 35.40 124.9 13450 30.12 127.0 11450 7/8 24.83 129.2 9451 11/16 19.55 131.3 7452 9/16 14.27 133.5 5453 7/16 8.98 135.7 3454 5/16 3.70 138.0 1454.9375 0.00 139.5 0 Bottom

GB & RW 12-18-03


Gauging Table for 190 Gallon Framed Self Emptying Stainless Steel TankNVC Asset Tag # 002450/002451

Height from surface of liquid to Contents Height from surface of liquid to Contents Notestop edge of upper lid flange top edge of upper lid flange


0 190.73 0.0 722 Top of upper lid flange7/16 190.20 1.1 720

13/16 189.68 2.1 7181 1/4 189.15 3.2 7161 5/8 188.62 4.1 7142 188.09 5.1 7122 7/16 187.56 6.2 7102 13/16 187.03 7.1 7083 3/16 186.51 8.1 706 Bottom of upper lid flange3 1/2 185.98 8.9 7043 11/16 185.45 9.4 7023 7/8 184.92 9.8 7004 1/16 184.39 10.3 6984 1/4 183.86 10.8 6964 7/16 183.34 11.3 6944 5/8 182.81 11.7 6924 13/16 181.75 12.2 6885 180.69 12.7 6845 3/16 179.64 13.2 6805 3/8 178.58 13.7 6765 9/16 177.52 14.1 6725 3/4 176.47 14.6 6685 15/16 175.41 15.1 664 Top of straight side section6 1/8 174.35 15.6 6607 169.07 17.8 6407 13/16 163.79 19.8 6208 11/16 158.50 22.1 6009 9/16 153.22 24.3 58010 3/8 147.94 26.4 56011 3/16 142.65 28.4 54012 1/16 137.37 30.6 52012 15/16 132.09 32.9 50013 13/16 126.80 35.1 48014 5/8 121.52 37.1 46015 1/2 116.24 39.4 44016 3/8 110.95 41.6 42017 1/4 105.67 43.8 40018 1/8 100.39 46.0 38019 95.10 48.3 36019 7/8 89.82 50.5 34020 3/4 84.54 52.7 32021 5/8 79.25 54.9 30022 1/2 73.97 57.2 28023 3/8 68.68 59.4 26024 1/4 63.40 61.6 24025 1/8 58.12 63.8 22026 52.83 66.0 20026 7/8 47.55 68.3 180 Bottom of straight side section27 1/16 46.49 68.7 17627 1/4 45.44 69.2 17227 7/16 44.38 69.7 16827 5/8 43.32 70.2 16427 13/16 42.27 70.6 16028 41.21 71.1 15628 3/16 40.15 71.6 15228 3/8 39.10 72.1 14828 9/16 38.04 72.5 14428 3/4 36.98 73.0 14028 15/16 35.93 73.5 13629 1/8 34.87 74.0 13229 3/8 33.81 74.6 12829 9/16 32.76 75.1 12429 3/4 31.70 75.6 12029 15/16 30.64 76.0 11630 3/16 29.59 76.7 11230 7/16 28.53 77.3 10830 5/8 27.47 77.8 10430 7/8 26.42 78.4 10031 1/8 25.36 79.1 9631 3/8 24.30 79.7 9231 11/16 23.25 80.5 8831 15/16 22.19 81.1 8432 3/16 21.13 81.8 80 Top of lower door32 1/2 20.08 82.6 7632 13/16 19.02 83.3 7233 1/8 17.96 84.1 6833 7/16 16.91 84.9 6433 3/4 15.85 85.7 6034 1/8 14.79 86.7 5634 1/2 13.74 87.6 5234 7/8 12.68 88.6 4835 1/4 11.62 89.5 4435 5/8 10.57 90.5 4036 1/16 9.51 91.6 3636 1/2 8.45 92.7 3236 15/16 7.40 93.8 2837 3/8 6.34 94.9 2437 7/8 5.28 96.2 2038 1/2 4.23 97.8 1639 3/8 3.17 100.0 1240 7/16 2.11 102.7 842 1.06 106.7 443 0.53 109.2 2 Bottom of lower valve

0.00 0 Bottom of lower door

RW & GB 12-18-03


Tank FS06Criveller 400L tank 10.75L per inch or 2.841gals per inch

DRY TANK GAUGE

Ins Gals Ins Gals Ins Gals

3 105.80 15.5 70.29 28 34.79 3" to lid base

3.25 105.09 15.75 69.58 28.25 34.08 40.25" to bottom of tank

3.5 104.38 16 68.87 28.5 33.37 37.2" for holding of liquid

3.75 103.67 16.25 68.16 28.75 32.66

4 102.96 16.5 67.45 29 31.95

4.25 102.25 16.75 66.74 29.25 31.24

4.5 101.54 17 66.03 29.5 30.53

4.75 100.83 17.25 65.32 29.75 29.82

5 100.12 17.5 64.61 30 29.11

5.25 99.41 17.75 63.90 30.25 28.40

5.5 98.70 18 63.19 30.5 27.69

5.75 97.99 18.25 62.48 30.75 26.98

6 97.28 18.5 61.77 31 26.27

6.25 96.57 18.75 61.06 31.25 25.56

6.5 95.86 19 60.35 31.5 24.85

6.75 95.15 19.25 59.64 31.75 24.14

7 94.44 19.5 58.93 32 23.43

7.25 93.73 19.75 58.22 32.25 22.72

7.5 93.02 20 57.51 32.5 22.01

7.75 92.31 20.25 56.80 32.75 21.30

8 91.60 20.5 56.09 33 20.59

8.25 90.89 20.75 55.38 33.25 19.88

8.5 90.18 21 54.67 33.5 19.17

8.75 89.46 21.25 53.96 33.75 18.46

9 88.75 21.5 53.25 34 17.75

9.25 88.04 21.75 52.54 34.25 17.04

9.5 87.33 22 51.83 34.5 16.33

9.75 86.62 22.25 51.12 34.75 15.62

10 85.91 22.5 50.41 35 14.91

10.25 85.20 22.75 49.70 35.25 14.20

10.5 84.49 23 48.99 35.5 13.49

10.75 83.78 23.25 48.28 35.75 12.78

11 83.07 23.5 47.57 36 12.07

11.25 82.36 23.75 46.86 36.25 11.36

11.5 81.65 24 46.15 36.5 10.65

11.75 80.94 24.25 45.44 36.75 9.94

12 80.23 24.5 44.73 37 9.23

12.25 79.52 24.75 44.02 37.25 8.52

12.5 78.81 25 43.31 37.5 7.81

12.75 78.10 25.25 42.60 37.75 7.10

13 77.39 25.5 41.89 38 6.39

13.25 76.68 25.75 41.18 38.25 5.68

13.5 75.97 26 40.47 38.5 4.97

13.75 75.26 26.25 39.76 38.75 4.26

14 74.55 26.5 39.05 39 3.55

14.25 73.84 26.75 38.34 39.25 2.84

14.5 73.13 27 37.63 39.5 2.13

14.75 72.42 27.25 36.92 39.75 1.42

15 71.71 27.5 36.21 40 0.71

15.25 71.00 27.75 35.50 40.25 0.00

Napa Valley College Winery Procedures Manual Page 5 of 135


Standard Operation Procedure

Gauging Procedure For Keg Type Containers Developed by Richard Wolf and Graham Baskerville November 2003 I Introduction Gauging of containers used to store and process juice and wines provides a fast means to estimate the volume of juice, must or wine in the container. This facilitates the accurate estimation of juice volume for the calculation of additives during processing and for record keeping. To avoid contamination of the juice/wine by the measuring device, it is better to measure the height from the surface of the liquid to a defined reference point, usually the rim of the top opening, rather than measuring the depth of the liquid directly. The table attached uses this measurement method for a 15 gallon/59 liter stainless steel keg. The procedure for gauging varies depending upon the type of container. This procedure is for opaque vessels with no bottom outlet/valve, such as a stainless steel keg. II Equipment Vessel to be gauged 500 mL measuring cylinder 2 L or other appropriately sized jug Marking pen Metal rod at least 6” longer than the depth of the container (A second similar metal rod will be required if the container is non conducting) Tape measure Electrical resistance meter Notebook to record results III Method It is not possible to visually measure the liquid level in an opaque container with a small opening, so a metal rod is used as an electrical probe with an ohm-meter (electrical resistance meter) connected between the tank and the probe. A small amount of citric acid (100 grams) can be included in the first measuring cylinder of water to improve the electrical conductivity of the water. As the probe is inserted into the container the electrical resistance will drop immediately upon the probe contacting the water. When this happens, put a mark on the probe, level with the reference point of the container and then remove the probe from the container. Measure the distance from the tip of the probe to the mark. This is the distance from the water to the reference point and should be recorded. Care must be taken to keep the probe from contacting the neck of the container, as this could give an erroneous result. If the container is non-conducting, insert a second conducting probe into the water to provide the required electrical continuity.

Napa Valley College Winery Procedures Manual Page 6 of 135 IV Procedure 17. Place the container to be gauged on a stable, level surface. 18. Identify the reference point from which measurements are to be made, usually the top of the

threaded flange if a stainless steel keg type container. 19. Measure the depth of the container from the reference point to the bottom of the container.

Record. 20. To provide adequate resolution, water should be removed from the container in such

increments that the container’s water level rises about 0.5” for each measurement. For a 15 gallon keg, 2L is an appropriate volume to add.

21. Using the measuring cylinder, add 2L of water to a suitably sized jug and carefully mark the water level on the jug. This mark will be used for subsequent filling of the jug.

22. Pour 2L of water from the jug into the container. 23. Measure the distance from the surface of the water to the reference point, using the method

described above, and record both this distance and the volume of water added. 24. Repeat steps 6 and 7 until the water level in the container reaches the top of the straight side of

the container 25. Near the top of the container it may be necessary to add water in smaller increments to

accurately measure the full volume. 26. If the container does not have parallel sides then it will be necessary to add water in smaller

increments as the diameter reduces in order to get measurements approximately every 0.5” 27. Tabulate the results, showing the height from the surface of the liquid to the reference point,

together with columns showing the volume of liquid in both liters and gallons. Ensure that the reference point is clearly identified on the table.

28. An example for a 15 gallon stainless steel keg is attached. 29. In using these tables to measure the volume of juice or wine in a container, ensure that the

measuring device has been thoroughly sanitized before use, in accordance with the Sanitizing Procedures in this manual.

30. If the probe and ohm-meter are not available, then a wooden dowel stirring rod can be used as follows: ensure it has been sanitized, in accordance with the Sanitizing Procedures in this manual, and is sufficiently dry to be able to see where the liquid level comes to on the rod. Then insert into the tank until it is below the liquid level and mark the reference point level on the rod. Remove the rod and measure the distance from the reference point mark to the mark left by the container liquid. This is the distance from the liquid level to the reference point. Dry the rod for the next measurement.


Gauging Table for 15 Gallon Stainless Steel Keg

Height from surface of liquid to Contents Height from surface of liquid to Contentsouter edge of threaded flange outer edge of threaded flange


21 3/4 0.00 55.2 0.0020 3/16 0.53 51.3 2.0019 1/2 1.06 49.5 4.0018 7/8 1.59 47.9 6.0018 1/4 2.11 46.4 8.0017 5/8 2.64 44.8 10.0017 3.17 43.2 12.0016 5/16 3.70 41.4 14.0015 5/8 4.23 39.7 16.0015 4.76 38.1 18.0014 3/8 5.28 36.5 20.0013 3/4 5.81 34.9 22.0013 1/16 6.34 33.2 24.0012 3/8 6.87 31.4 26.0011 3/4 7.40 29.8 28.0011 1/8 7.93 28.3 30.0010 1/2 8.45 26.7 32.009 7/8 8.98 25.1 34.009 1/4 9.51 23.5 36.008 9/16 10.04 21.7 38.007 15/16 10.57 20.2 40.007 5/16 11.10 18.6 42.006 11/16 11.62 17.0 44.006 12.15 15.2 46.005 3/8 12.68 13.7 48.004 3/4 13.21 12.1 50.004 1/16 13.74 10.3 52.003 7/16 14.27 8.7 54.002 13/16 14.79 7.1 56.002 1/8 15.32 5.4 58.001 7/8 15.45 4.8 58.501 1/2 15.59 3.8 59.00

RW & GB 11-15-03


13 gallon Milk Urns

Gauging Table for 50L Milk kegs (13.21gals)

Ins Gals Ins Gals

0 13.21004 10.25 6.439894 0.25 13.04491 10.5 6.274769 0.5 12.87979 10.75 6.109643 Kegs are 20ins high (50.8cm)

0.75 12.71466 11 5.944518 diameter of 14 5/8 ins (37.14cm)

1 12.54954 11.25 5.779392 1.25 12.38441 11.5 5.614267 1.5 12.21929 11.75 5.449141

1.75 12.05416 12 5.284016 2 11.88904 12.25 5.11889

2.25 11.72391 12.5 4.953765 2.5 11.55878 12.75 4.788639

2.75 11.39366 13 4.623514 3 11.22853 13.25 4.458388

3.25 11.06341 13.5 4.293263 3.5 10.89828 13.75 4.128137

3.75 10.73316 14 3.963012 4 10.56803 14.25 3.797886

4.25 10.40291 14.5 3.632761 4.5 10.23778 14.75 3.467635

4.75 10.07266 15 3.30251 5 9.90753 15.25 3.137384

5.25 9.742404 15.5 2.972259 5.5 9.577279 15.75 2.807133

5.75 9.412153 16 2.642008 6 9.247028 16.25 2.476882

6.25 9.081902 16.5 2.311757 6.5 8.916777 16.75 2.146631

6.75 8.751651 17 1.981506 7 8.586526 17.25 1.81638

7.25 8.4214 17.5 1.651255 7.5 8.256275 17.75 1.486129

7.75 8.091149 18 1.321004 8 7.926024 18.25 1.155878

8.25 7.760898 18.5 0.990753 8.5 7.595773 18.75 0.825627

8.75 7.430647 19 0.660502 9 7.265522 19.25 0.495376

9.25 7.100396 19.5 0.330251 9.5 6.935271 19.75 0.165125

9.75 6.770145 20 0 10 6.60502


5 gallon carboy and 30 gallon trash can

5 gal Carboy Dry Measure 30gal Trash Can Dry Measure

1" = 1.3gal

Volume (Gals) Dry Measure(ins)

Volume (Gals)

Dry Measure(ins)

0 18.625 1 31.2 0.25 17.75 2 29.9 0.5 17.25 3 28.6

0.75 16.875 4 27.3 1 15.875 5 26

1.25 15.25 6 24.7 1.5 14.5 7 23.4

1.75 13.625 8 22.1 2 13.125 9 20.8 3 10.25 10 19.5 4 7.875 11 18.2

4.25 7 12 16.9 4.5 6.25 13 15.6

4.75 5.625 14 14.3 5 4.75 15 13

5.125 3.625 16 11.7 5.1875 0 17 10.4

18 9.1 19 7.8 20 6.5 21 5.2 22 3.9 23 2.6 24 1.3 25 0


3 gallon carboy

Gauging Table for 3 Gallon Glass Carboy

Height from surface of Contents Height from surface of Contentsliquid to top of carboy rim liquid to top of carboy rim


15 3/4 0.00 40.0 0.0015 5/16 0.13 38.9 0.5014 13/16 0.26 37.6 1.0014 5/16 0.40 36.4 1.5013 13/16 0.53 35.1 2.0013 5/16 0.66 33.8 2.5012 3/4 0.79 32.4 3.0012 1/4 0.92 31.1 3.5011 3/4 1.06 29.8 4.0011 1/4 1.19 28.6 4.5010 3/4 1.32 27.3 5.0010 3/16 1.45 25.9 5.509 11/16 1.59 24.6 6.009 1/8 1.72 23.2 6.508 5/8 1.85 21.9 7.008 1/16 1.98 20.5 7.507 9/16 2.11 19.2 8.007 2.25 17.8 8.506 1/2 2.38 16.5 9.006 2.51 15.2 9.505 1/2 2.64 14.0 10.005 2.77 12.7 10.504 3/8 2.91 11.1 11.004 2.97 10.2 11.253 3/8 3.04 8.6 11.50

GB & RW 11-15-03



Cleaning and Sanitation Procedures Developed by Timm Crull, Nancy Barnet-Moore and Gerry Ritchie December 2001, 2005 I Introduction The cellar and the equipment used in all winemaking process must be maintained and used in a clean and sanitized environment, thus avoiding contamination of wine with spoilage organisms. Chlorine and Iodine should not be used as sanitizers because of the risk of TCA formation. Keeping the winery and equipment clean at all times is the first step in minimizing contamination by spoilage organisms. II General Cleaning Equipment

Water source Water hose with adjustable spray gun Pressure washer Cleaning brushes Scotch Bright pads 5 gallon buckets Protective eye wear Gloves Barrel washing spray ball Small flashlight 2 gallon hand sprayer for Quat

III General Chemicals

Soda Ash / Sodium bicarbonate Citric Acid Caustic soda / Sodium Hydroxide Bio Quat Chemco 40 Proxy Clean

Potassium metabisulfite (KMBS) High proof ethanol

IV Procedures Summary

Procedure Uses Chemicals Three Cycle Wash The major method for cleaning

stainless steel and non porous plastic tanks, equipment & surfaces. When equipment is to be used for white wines just after it has been used for red wines

Chemco / Caustic Soda / Soda Ash / Proxy Clean Citric Acid / Peracetic acid KMBS Water

Quat (Quaternary Ammonia) Sanitize equipment and surfaces that are already clean

BioQuat Water

Sulfur Dioxide (SO2) Sanitize equipment and surfaces that are already clean

KMBS Citric acid Water

Alcohol (Ethanol) Sanitize equipment that is already clean when food grade sanitizer is required

Vodka (highest strength)

Barrel Cleaning Barrels WATER OR OZONE ONLY!


Three cycle wash The three cycle wash is used to clean and sanitize a wide variety of winery equipment, including: tanks, fittings, transfer hoses and pumps, filters, and most other non-porous surfaces. In theory, it consists of an alkali wash (cycle 1), followed by an acid wash / sanitize step (cycle 2) and then a thorough rinse with water (cycle 3). In reality, there are several steps in the process. Now that we cannot use chlorine as a sanitizer, we have substituted 50ppm SO2 in the acid cycle of the three cycle wash. The concentration is lower than when using the SO2 sanitizer solution (see p.23) because there is a longer contact time in this method. In order to speed up the cleaning and sanitizing procedure at the NVC Winery, we may use a bin that contains the alkali and another bin that contains the acid/SO2 solution. Any appropriate piece of equipment that can fit in the bins can be immersed in the solution and left to soak which minimizes the amount of scrubbing required. Three cycle wash should generally not be used on the inside of barrels or wooden tanks. The exception to this is the occasional use of Sodium Percarbonate (Proxy Clean) to try and “save” a barrel with mild sensory defects. Preparation of Picking Bins of Caustic Soda and Citric Acid / SO2

Fill each picking bin with water (from the faucet) to 6 inches below the top (i.e. 130gals). Weigh out the appropriate quantities of caustic soda, citric acid and KMBS as given in Table 2 and place each chemical in a separate 5 gal bucket. Pulverize any large lumps of chemical as this will speed up their dissolution. Add water to each bucket carefully and dissolve as much of each chemical as possible before tipping it into the appropriate picking bin. The caustic soda bin is always on the left as you face them on the crush pad. Thoroughly dissolve allthe chemical before using the solution. I Procedure

1 Assess surface to be cleaned a If no surface debris, proceed to step 3.

2 Debris removal a Use pressure washer, brushes, scrapers, and/or scotch bright pads to remove all surface debris, including

but not limited to grape skins, pomace, tartrates, and visible molds. 3 Rinse with water

a Rinse with water to remove gross, loose soil. 4 Wash with alkaline cleaning agent (Soda Ash / Caustic Soda / Chemco 40)

wear gloves and protective eye wear. a Make up a 1% Soda Ash solution using Table 1.1 b For equipment: Remove all residual soil with a 1% Soda Ash solution by appropriate scrubbing with a

brush and/or scotch bright pads. i If soaking in the alkali bin , soak for 10mins

c For tanks: Use a tank spray ball and circulate 1% Soda Ash solution for 20 minutes. 5 Rinse with water

a Removal and rinsing of Soda Ash residue and any debris with clean water (3 min using spray ball for tanks).

6 Rinse with acidic cleaning agent (Citric acid) a Mix a 1% Citric acid plus 0.01% SO2 solution using table 1.2 b For equipment: Thoroughly wash all surfaces with the citric acid solution, making sure to wear gloves

and protective eye wear. i If soaking in the acid/SO2 bin, soak for 5min).

Napa Valley College Winery Procedures Manual Page 14 of 135 c For tanks: If using tank spray washers 1% citric/SO2 solution should continue to circulate for 15 minutes

7 Rinse with water a Remove and rinse away citric residue with clean water (5min) until water tastes acid free.

Napa Valley College Winery Procedures Manual Page 15 of 135 Solution Mixing Guidelines

Table 1.1 Soda Ash / Caustic Soda Approx. 1% Solution

Gallons of Water Liters of Water* Grams of Caustic

Soda* Ounces of

Caustic Soda

Approximate quantity in ml (100g= 80 ml)

0.25 1.0 10 0.5 8

1.0 3.8 38 1.5 30

2.0 7.6 76 3 61

3.0 11.4 114 4 91

4.0 15 150 57 121

5.0 19 190 7 151

10.0 38 380 13 303

20.0 76 760 27 606

50.0 190 1900 66 1514

100.0 380 3800 132 3028

130.0 490 4900 174 3936

* numbers have been rounded to nearest whole number for convenience

Table 1.2 Citric for an approx. 1% Solution and KMBS for an approx 50ppm SO2 solution

Gallons of Water Liters of Water* Grams of

Citric* Ounces of Citric*

Approximate Citric in ml (100

g = 92 ml)

Grams of KMBS*

0.25 1.0 10 0.5 8.7 0.1

1.0 3.8 38 1.5 35 0.4

2.0 7.6 76 3 70 0.8

3.0 11.4 114 4 104 1.2

4.0 15 150 57 140 1.6

5.0 19 190 7 174 2

10.0 38 380 13 348 4

20.0 76 760 27 696 8

50.0 190 1900 66 1741 20

100.0 380 3800 132 3482 40

130.0 490 4900 174 4527 50


Napa Valley College Winery Procedures Manual Page 16 of 135 Table 2 Approx. Three-Cycle Wash Quantities

Scoops of

Container

Soda Ash

Citric

5gal bucket / FYB (4gal)

½

½

264gal tanks

2

2

30gal trash can (25gal)

3

3½

50gal trash can (45gal)

5½

6½

½ ton picking bin

(~130gal)

15

17 + 50g KMBS

1 scoop = 1 cup = 8 fl. Oz. = 250ml


Sanitizing with Quat (Quaternary Ammonia) Quat can be used on a wide variety of winery equipment, including: presses, destemmer-crushers, tanks, fittings, transfer hoses and pumps, filters, walls, and floors. It should not be used on the inside of barrels or wooden tanks. It can be used on the wooden slats of a basket press. The active sanitizer Quat (Quaternary Ammonium Compounds) is highly water soluble, colorless, tasteless, and has low toxicity and is non-corrosive. The residual activity of Quat allows solutions sprayed on walls, floors and ceilings to inhibit mold growth. Procedure

1 Assess surface to be cleaned, if there is any visible surface debris proceed to the three cycle wash. 2 Apply Quat

a For fittings and tools: make up a solution of 200ppm Quat per Table 1.3 into a 5 gallon bucket. Submerge and remove the object to be sanitize and allow to sit for 15 minutes

b For large equipment (that cannot be submerged): use the 2 gallon tank sprayer with a solution of 200ppm Quat (see Table 1.3 for quantities). Spray a liberal amount to all surface areas and leave for 15 minutes.

c For Walls (that have a coating of mold): use the 2 gallon tank sprayer with a solution of 200ppm Quat (see Table 1.3 for quantities). Spray a liberal amount on the wall and leave. DO NOT RINSE WALLS WITH WATER

d For contact sanitization when time does not permit soaking Use same procedures but make solution at 540 ppms.

3 Rinse with water a Remove all Quat residues on equipment with through rinsing with cold water. In some food industry

applications, Quaternary ammonia is used as a no-rinse sanitizer but these methods are generally not followed in the wine industry out of concern for long-term chemical interactions.

Table 1.4 - Quat 200 PPM Solution

Gallons of Water Liters of Water*

Quantity of Bio-Quat (fluid oz.)

Quantity of Bio-Quat (ml)

0.25 1.0 0.03 0.784

1.0 3.8 0.13 3.750

2.0 7.6 0.25 7.500

3.0 11.4 0.38 11.250

4.0 15 0.50 15.000

5.0 19 0.63 18.750

10.0 38 1.25 37.500

20.0 76 2.50 75.000

50.0 190 6.25 187.500

100.0 380 12.50 375.000



Sanitizing with SO2 solutions Sulfur dioxide is used to sanitize only equipment that is already clean! It can be used on small winery equipment, including: fittings, small diameter hoses, wine thieves and for sanitizing filtration systems. The acid concentration is lower than in the 3 cycle wash because it is being used to lower the pH of the solution rather than clean the equipment. The SO2 concentration is higher because the contact time is much shorter. Preparation Make up a solution of 0.1% SO2 and 0.5% citric acid. Use the following table or Table 2 to work out the quantities required for different volumes of water.

Gallons Water

Grams KMBS for 0.1%

SO2 soln. (1000 ppms SO2)

Grams Citric acid for 0.05% soln.

1 7.56 1.89 5 37.8 9.45

15 113.4 28.35 30 227.1 56.7 50 378.5 94.6 60 454.2 113.6 80 605.6 151.4

1 Weigh out the appropriate quantities of KMBS and citric acid. 2 Dissolve the citric acid in the water. 3 Dissolve the KMBS separately and add to the solution. Caution! The solution will become volatile at this point

and may cause irritation of the eyes or lungs. 4 Stir briefly before use Procedure

1 Assess equipment to be sanitized, if any visible surface debris or stains, proceed to the three cycle wash. 2 Immerse in SO2 solution

a For small equipment:. Submerge the object to be sanitized for 1 minute. Glass wine thieves can be left soaking in the SO2 solution after cleaning.

b For large equipment see individual procedures in manual. 3 Rinse with water

a Rinse thoroughly with cold water immediately before use.


Sanitizing with Alcohol Alcohol is used to sanitize only! It can be used on small winery equipment, including: valves, fittings, wine thieves, stirrers. Materials Use the highest strength Ethanol you can find (~ 70%) 1L spray bottle Procedure

1 Assess equipment to be sanitized, if any visible surface debris or stains, three cycle wash before sanitizing. 2 Spray equipment or surface liberally with alcohol using the spray bottle. 3 Let the alcohol evaporate before using the equipment or surface.


Barrels Cleaning “Sweet Barrels” require thorough cleaning after each use and prior to the next use. Times for cleaning vary with the age of the barrel and the condition of the wine and/or lees that are present. In all cases make sure to inspect and smell barrels for faults prior to re-use.

1 Clean exterior surface with pressure washer 2 Attach the barrel-washing wand to the hose. Insert wand into barrel in the bung down position. Rinse barrel

according to the following table, or until outflow is clear and taste is clean. If tartrates are present use a flashlight to check for removal and increase hot wash time if needed.

Barrel Age Water If clean If heavy lees If tartrates

New Cold 2 minutes 2 minutes 2 minutes Hot None None None Ozone 4 minutes 4 minutes 4 minutes

1 to 2 years Cold 3 minutes 5 minutes 5 minutes

Hot 3 minutes 3 minutes 5 minutes or until gone

Ozone 4 minutes 4 minutes 4 minutes > 2 years Cold 3 minutes 5 minutes 5 minutes

Hot 5 minutes 5 minutes 5 minutes or until gone

Ozone 4 minutes 4 minutes 4 minutes

3 In the bung down position, allow the barrel to drain. It is now ready to fill or store. 4 If storing: allow the barrel to drain for 24 hrs, apply 5 seconds of SO2 gas( making sure to wear the SO2

respirator). Insert the bung and move the barrel so that the bung is in the 8 o’clock position. 5 Alternatively, use the wet storage method described later in this manual.

Maintenance of stored empty Barrels This process is to be carried out every 8 weeks for barrels stored with SO2 gas

1 Smell barrel for VA and other undesirable aromas. Separate out any barrels that have problems and do not use for storing wine. Caution! SO2 gas may still be present. If it is strong then it will be hazardous to your health and will impair your ability to detect sensory defects. Wash the barrel with cold water for 8 minutes before smelling or wait until the next time the barrel is washed to evaluate.

2 While wearing an SO2 respirator (stored in the Winery Lab), apply 5 seconds of SO2 gas from the SO2 cylinder. Insert the bung inside of a plastic bag to protect the bung from the SO2. Move the barrel so that the bung is in the 8 o’clock position.




Barrel Preparation Developed by Gordon Kuang and Gerry Ritchie December 2003 I Introduction Barrels are made in a wide range of sizes, sources, seasoning of staves, and toasting depending on the intended use. Many of the benefits of barrel use come from the relatively large surface area of the barrels. As with most winemaking practices, opinions differ considerably on whether and how to condition barrels. II Equipment Flashlight Water Source Siphon hoses Barrel Washer III Procedure Optimum Procedure when there are no time limits or water shortages 31. Inspect the inside of the barrel for any imperfections 32. Fill the barrel completely with water and leave overnight 33. Use several siphon tubes to begin the emptying of the barrel. 34. When the barrel is light enough, spin it around so that it is bung-hole down and let

drain. 35. The barrel should be filled within 24 hours Procedure when there are time constraints / Water issues 1. Put 10gals of water in the barrel, roll it around on its side for a few minutes. 2. Tip onto one head and leave for 10mins. 3. Tip onto side and repeat rolling in step 1 4. Tip onto other head and leave for 10mins 5. Use a hose and spray gun to wet the outside of the barrel


Pressure Washing procedures Developed By Joe Curley December 2003 I Introduction The gasoline portable pressure washer is used for the general cleaning of the winery and the equipment used in the winery and its operation. It should be noted that the “use of this pressure washer should be used outside only” as it runs on gasoline and produces harmful vapors.

II Equipment KARCHER – Model 2400 Pressure Washer Equipped with Honda GC 160 Engine Support Equipment includes: Pressure Hose Wand and 5 Color-Coded Tips for Cleaning Detergent Attachments Water Hose

Wear safety glasses. III Preparation 1. Check both the oil level on engine and the gasoline in the fuel tank. 2. Connect supply water hose to pressure washer (turn on). 3. Take washing wand and depress trigger to release trapped air in lines. 4. Close choke on engine. 5. Move gas throttle approximately one-third to one-half way to Fast position. 6. Pull starter cord to start. 7. When running, slowly open choke for smooth, clean running. IV Operation 1. Check to see if water flow is adequate. 2. Choose the proper tip (colored nozzle) for the job. 3. Check for proper ventilation of running equipment. 4. Select item or area to be washed. Note: Use care when washing wood as to not

“grain” wood with too much pressure from machine. 5. Pressure can be regulated by the speed of the engine and the proper tip on the wand. 6. Avoid keeping nozzle in or on the same area for a prolonged time.


V Shutting Down and Clean Up

1. If using detergent, remove suction from pail or bucket. 2. Press engine throttle down to shut off engine. 3. Turn off water supply. 4. Release pressure in line by squeezing wand handle. 5. Disconnect water supply. 6. Lock trigger lock on nozzle handle. 7. Roll up hose (pressure), place on side hanger. 8. Place wand in holder. 9. Make sure all nozzle tips are replaced in their nozzle holders. 10. Check gas and oil levels. Fill, if needed, for the next person to operate.




Ozone Sanitation Developed by Jessica Loring, Theo Papathanasis and Chris Vallerga December 2002 I Introduction The ozone machine can be used to sanitize wine barrels, tanks, the winery floor, walls and other equipment. The ozone machine does not clean; it only sanitizes. Therefore it is important to wash floors and walls first to clean them and rinse them before applying ozonated water to kill residual microbes and bacteria. II General Cleaning Equipment McClain Ozone Machine 2 garden hoses 1 five gallon bucket 1 barrel washer wand 2 adapters to convert 1 ½” tri-clamp to ¾ inch male hose screw thread III Procedure Turning on and operating the McClain Ozone Machine: 36. Roll the McClain Ozone machine to the outdoor pad at the rear of the winery. 37. Bring out to the pad the barrels and mobile equipment you wish to sanitize. 38. Attach one end of a hose to the water faucet and the other end of that hose to the inlet

valve on the McClain Ozone machine using one tri-clamp adapter. 39. Attach the other hose to the outlet valve on the McClain Ozone machine using the

other tri-clamp adapter. Afix the barrel washer wand to the other end of that hose. 40. Never operate the McClain Ozone Machine before it has been flushed through

with water to remove all air from the system. 41. Verify “on/off” switch is in “off” position and plug in the McClain Ozone machine. 42. Turn on the water at the faucet and let run through the machine for 2 minutes. 43. Turn on the “on/off” switch on the Ozone machine. The green operation light will

come on. 44. Fill the 5 gallon bucket with water that is coming out of the outlet hose. When the

water ceases to have bubbles in it, the water is ready to be ozonated. 45. Turn on and adjust the “Ozonation” knob. The yellow ozonation light will come on to

indicate that the water is being ozonated. 46. Important Safety Procedure: Measure Air To Check For Ozone Use the air

testing meter to check that there is NO ambient ozone in the air. Simply turn on the switch and read the dial which indicates if ozone is present. If the meter indicates ANY ozone in the air, immediately shut off the machine and call the manufacturer at (707) 226-1250 for assistance. [The OSHA standard for ozone in the work place is .01ppm for an 8 hour work day. However, you want NO ozone in the air.]


47. To check the amount of ozone in the ozonated water, use the modified hot chlorine kit. (It is similar to the kits used to check chlorine in swimming pools, but has slightly different chemicals.) Follow the steps below:

[WARNING: The chemicals in the kit may be hazardous to the health and safety of the user if inappropriately handled. Read all warnings before performing the test and use appropriate safety equipment.]

A. Fill the flask to the 40 mL mark with the water to be tested. Take the

sample water from the bottom ½ of the 5 gallon bucket so that the ozone is not lost to the atmosphere.

B. Tear open one Sulfite 1 Regent Powder Pillow. Add contents to the flask. Swirl to mix.

C. Tear open one Sulfamic Acid Powder Pillow. Add the contents to the flask. Swirl gently to mix. If Ozone is present a blue color will develop. This is the prepared sample.

D. Measure 10 mL of the prepared sample and pour it into the graduated cylinder.

E. Add Sodium Thiosulfate Standard Solution (“titrate solution”) drop by drop to the mixing bottle. Hold the dropper vertically above the bottle to add the drops. Swirl the bottle consistently while adding the drops and count each drop as it is added. Continue to add titrate solution until the sample bottle becomes colorless.

F. Calculate the amount of ozone in the water. Each drop used to bring about the color change in step 5 is equal to 0.68 mg/L Ozone.

13. The time needed to sanitize the equipment is based upon the concentration of ozone in

the water. Refer to the table below: CONCENTRATION OF OZONE IN WATER

TIME IN MINUTES TOTAL MINUTES NEEDED TO SANITIZE

4 PPM OZONE 5 MINUTES 4x5=20 MINUTES 7 PPM OZONE 3 MINUTES 7x3=21MINUTES 10 PPM OZONE 2 MINUTES 10x2=20 MINUTES 14. Barrel Washing

A. Turn the barrel so the bung hole is facing downward. B. Attach barrel-washing wand to the hose. Insert wand into the barrel in the bung

down position. Rinse barrel for 5 minutes if you suspect it has bacterial contamination and for 1 minute if the barrel if you do not suspect bacterial contamination.

C. Let the barrel drain for 30 minutes because ozone has a 30 minutes half-life. D. Refill barrel with wine or let drain for 2 to 17 hours before adding SO2.

15. Winery Floor and Wall Washing To wash walls and winery floors spray ozonated water on the surfaces. They are cleaned by contact with the water.


16. Shutting down the McClain Ozone Machine To shut down the Ozone Machine reverse steps 1 through 8 above. For technical assistance or service call (707) 226-1250.


Napa Valley College, Viticulture and Winery Technology Standard Operating Procedures

Tank Cleaning Procedures Developed by Tony Kolonie, Louis Horta, John Starr and Miguel Avina December 2002 I Introduction Tanks must be cleaned and sanitized before use to ensure there is no contamination of the receiving wine by undesirable debris, dirt or micro-organisms. These procedures are designed for use with the air pump and may be adapted for use with the Vogelsang or other pump. II Cleaning equipment Elbow fitting

Compressed air Cleaning brushes Air pump Bucket 1 inch suction hose Measuring cup 1 inch discharge hose Spray nozzle Spray ball Adapter fitting Tri-clamp fitting Tarpaulin Gasket between fittings

III Chemicals

Soda Ash Citric Acid Water KMBS

IV Equipment setup A circulating system must be set up, to develop a complete circulation of water moving out of the bottom valve of a tank into a 5gal bucket. The water is then pulled out of the bucket by a pump, and pushed through a spray ball back into the tank.

1. Attach an elbow fitting to the bottom valve of the tank to be cleaned. The elbow

should point downwards. 2. Place a short-sided 3-gallon bucket beneath the elbow. 3. Attach a 1 inch suction hose to the inlet side of the pump and attach a valve or T (to

weigh the end down when it is placed in the bucket) on the other end of the hose. The other end of the hose will be placed in the 3 gal bucket, with the end raised about two inches above the bottom of the bucket, deep enough to avoid sucking-up air, and not stick to the bottom of the bucket.

4. Attach a 1 inch discharge hose to the outlet of the air pump. 5. Attach a spray ball to the other end of the 1 inch discharge hose using the proper

fittings. The spray ball is placed inside the tank a few inches bellow the top opening and the lid replaced as far as possible.


In the 264 gal variable volume tanks, the hose fitting does not fit through the opening in the removable lid. In this case, attach an elbow and sufficient quick release fittings to the 1inch hose to pass through the small opening in the lid of the variable volume tanks. Then balance the lid over the edge of the top of the tank and pass the quick release fittings on the end of the hose through the small hole in the lid and then attach the spray ball to the fittings so that the spray ball is now adjacent to the interior side of the lid.. The cover is placed into the tank, and the gasket is inflated to secure the cover near the top of the tank.

6. Connect the air inlet on the pump to the compressed air supply using the orange air line.

7. Open the compressed air valve at the wall V Cleaning procedure for a three-cycle wash 8. Remove any large debris with a broom or squeegee 9. Using a spray nozzle with hot water, spray down the inside wall of the tank. Spray

both, through the top opening, and the pomace manway. Let the water drain through the open bottom valve, out onto the floor.

10. Use a brush to scrub off any accessible deposits not removed earlier. 11. When the interior is visibly clean, close and seal the pomace manway in preparation

for the next step. 12. Place a 3-gallon bucket under the elbow attached to the tank, and fill the bucket with

water. Priming the pump and setting up the circulation 13. Prime the pump by lifting up the 1 inch suction line attached to the pump inlet and fill

the line with water (this prevents air bubbles in the line during pumping) and close the valve:

14. Immerse the valve in the water in the bucket. 15. Simultaneously open the valve immersed in the bucket and switch on the pump to a

medium speed. 16. Keep filling the bucket with water, until the water starts running out of the bottom

valve of the tank the tank 17. (Should air bubbles persist in the line, raise the line, higher than the pump, to push the

bubbles upwards. Repeat as needed, until all persistent bubbles disappear.) 18. Turn off the water. Adjust the butterfly valve until the water coming from the tank

into the bucket equals the water being sucked up by the pump i.e. the water in the bucket remains at a constant level.

19. Check the complete circuit of lines, pump, and tank for leaks. Repair leaks if any. 20. Turn off the pump, and close the butterfly valve. 21. Adding and using cleaning / sanitizing Agents 22. Put 2 cups (1 cup = 250ml / 8oz) of soda ash into the bucket and stir until thoroughly

dissolved. 23. Turn on the pump, adjust the valve as above and let the water cycle through for 15

minutes. 24. Remove the bucket from under the elbow, tipping the soda ash solution onto the floor

being careful not to splash anyone.


25. Disconnect discharge hose from pump outlet and attach a water hose to it using a tri-clamp / ¾”male quick release converter. Switch on water and rinse tank with fresh water for 3 minutes.

26. Turn off water and reconnect the wine hose to the pump outlet. 27. Place a bucket with clean water under the elbow. Turn on pump and refill circuit with

water as before. 28. Turn off pump when the bucket is full of water and the level is being maintained

constant. Put 2 cups (1 cup = 250ml / 8oz). of citric acid and 12 g of KMBS in the bucket and stir to dissolve.

29. Switch on the pump to re-activate the circuit and let it run for 15 minutes. 30. Remove the bucket and let the circulating acidified SO2 solution drain out. 31. Set up the water rinse as before ad run for about 5mins. 32. Start tasting the water as it exits the tank and when it is clean (i.e. no acid), the tank is

now clean. 33. Empty all lines, and proceed to the wine processing step.



Assessing Grape Maturation Developed by Joshua Lowell December 2001 I INTRODUCTION: Great wine is made from great grapes, but even great grapes are useless to the winemaker if they are not picked at the proper time. Assessing grape maturation is the key to determining the proper time. The winemaker must sample the grapes and decide on a style of wine to be made from them. Then, they must track certain indicators to determine when the grapes have reached a maturity suitable for their style. The indicators used are both qualitative (taste, smell…) and quantitative (pH, TA, Brix…) [Appendices A. & C.] These indicators may also be compared to vineyard records (degree-days, date of veraison…) to identify trends to help predict vintage outcomes and identify the vineyard practices that play a major role in improving quality. [Appendices D. & E.] I EQUIPMENT: Zip-lock bags, grape knife or clippers, and ice chest (if unable to test immediately.) II PREPARATION: Tracking indicators of grape maturity is accomplished through berry sampling. Sampling Strategy: The samples should represent the entire vineyard as closely and with as much consistency as possible. Grape qualities can vary drastically depending on vine location in the vineyard, bunch location on the vine, and position on the bunch. Therefore, how one collects their sample can greatly affect the perceived maturity of the whole vineyard. As well, samples should be taken at the same time of day because grapes are subject to circadian patterns. Sampling Frequency: Samples should be taken approximately once a week and with more frequency as the grapes mature. Extra vigilance should also be taken during climatic changes or inclement weather, as they can have dramatic effect on grape maturity and health. Analyses and Observations: All indicators obtained through sampling should be recorded on a worksheet to track maturation through the growing season. [Appendix C.] IV. PROCEDURE: 1. Collect a sample of approximately 200 berries. 2. Berries should be collected as whole as possible. 3. Zigzag between the rows, covering the whole vineyard. [Appendix B.] 4. Pick from different heights on the vine and from different areas on the cluster. 5. Record observations 1-12 on worksheet. 6. Keep berries whole and cool until testing is done. 7. For testing, gently mash berries in the bag and then strain for juice. 8. Hold some whole berries and juice aside for tasting and smelling. 9. Carry out analyses (15-18) as outlined in Analytical Procedures Manual. 10. Record observations 13 and 14. 11. Compare results with criteria required for wine style.


Appendix A.

General Scenario for Cabernet Maturation

1-Aug

15-A

ug

29-A

ug

12-S

ep

26-S

ep

10-O

ct

24-O

ct

AcidityHerbal FlavorsSugarFlavorpHChance of Rain

Appendix B. BERRY SAMPLING PATTERN EXAMPLE


Appendix C. MATURATION WORKSHEET

Vineyard and grape observations and analyses

Dates

1. Days since veraison

2. Degree of bird damage (no, low, high) Where?

3. Degree of insect damage (no, low, high) Where? 4. Degree of bunch rot & mildew (no, low, high) Where? 5. Degree of Sunburn (no, low, high) Where?

6. Canopy condition (thick, thin) Where?

7. Early maturity in parts of the vineyard (East, West, Rows…)

8. Stem color (green, yellow, brown)

9. Seed color (red, green, yellow, brown)

10. Skin texture in mouth (soft, chewy, crunchy)

11. Skin color extraction (easy, difficult)

12. Tannic taste of skins (low, medium, high, dry, harsh)

13. Juice smell

14. Juice taste

15. Brix

16. pH

17. Titratable Acidity

18. Brix-Acid Ratio


Appendix D.

Starting Dates for Veraison and Picking of Napa Valley Chadonnay and Cabernet*

9-May

29-May

18-Jun

8-Jul

28-Jul

17-Aug

6-Sep

26-Sep

16-Oct

5-Nov

Char. Veraison 27-Jul 17-Jul 6-Aug 5-Aug 7-Jul

Char. Picking 3-Sep 13-Sep 20-Sep 29-Sep 21-Aug

Cab. Veraison 1-Aug 5-Aug 18-Aug 12-Aug 17-Jul

Cab. Picking 7-Sep 26-Sep 17-Oct 18-Oct 4-Sep

2001 2000 1999 1998 1997

*Dates provided by Napa Valley Vintners Association


Appendix E.

Monthly Sum of Degree-Days* for Oakville**

0

100

200

300

400

500

600

700

1997 281 514 520.5 581 602 597.5 335

1998 153 188.5 424.5 587.5 654 518 289

1999 177 283.5 409.5 499 534.5 487 360

2000 237.5 388.5 491.5 495 554.5 506.5 269

2001 122.5 512 523.5 517 550.5 449.5 390.5

April May June July Aug Sept Oct

* Degree-days are calculated by subtracting 50F from the average temp. of the day: (High Temperature + Low Temperature) - 50F 2 ** Fahrenheit temperatures taken from the Oakville CIMIS Station.


Napa Valley College, Viticulture and Winery Technology Department Standard Operating Procedure

Pre-Harvest Operations Developed by Brandy LaVoy, Anthony Guerrera and Judy Colberg December 2003 I. Introduction The Pre-Harvest Operations are the preventative maintenance steps that wineries must take in order to prevent things from going wrong during harvest, crush and winemaking. Before the grapes are harvested it is essential to thoroughly clean the winery in order to prevent contamination of the grapes, or must by any microorganism or other contaminant which may exist in the winery. Everything in the winery must be cleaned starting with the winery itself to any equipment that may come into contact with the grapes, juice, or must. The cleaning procedure is, in general terms, to physically clean the item removing any debris, then put it into an acid solution, rinse it with warm water, then put it into a basic solution then rinse it with warm water and then allow it to dry. The term winery should be understood to mean the entire building including the cellar. The equipment that needs to be cleaned is included in an itemized list below along with the methods required. This is the appropriate stage to take an inventory of chemicals and check to make sure that they have not gone past their expiration date. At this time also take an inventory of the equipment and make sure that it is in good working order. Do not forget equipment in the 40’ storage container outside of the winery. Any problems should be taken care of now so that they do not come up at the height of harvest (for instance: expired chemicals must be re-stocked and broken equipment must be repaired or replaced). These preventative maintenance steps should occur 2-3 weeks before harvest is expected to take place. This should be adequate time to complete the cleaning and to correct any problems. Depending on the size of the winery and the size of the crew this maintenance should take between 3-5 days to complete. II. General Cleaning Equipment Water source Water hose with adjustable spray gun ½ Ton bins Protective eyewear Gloves Scrubbing brushes Bottle brushes 2 gallon hand sprayer for Quat Tank Cleaning Equipment -

Compressed air

Air pump 1 ½ inch suction hose 1 ½ inch discharge hose Spray ball Gasket between fittings Elbow fitting Bucket Measuring cup Adapter fitting

III. General Chemicals Soda Ash Citric Acid

Bio Quat


IV. Procedure Following is a checklist of the winery equipment that needs to be cleaned in preparation for the harvest and crush. For specific instructions on each of the Sanitation Procedures, please refer to your Procedures Manual. Immediately following the cleaning checklist is a list of chemicals that should be stocked and kept on hand. Finally, remember to check the 40’ container outside of the winery building used for storage and pull any equipment forward that will be needed for harvest.

Equipment 3-Cycle Wash

Single Cycle with Quat

Overnight Caustic Alkali

409 & Hot Water

FYB’s/ Lug boxes X Buckets X ½ Ton Bins X 1 Ton Bins X Trash Cans (10, 30 & 60 gal) X Beer Kegs (15.5 gal) X Milk Kegs (13.89 gal) X Carboys (750 ml, 3 gal, 5 gal) X Jugs (1 gal) X Bottles (375 & 750 ml) X Fittings X Barrel Heat Exchanger X Barrel Wands X Pumps X Hoses/Lines1 X Destemmer/Crusher1 X Moving-Head Press1 X Barrel Room - X – Hot

Water Wash

Shelves X All Wooden Materials X Basket Presses (Bladder & Ratchet)

X

Caps X Bungs X Airlocks X Thieves X Stainless Steel Table X Peg Boards X Sinks X Steel Tanks2 X Barrels3 (Water ONLY) 1Connect pumps and hoses to cleaning solution bins to clean both hoses and equipment being cleaned. 2Refer to Tank Cleaning Procedure 3Refer to Barrels Procedure


V. Chemical Inventory:

Chemical Additional Quantity Needed

Phenolphthalein Sodium Hydroxide (NaOH) Distilled Water pH 7.0 Buffer Solution pH 4.0 Buffer Solution Citric Acid Soda Ash Chemco 40 Sodium Hydroxide Bio Quat Potassium Metabisulfite (KMBS) Active Dry Yeast Tartaric Acid Malolactic Bacteria Enzymes Super Food/DAP Clinitest Kits



Picking and Sorting Grapes Prior to Winemaking Developed by Kari Flores and Mike Bielawski December 2001 I INTRODUCTION The winemaker, in conjunction with others, must decide on a harvest date based on wine objective, fruit maturity, and practicality. “Picking and sorting” is the process of removing the crop from the vineyard and delivering it to the winery at a designated level of quality for winemaking. At the Napa Valley College vineyard, harvest is done with minimal mechanization. A significant crew is necessary. II EQUIPMENT 1. Picking bins, aka FYBs (1 per 35 lbs of crop) 2. Larger containers if sufficient bins are not available (e.g. trash cans) 3. Crew (average person can pick 30 to 50 lbs. per hour depending on crop quality) 4. Picking knives or pruning shears (one for each crew member) 5. Gloves (some may want to wear protective gloves) 6. Scale (sufficient to weigh a loaded bin) 7. Record keeping (e.g., weigh tags, clipboard, pencil, calculator, watch, etc.) 8. Transportation from/to the winery (pickup truck(s)) III PREPARATION

1. All bins and containers should be thoroughly washed and dried – triple washed, if necessary.

2. Knives and pruners should be sufficiently cleaned, sharpened, and oiled. 3. The scale should be calibrated and a tare-weight (weight when empty) determined

for each type of FYB. Consider calibrating the scale to zero at the bin’s tare-weight.

4. Picking should be scheduled for cool weather and early morning. 5. The crew should be briefed on the logistics including: date and location, parking

for non-NVC vineyards; start and stop time expectations; meeting place, location of water and bathroom facilities; picking strategy (such as starting from the east working west, middle of row working toward the ends, etc.).

6. The crew should be well informed of the quality expectations relative to the current state of the crop.

7. Any specific roles should be assigned including: transportation of materials and crop to and from the winery, record keeper, and scale operator. Consider that not every one is suited to lifting 35+ lb. Bins.


IV PROCEDURE

Picking 1. Start the picking session with a review of strategy and examples of acceptable and

unacceptable fruit should. 2. Cut the clusters from the vine such that minimal stem is included. Drop the cut

clusters into the bin without breaking the grape skins. Slide the bin under the fruit zone with your feet.

3. Full bins must be carried to the scale for weighing. Consider combining bins to carry to the scale before they are over loaded and become difficult to slide with your feet.

Sorting 1. Sorting occurs primarily ‘in the field’, meaning that the picker will not place

inferior fruit or MOG (material other than grape) in the bin. Diseased fruit and MOG must remain less than 1% of the harvest.

2. Diseases likely to be encountered include: mildew, botrytis, and infection resulting from bird damage. Symptoms can generally be easily seen but may exist on only a small portion of the cluster (including interior sections).

3. All efforts should be made to discard diseased or otherwise inferior fruit. However, higher quality standards will lengthen the time it takes to harvest and reduce total yield. If necessary to meet harvest targets, individual bunches can be separated into acceptable and unacceptable fruit.

4. Fruit that will upset the ‘chemistry’ of the harvest should be discarded. In particular, second harvest (i.e. immature small clusters originating after the first few nodes on the cane) and raisined (dehydrated) grapes should be avoided. Avoid green stems that are bitter and an indicator of immature fruit. Pickers should taste a berry now and then to calibrate their sense of ripeness.

5. Full bins should be given a quality control check at the scale to ensure consistently applied sorting standards in the field.

Weighing and transport 1. Full bins must be weighed and recorded then stacked in the pickup truck or poured

into larger transportation containers – again, taking care not to squash or break skins.

2. When the harvest is complete, the crop must be transported to the winery and unloaded. This handoff must be coordinated with winery staff.

3. At all times, waiting bins of grapes should be kept in a cool and shaded place.

Record keeping 1. Total harvest weight must be kept as required by the TTB for any marketed

product. 2. Other data should be kept to further the ability to plan for future harvests,

including: actual start and stop times, number of crew, weight picked per person-hour, average weight picked per bin, average weight picked per acre or vine.

3. Consult the picking crew and winery staff to consider areas for process improvement. Document and communicate ‘lessons-learned’ appropriately.



Making Additions to Musts and Wines Developed by Jack Hussey and Reese Wilson December 2001 INTRODUCTION Various compounds are added to wines at different times in order to improve the structure and balance (e.g. tartaric acid) and / or to prevent microbial spoilage and oxidation (e.g. sulfur dioxide).

SO2 Additions to Juice and Must I INTRODUCTION Sulfur may be added to the must or juice at crush in order to minimize contamination by unwanted bacteria, indigenous yeasts or other undesirable microorganisms. II EQUIPMENT 1. Scale 2. 100 ml (or larger) plastic beaker for weighing KMBS III CHEMICALS 1. Potassium Metabisulfite (KMBS) IV PREPARATION Make sure scale is clean, especially the weighing surface V PROCEDURE 1. Review work order and make note of parts per million (ppm) total SO2 required. 2. Convert tons or pounds of fruit to gallons juice assuming 150 gal/ton 3. Using formula below, determine amount of potassium metabisulfite (KMBS) required

for Gallons of Juice Using 100 ml (or larger) plastic beaker, weigh out required amount of KMBS and dissolve in water or juice. Pour the addition into the must or juice and stir gently. FORMULAS for powedered KMBS and for 6% SO2 solution

Grams KMBS = = ppm required x gals x 0.0076 Mls of 6% SO2 solution = ppm required x gals x .063


Must/Juice Amount of KMBS in Grams to Add to Achieve 1- 50 ppm total SO2

Volume Note: Translate Pounds of Grapes to Gallons of Must or Juice assuming 160 gal/ton

in Gallons 1 20 25 30 35 40 45 50

1 0.0075706 0.15 0.19 0.23 0.26 0.30 0.34 0.38 2 0.015 0.30 0.38 0.45 0.53 0.61 0.68 0.76 3 0.023 0.45 0.57 0.68 0.79 0.91 1.02 1.14 4 0.030 0.61 0.76 0.91 1.06 1.21 1.36 1.51 5 0.038 0.76 0.95 1.14 1.32 1.51 1.70 1.89

10 0.076 1.51 1.89 2.27 2.65 3.03 3.41 3.79 20 0.151 3.03 3.79 4.54 5.30 6.06 6.81 7.57 30 0.227 4.54 5.68 6.81 7.95 9.08 10.22 11.36 40 0.303 6.06 7.57 9.08 10.60 12.11 13.63 15.14 50 0.379 7.57 9.46 11.36 13.25 15.14 17.03 18.93 100 0.757 15.14 18.93 22.71 26.50 30.28 34.07 37.85 150 1.136 22.71 28.39 34.07 39.75 45.42 51.10 56.78 200 1.514 30.28 37.85 45.42 52.99 60.56 68.14 75.71 300 2.271 45.42 56.78 68.14 79.49 90.85 102.20 113.56 400 3.028 60.56 75.71 90.85 105.99 121.13 136.27 151.41 500 3.785 75.71 94.63 113.56 132.49 151.41 170.34 189.27

1,000 7.571 151.41 189.27 227.12 264.97 302.82 340.68 378.53 2,000 15.141 302.82 378.53 454.24 529.94 605.65 681.35 757.06


Rehydration of Yeast for Fermentation I INTRODUCTION Yeast is often added to must or juice to help achieve style objectives and/or achieve a complete fermentation to dryness. II EQUIPMENT

1. Weighing Scale 2. 100 ml (or larger) plastic beaker for weighing yeast 3. 1 L (or larger) beaker for preparing yeast 4. Alcohol thermometer (not mercury) 1 L (or larger) beaker for juice to add to Yeast preparation

III MATERIALS 1. Active Dry Yeast 2. Hot and cold tap water 3. Juice from grapes to be inoculated IV PROCEDURE 1. Make note of type and amount of Yeast in Pounds per 1000 gallons 2. Using Table below, determine amount of Yeast and Water required for Gallons of Must to

be inoculated 3. Convert tons or pounds of fruit to gallons juice assuming 160 gal/ton 4. Using 100 ml plastic beaker, weigh out required amount of Yeast 5. Add hot and cold tap water to 1 L beaker in the amount from table to yield a temperature of

~ 104 oF or as stated on the packet. 6. Sprinkle Yeast on surface of water; when Yeast has sunk, stir gently to get rid of any

lumps. 7. Wait 15 minutes. 8. Measure the temperature of the rehydrated yeast and then pour in juice until the

temperature has dropped by 18oF. Wait 15mins 9. Repeat step 8 until the Yeast preparation is within 18oF of desired temperature for the

beginning of fermentation 8. Carefully add the rehydrated yeast to must or juice and:

a. for Whites, don't stir b. for Reds, gently punch down until Yeast just disappears from sight

FORMULA

Grams of yeast required = (rate of addition in #/1000 x gals must / juice x 454)/1000


Must Amount of Yeast in Grams to Add to Selected

Volume Must Volumes and Pounds Yeast per 1000 Gallons Ratios (plus Water in ml)

in Gallons 1.0 #/Kgal Water (ml) 1.5 #/kgal Water (ml) 2.0 #/kgal Water (ml)

1 0.454 100 0.680 100 0.907 100

3 1.36 100 2.04 100 2.72 100

5 2.27 100 3.40 100 4.54 100

10 4.54 100 6.80 200 9.07 200

15 6.80 200 10.21 200 13.61 400

20 9.07 200 13.61 400 18.14 400

30 13.61 400 20.41 400 27.22 800

40 18.14 400 27.22 800 36.29 800

50 22.68 800 34.02 800 45.36 800

60 27.22 800 40.82 800 54.43 1,200

120 54.43 1,200 81.65 1,200 108.86 1,600

180 81.65 1,200 122.47 1,600 163.29 2,000

240 108.86 1,600 163.29 2,000 217.72 2,000

300 136.08 1,600 204.12 2,000 272.16 2,400

360 163.29 2,000 244.94 2,400 326.59 2,800


Nutrient Additions I INRODUCTION Nutrients are often added to the must or juice just before inoculation with a yeast to help complete the fermentation process within a reasonable time frame for the chosen style. II EQUIPMENT

1 Scale 2 Plastic baggie or other receptacle for weight measurement(s) 3 Beaker or other receptacle 4 Spoon

III MATERIALS

1 Nutrients (e.g., DAP, Superfood) IV PROCEDURE

1 Make note of type and amount of Nutrient (e.g., 200ppm or 2 pounds per 1000 gallons) and volume of must (red wines) or juice (white wines) to which Nutrients will be added

2 Use the appropriate Table to calculate the grams of Nutrient required for specified rate of addition and volume of must/juice

3 Convert tons or pounds of fruit to gallons juice assuming 160 gal/ton 4 Make sure the scale is clean and in working order 5 Put a receptacle large enough to hold Nutrients on scale 6 Tare / Zero out the scale 7 Using a clean spoon or spatula, weigh out the Nutrient 8 Dissolve Nutrient thoroughly in a small amount of must or juice (e.g., 500 ml for a 5-10

gal total volume 9 Stir into Must or Juice

FORMULA

When rate of addition is expressed as lbs / 1000gal (Use Table 1) Grams nutrient required = #/kgal x gal x 454/1000 = #/kgal x gal x 0.454 When rate of addition is expressed as ppm or mg/L (Use Table 2) Grams nutrient required = ppm x gal x 3.785/1000 [ppm is equal to mg/L] = ppm x gal x 0.003785


Table 1. Making additions as pounds per 1000 gallons (#/ 1000gal or #/ kgal) Fermentation Amount of Nutrients in Grams to Add to for Selected

Volume in Pounds per 1000 Gallons Targets and Volumes Must/Juice in Gallons

Gallons 0.5 #/1000 0.75 #/1000 1.0 #/1000 1.25 #/1000 1.5 #/1000 1.75 #/1000 2.0 #/1000

1 0.23 0.34 0.454 0.57 0.68 0.79 0.91 2 0.45 0.68 0.91 1.13 1.36 1.59 1.81 3 0.68 1.02 1.36 1.70 2.04 2.38 2.72 4 0.91 1.36 1.81 2.27 2.72 3.18 3.63 5 1.13 1.70 2.27 2.83 3.40 3.97 4.54

10 2.27 3.40 4.54 5.67 6.80 7.94 9.07 15 3.40 5.10 6.80 8.50 10.21 11.91 13.61 20 4.54 6.80 9.07 11.34 13.61 15.88 18.14 25 5.67 8.50 11.34 14.17 17.01 19.84 22.68 30 6.80 10.21 13.61 17.01 20.41 23.81 27.22 35 7.94 11.91 15.88 19.84 23.81 27.78 31.75 40 9.07 13.61 18.14 22.68 27.22 31.75 36.29 45 10.21 15.31 20.41 25.51 30.62 35.72 40.82 50 11.34 17.01 22.68 28.35 34.02 39.69 45.36 55 12.47 18.71 24.95 31.18 37.42 43.66 49.90 60 13.61 20.41 27.22 34.02 40.82 47.63 54.43

Table 2. Making additions as parts per million (ppm) or milligrams per liter (mg/L)

Must/Juice Amount of Nutrients in Grams to Add to Achieve 1- 50 ppm

Volume Note: This chart shows ppms of total substance, NOT ppms of Yeast available Nitrogen! If you want this information, you must figure out the rate of YAN based on your product info

or refer to the chart that appears in “Nitrogen Additions”. in Gallons 1 20 25 30 35 40 45 50

1 0.003785 0.08 0.10 0.12 0.13 0.15 0.17 0.19

2 0.01 0.15 0.19 0.23 0.27 0.31 0.34 0.38

3 0.01 0.23 0.29 0.34 0.40 0.46 0.51 0.57

4 0.02 0.31 0.38 0.46 0.53 0.61 0.68 0.76

5 0.02 0.38 0.48 0.57 0.66 0.76 0.85 0.95

10 0.04 0.76 0.95 1.14 1.33 1.52 1.71 1.90

20 0.08 1.52 1.90 2.27 2.65 3.03 3.41 3.79

30 0.11 2.27 2.84 3.41 3.98 4.54 5.11 5.68

40 0.15 3.03 3.79 4.54 5.30 6.06 6.82 7.57

50 0.19 3.79 4.73 5.68 6.63 7.57 8.52 9.47

100 0.38 7.57 9.47 11.36 13.25 15.14 17.04 18.93

150 0.57 11.36 14.20 17.04 19.88 22.71 25.55 28.39

200 0.76 15.14 18.93 22.71 26.50 30.28 34.07 37.86

300 1.14 22.71 28.39 34.07 39.75 45.43 51.10 56.78

400 1.51 30.28 37.86 45.43 53.00 60.57 68.14 75.71

500 1.89 37.86 47.32 56.78 66.25 75.71 85.17 94.64

1,000 3.79 75.71 94.64 113.56 132.49 151.41 170.34 189.27

2,000 7.57 151.41 189.27 227.12 264.97 302.83 340.68 378.53



Nitrogen additions Developed and Designed by Kiki Lee and Jean-Claude Pijanowski December 2003 I. Introduction Analyzing and regulating nitrogen is critical to the survival of yeast cells.

(Yeast – electron microscope) . . . . Alive, It’s Alive!!, It’s ALIVE!!!!! (Gene Wilder - Young Frankenstein – The Movie 1974) Yes, yeast is a living single cell fungi and requires various nutrients for survival. Yeast cells contain many of the same organelles as a multicellular plant or animal. They also contain a nucleus with chromosomes and propagate through exponential cell growth budding. Yeast cells may become stressed through nutrient deficiency and inappropriate fermentation temperatures. Yeast first consumes the ammonium nitrogen ( NH4+ ) and free amino acids in the must with the exception of proline. These components together constitute the total “Yeast Available Nitrogen” (YAN). YAN promotes the synthesis of proteins, which are essential to yeast activity. Nitrogen also is used during the growth and formation of cell walls within the yeast. Too low a concentration of fermentable Nitrogen can cause a sluggish, protracted fermentation, and may contribute to the production of volatile sulfur compounds. The principle factor influencing the production of desirable fermentation volatiles is the nitrogen source for the yeast. Too much nitrogen can cause the fermentation to occur too quickly resulting in the loss of desirable volatile components and increased production of both volatile sulfur compounds and ethyl carbamate (can be carcinogenic).


II. Procedure In order to decide whether any nitrogen needs adding to a must, we need to measure the brix and YAN (either by the Formol method, or a combination of an ammonia method and the NOPA amino acid analysis). Here, we shall use the Formol method. STEP 1 - Recognize the three elements required for the addition of nitrogen.

a. A Brix value of the juice BEFORE inoculation.

BRIX value represents the percentage of sugar in the juice and can be measured with a refractometer or hydrometer (see lab manual). Accurate measurements are essential for determining nutrient additions and should be recorded diligently.

b. An analysis of YAN in the must through the use of the FORMOL METHOD.

FORMOL METHOD is the analysis performed on grape berry samples prior to harvest. The analysis produces a number expressed as YAN (see lab manual)

c. Adding the appropriate type and amounts of nitrogen at different stages of fermentation.

ADDING NUTRIENTS is the physical act of the preparing and adding of compounds to the juice (must). Nutrient preparation is explained in detail elsewhere in the procedures manual. Below is a list of nitrogen sources that may be used at different amounts and stages during fermentation. Commercial Nitrogen Supplements:

Supplement Nitrogen source as a % of total YAN in the

supplement

YAN as a % of the total wt. of the supplement

mg/L of YAN added when supplement is added at ~1#/kgal

DAP NH4 (100) 21.7 27 Fermaid K Amino (?), NH4 (?) 10.0 12.5 Superfood Amino (33-44), NH4 (67-56) 7.4 9 Actiferm 1 Amino (3.7), NH4 (96.7) 13.5 17 Actiferm 2 Amino (6.9), NH4 (93.1) 14.5 18 Go Ferm Amino (100) 3.3 4.1

STEP 2 – At this step two values are required in order to proceed. BRIX & YAN (hydrometer/refractormeter) (Formol Method lab analysis) There are three tables listed below (A, B, & C) with different Brix ranges. Use your brix value and find which table applies to your sample. Next, on the far left of the table is the YAN value. Match the YAN number of your sample to the corresponding number range


Example: Your juice sample (grapes or must) has a Brix of 25.5 and a YAN of 162 Solution: Use table C and with the low range additions (150-200):

NITROGEN ADDITION PROTOCOLS:

Table - A - Brix 22 - 23 (even after dilution to <23 brix) Juice YAN

(mg/L) Rehydration

of water End of Lag

Phase End of Lag

Phase 1/3 sugar depletion

Total Supplement after rehydration

Go-Ferm

(#/Kgal) DAP

(#/Kgal) Supplement

(#/Kgal) Supplement

(#/Kgal) #/Kgal ppm

high > 250 1 0 0 1 1 120

med (150-250) 1 0 1 1 2 240

low (100 -150) 2 1 1 1 3 360

v. low < 100 2.5 2 1 2 5 600

Table - B - Brix 23 - 25 (even after dilution to 24 brix) Juice YAN

(mg/L) Rehydration

of water End of Lag

Phase End of Lag

Phase 1/3 sugar depletion


Go-Ferm

(#/Kgal) DAP

(#/Kgal) Supplement

(#/Kgal) Supplement

(#/Kgal) #/Kgal ppm

high >300 1 0 0 1 1 120

med (200-300) 1.5 0 1 1 2 240

low (125 -200) 2 1.5 1 1 3.5 4208

v. low < 125 2.5 2 1 2 5 600

Table - C - Brix 25 - 27 (even after dilution to 24 brix) Juice YAN

(mg/L) Rehydratio

n of water

End of Lag Phase

End of Lag Phase

1/3 sugar depletion


Go-Ferm (#/Kgal)

DAP (#/Kgal)

Supplement(#/Kgal)

Supplement (#/Kgal)

#/Kgal ppm

high > 350 1 0 0 1 1 120

med (250-350) 1.5 0 1 1 2 240

low (150-250) 2 2 1 1 4 480

v. low < 150 2.5 2 1 2 5 600

Low 150-200

2 2 1 1 6 718.8


STEP 3 – Time to physically prepare additions and mix with the juice must. There are three stages within table A, B, & C in which nitrogen is added. These phases are the “Rehydration of water”, “the End of Lag“ and “1/3 Sugar depletion”. Rehydration of water: FIRST STAGE This is the first nitrogen addition (Go-Ferm) and is added with the yeast at the moment of rehydration (see separate procedure). End of Lag phase: SECOND STAGE This stage occurs during initial active fermentation and is recognized when the brix has dropped 2-3 degrees. Most nitrogen and ammonia is depleted and additions (e.g. DAP and Superfood) are added at this point in order for yeast to continue their growth cycle. Again, follow addition procedures described earlier. 1/3 Sugar depletion: THIRD STAGE At this stage, nitrogen is needed to sustain cell budding and the alcohol is still low enough for yeast to uptake nitrogen. IT IS THE MOST IMPORTANT ADDITION. Example: Inoculation at 24 brix = 1/3 depletion at 16 brix. Follow addition procedures and continue monitoring fermentation until completion.

STEP 4 - Remember, a successful fermentation cycle is paramount to creating wine. The most important factor during fermentation is the survival of yeast and the complete conversion of sugars to ethanol. If there is one mantra to follow during this phase it is:

“Don’t’ stress the yeast!” Quotes for winemakers : "Good wine is a necessity of life for me." - Thomas Jefferson

"...good company, good wine, good welcome, can make good people."

- William Shakespeare “Good wine is a necessity of life for me.” - Benjamin Franklin “Wine is sunlight held together by water.” - Galileo “Nothing more excellent or valuable than wine was ever granted by the Gods to man.” - Plato

"The discovery of a wine is of greater "The discovery of a wine is of greater moment than the discovery of a constellation. The universe is too full of stars."


Tartaric Acid Additions to Musts and Wines I INTRODUCTION Tartaric acid can be added to musts and wine to lower its pH and raise its titratable acidity (TA). A rule of thumb states: addition of 1 gram tartaric acid per liter (equivalent t 8.2 # /1000 gal) decrease pH by 0.1 while raising TA by 1 g/L. The actual decrease in PH must be determined by lab trial because it will depend on the buffering capacity of the wine. Tartaric acid is usually added to lower pH and thus reduce the potential of adverse microbial activity and/or to increase acid and reduce or mitigate flabbiness in the mouth. II EQUIPMENT

1 Scale 2 Container for tartaric acid solution 3 Beaker for 500 ml wine sample 4 5 or 10 ml pipette 5 100 ml graduated cylinder 6 Five wine glasses

III CHEMICALS

1 Tartaric acid IV PROCEDURE

1 Assess the amount to add During the early stages of winemaking, acid is usually added in order to minimize microbial infection. This is achieved by keeping the pH below 3.7-3.8 for reds and below 3.6 for whites. Alternatively, trials during previous vintages with the same grapes and wine style will have indicated a suitable level for both parameters. As the winemaking process proceeds, it becomes more important to conduct taste trials before making any acid additions.

a Based on pH and TA Analysis Use the rule of thumb, that 1g/L or 8.2# / 1000gal decreases the pH by 0.1 units and increases the TA by 1g/L. Actual decrease in PH will depend on the buffering capacity of the wine. To precisely hit a target PH, refer to the acidification/de-acidification trial procedure in the lab manual.

b Based on an Acid Trial

1. Make a 100 g/L aqueous solution by dissolving 10 grams of tartaric acid in 100 ml of distilled water (or 25 grams in 250 ml water, etc.).

2. Set up 5 wine glasses and mark them as Control, 0.25g/L, 0.5 g/L, 0.75 g/L, and 1 g/L.

3. Using a pipette, put:


a. 0.25ml into the 0.25g/L glass b. 0.5 ml of solution into the 0.5 g/L glass c. 0.75 ml in the 0.75 g/L glass d. 1 ml in the 1 g/L glass.

4. Draw 500 ml (or slightly more) wine, put it in a beaker, and using a graduated cylinder put 100 ml of wine into each of the five (5) wine glasses; stir.

5. Taste the control and each of the four trials and record aroma, flavor, structure, balance & finish, and other sensory attributes important to the style of wine being made.

6. Select the acid addition that reflects the wine style. 7. Add less rather than more tartaric acid, e.g., if 2 g/L if selected as "optimal" add

1 g/L (can add more later) 8. If it is a toss-up between two, say 0.75 and 1 g/L, redo the trials for control,

0.70, 0.80, 0.90 & 1.0 g/L 9. Once a decision has been made on the amount to add, measure and record the

pH & TA of the must / wine with the chosen level.

2 Making the Addition

a Having established the concentration to add, calculate the weight of tartaric acid to

be added to the volume of must or wine using the formula below b Convert tons or pounds of fruit to gallons juice assuming 160 gal/ton c Using 100 ml (or larger) plastic beaker, weigh out required amount of Tartaric acid

and dissolve thoroughly in water, juice, or wine: d Pour into must, juice or wine and stir gently

FORMULA

Grams Tartaric acid required = g/L required x gals x 3.785 Lbs Tartaric acid required = g/ l required x gals x 3.785 / 454



SO2 Additions to wines Developed by Gerry Ritchie December 2001 I INTRODUCTION Sulfur dioxide (SO2) is added to minimize growth of undesirable microorganisms and enzymes and to help minimize oxidation. SO2 additions are either made on a regular basis (e.g. every 1-3 months) or after a particular stage or operation. It can be added as a gas, a solution or by using potassium metabisulfite (KMBS). We shall either use a solution (called a stock solution) or dissolve KMBS in some wine and then add it to the wine. SO2 Additions are made after:

MLF Racking Moving Topping Acidity adjustment Filtration Fining or Stabilization Before Bottling

I CHEMICALS

a Potassium Metabisulfite (KMBS) II EQUIPMENT

i Gas mask (if you are sensitive to SO2)

ii pH meter if pH is not known

iii equipment for measuring free SO2 (FS)

Adding KMBS to wines i Weighing Scale ii 100 ml plastic beaker for weighing KMBS

iii 1 liter plastic beaker for wine

iv stirring equipment for wine in beaker and wine in container being adjusted

Adding stock solution to wines (see end of procedure for making stock solutions) i 10, 50 or 100ml measuring cylinder

ii Stirring equipment 1. PREPARATION

a Assemble equipment b Make sure the weighing surface of the scale is clean. c Measure pH if necessary (see lab manual) d Measure FS if necessary (see lab manual)


2. PROCEDURE There are four stages to making an SO2 addition. We have to

i Assess whether the add is an initial or a subsequent addition: Note the stage of the winemaking process and the winemaking plan

Initial (i.e. after AF or MLF, depending on the plan). SO2 added at harvest is not counted as an initial add.

Subsequent (i.e. additions made, after the initial add, at regular intervals in order to maintain the FS at an adequate level to minimize contamination of the wine)

ii Decide the form of the SO2 that we are going to add: Stock solution or KMBS

iii Estimate how much to add It depends on whether the pH is above or below pH3.55, how much free SO2 (FS) is already present (if any) and the amount of bound SO2

It is critical to get someone to check your calculations as mistakes are difficult to rectify without decreasing the quality of the wine

iv Make the addition. It is critical to dissolve all the KMBS thoroughly before adding to the bulk of the wine It is critical to thoroughly mix it into the bulk of the wine

In the NVC winery we mainly use KMBS 3. ESTIMATING HOW MUCH TO ADD a. Estimating Initial SO2 Additions Using KMBS (i.e. When you do not have many barrels or small containers) 1. If pH is < 3.55, add sufficient to achieve 0.5mg/L molecular SO2 (see Fig. 1) plus an

estimate to correct for bound SO2 (see Table 1). Follow procedure given under section Vb and in step 2, assume free SO2 (FS) = 0. A common starting point is to add 40-50ppm.

2. If pH is > 3.55, add sufficient to achieve FS of 30ppm after correcting for bound SO2 (see Table 1). Follow procedure given under section Vb and assume FS = 0. A common starting point is to add 50-60ppm.

Using a stock solution (i.e. When you have plenty of volume / barrels or containers) 1. Add increasing amounts of a 5.58 or 7.5% SO2 stock solution to each of 3 barrels (e.g.

110ml, 140ml, 160ml) 2. Stir without disturbing lees, sample and analyze for Free SO2 3. Repeat process until addition hits target FS 4. For all the other barrels, use the addition rate that gives the target Free SO2


Table 1. Method for guestimating bound SO2.

Stage Initial Guess at Fraction Bound

Unsulfured wine / juice

0.25 – 1.0 Red > white

Previously sulfured wine 0.15 - 0.25

Microbially challenged wine Greater than normal

Pre bottling 0.05 – 0.15 (should know the value by now)

b Estimating Subsequent SO2 Additions

Using KMBS 1. Measure pH (see Lab Analyses Manual) 2. Measure Free SO2 (see Lab Analyses Manual) 3. Estimate fraction bound (see Table 1 for guestimates) 4. If pH is < 3.55, decide on target molecular SO2 (0.5 or 0.8mg/L) and estimate

corresponding free SO2 at pH of wine (see Fig. 1) If pH > 3.55, choose 30ppm as target FS if wine is healthy or 35ppm FS if wine has a high VA or there is a risk of contamination

5. Subtract measured Free SO2 from target free SO2 (Step 4 – Step 2) 6. Multiply amount in Step 5 by fraction bound decide upon in Step 3 7. Add the FS calculated from Step 5 to the bound value calculated in Step 6. This

gives the required FS 8. Calculate amount to add as KMBS or use Table 2

Grams (g) of KMBS to add = ppm FS required x gals x 3.785 x 2/1000 = ppm FS required x gals x 0.00757

Using a stock solution

1. Carry out steps 1-7, as for using KMBS 2. Calculate amount to add as a 0.38, 5.58 or 7.5% SO2 stock solution or use Table 3

mls of 0.38% solution to add = ppm FS required x gals x 3.785 x 100/(0.38*1000) = ppm FS required x gals mls of 5.58% solution to add = ppm FS required x gals x 3.785 x 100/(5.58*1000) = ppm FS required x gals mls of 7.5% solution to add = ppm FS required x gals x 3.785 x 100/(7.5*1000) = ppm FS required x gals x 0.0505


Example: Initial FS = 23ppm pH = 3.6 Final FS desired = 30ppm Fraction Bound = 0.20 Grams of KMBS / bbl = ((30 – 23) + (7 x 0.2)) x 2 x 59 x 3.785 / 1000 =3.75g / bbl

Fig. 1. The variation in Free SO2 (FS) with pH for 0.5 and 0.8 molecular SO2.


Table 2. Grams of KMBS required to raise the ppm of FS in different volumes of wine (the required FS in step 7 on p.60)

ppm FS required

Volume of Wine (gals)

1 2 3 5 15 50 59

1 0.38 0.45 2 0.23 0.76 0.89 3 0.34 1.14 1.34 4 0.15 0.45 1.51 1.79 5 0.19 0.57 1.89 2.23 6 0.23 0.68 2.27 2.68 7 0.16 0.26 0.79 2.65 3.13 8 0.18 0.30 0.91 3.03 3.57 9 0.20 0.34 1.02 3.41 4.02

10 0.15 0.23 0.38 1.14 3.79 4.47 11 0.17 0.25 0.42 1.25 4.16 4.91 12 0.18 0.27 0.45 1.36 4.54 5.36 13 0.20 0.30 0.49 1.48 4.92 5.81 14 0.21 0.32 0.53 1.59 5.30 6.25 15 0.23 0.34 0.57 1.70 5.68 6.70 16 0.24 0.36 0.61 1.82 6.06 7.15 17 0.26 0.39 0.64 1.93 6.43 7.59 18 0.27 0.41 0.68 2.04 6.81 8.04 19 0.29 0.43 0.72 2.16 7.19 8.49 20 0.15 0.30 0.45 0.76 2.27 7.57 8.93 25 0.19 0.38 0.57 0.95 2.84 9.46 11.17 30 0.23 0.45 0.68 1.14 3.41 11.36 13.40 35 0.26 0.53 0.79 1.32 3.97 13.25 15.63


Table 3. Mls of 0.38, 5.0, 7.5 & 10% SO2 Stock Solutions required to raise the ppm of FS in barrels & smaller containers

ppm FS required

mls of 5-10% Stock Solution per Barrel

mls of 0.38% SO2 solution for 1-5gals wine

5% 5.58% 7.5% 1gal 2gals 3gals 5gals

1 4.47 4 2.98 1 2 3 5 2 9.00 8 6.00 2 4 6 10 3 14.00 12 9.00 3 6 9 15 4 18.00 16 12.00 4 8 12 20 5 23.00 20 15.00 5 10 15 25 6 27.00 24 18.00 6 12 18 30 7 32.00 28 21.00 7 14 21 35 8 36.00 32 24.00 8 16 24 40 9 41.00 36 27.00 9 18 27 45 10 45.00 40 30.00 10 20 30 50 11 50.00 44 33.00 11 22 33 55 12 54.00 48 36.00 12 24 36 60 13 59.00 52 39.00 13 26 39 65 14 63.00 56 42.00 14 28 42 70 15 67.00 60 45.00 15 30 45 75 16 72.00 64 48.00 16 32 48 80 17 76.00 68 51.00 17 34 51 85 18 81.00 72 54.00 18 36 54 90 19 85.00 76 57.00 19 38 57 95 20 90.00 80 60.00 20 40 60 100

MAKING THE ADDITION Using KMBS Weigh out required amount of KMBS into a 100 ml (or larger) plastic beaker 1. Dissolve the KMBS completely in some of the wine (~500mls) in a 1L plastic beaker,

using a magnetic stirrer if necessary OR Using a stock solution Measure out the required volume of stock solution in a 100ml (or less) measuring cylinder 2. Add to wine and stir gently but thoroughly 3. Re-check Free SO2 4. Repeat process until desired concentration (ppm) of FS is achieved


Preparation of Stock Solution

Equipment i Weighing Scale ii 100 ml plastic beaker for weighing KMBS

iii Funnel iv Volumetric Flask

v Magnetic Stirrer and stirring bar

vi Plastic container for holding Stock Solution 1. Decide the strength of the SO2 solution and how much stock solution will be required

in order to complete the task. Use Table 4 to determine the weight of KMBS required for the chosen volume and strength of stock solution.

2. Weigh out required amount of KMBS into a 100 ml (or larger) plastic beaker 3. Using a dry funnel, quantitatively transfer to a dry volumetric flask, (which has a

volume equivalent to the value decided upon in step 1) 4. Add some water (approximately ¾ of the final volume) and stir with a magnetic stirrer

until all, or nearly all, has dissolved 5. Remove stirring bar and top up to the mark with water 6. Invert flask 20 times to thoroughly mix the contents 7. Decant into plastic container and label (include date of preparation) Table 4. Grams KMBS required to make stock solution s of 0.38 -7.5% SO2

Final volume (mls) of Stock

Solution

% SO2 in Stock Solution

5 5.58 7.5 0.38

100 10 11.16 15 0.76 500 50 55.8 75 3.8 1000 100 111.6 150 7.6



Enzymes Additions Developed by Bobbie Curley December 2003 Introduction

Enzymes are naturally present in fruit and wine. Enzyme additions are made to facilitate and increase the rate of some chemical reactions in the must or in the wine. Some examples of desired chemical reactions from the use of enzymes are as follows:

Preserving freshness and aroma of the grapes

Extraction of phenolic compounds (including color) and flavors Settling of must and lees prior to fermentation Releasing juice to improve the press yield Fining, clarifying and filterability

Equipment

Thermometer Beaker Stirrer

Preparation of Liquid Enzymes

(Read manufacturer’s preparation instructions on the enzyme product package.)

Make an approximate 10% solution in cool water (21 – 25 C or 70 – 77 F).

Preparation of Powdered/Granular Enzymes

(Read manufacturer’s preparation instructions on the enzyme product package.) Add cool water (21 – 25 C/70 – 77 F) to the enzyme to create a paste. Then, add more cool water to dissolve completely.

Procedure – Proceed depending on the need:

Sprinkle the solution over the crushed grapes, before fermentation;

OR

Add to the tank and gently stir to disperse the enzyme solution;

OR

Gently mix the solution into the wine tank, after fermentation.



Tannin Additions Developed by Robert Davis December 2003 I Introduction HISTORY FRANCE- French winemakers have been adding tannins well before 1955 to correct a deficiency in a difficult vintage, to fix color and to provide grip. Tannin isn’t used to hide anything, but to reveal the quality of tannins that exist naturally in the wine grape. Tannins are usually added to lesser wines to stabilize color and inhibit the enzymatic activity of botrytis. AMERICAN- it may be an age-old enological practice in France, but it is a recent arrival in California, where many producers are experimenting. Many California producers refuse to officially recognize tannins, fearing consumers would stigmatize the practice as “unnatural” and “interventionist”. The structure of wine will fall apart when the supply of tannins is totally exhausted. AUSTRALIA- There is no consensus among winemakers. Some say it is only for the unimportant wines, others will use it for big, structured wines. WHY ADD TANNINS? Tannins play a crucial role in protecting a red wine’s flavor and aromatic components from the ravages of oxygen. As tannin molecules oxidize, they bond together to form a longer chain, which has a less astringent mouthfeel. Great wines must be balanced, an integration of concentrated flavors of ripe fruit with firm structure. In red wines, the structure mostly comes from tannins, a natural component of the skins, seeds and stems of the grape. To manage the quality and quantity of tannins, powdered tannins are added to achieve the balance desired. STABILIZE COLOR- The addition of proanthocyandic (catechin) tannins can help stabilize color. The anthocyanins are extracted principally in the early stages of fermentation (1-3 days). Most tannin extraction takes place later, largely related to the presence of alcohol. Addition of tannins at the beginning stage of anthocyanin extraction helps to protect the free anthocyanins from oxidation and create a stable bond between anthocyanins and proanthocyandic tannins. IMPROVE STRUCTURE AND MOUTHFEEL- The addition of tannins at the beginning of fermentation can improve mouthfeel and overall structure of the wine. Grapes grown in warmer areas do not have the same phenolic profile as those grown in the cooler regions. At optimum anthocyanin and sugar/acid maturity, grapes grown in warmer regions have lower tannin levels. By supplementing tannins at the beginning of fermentation, the winemaker can broaden the tannin/structure base of the wine.


WHICH TANNINS TO USE NAME PROPERTIES USES RED WINE: TANIN VR SUPRA Highly reactive with proteins - stabilize color, enhance structure

Combines with anthocyanins - inhibit laccase and protect Enhances structure and aging potential anthocyanins in grapes from rot

- Antioxidant BIOTAN Grape tannin component for poor RED,ROSE, WHITE WINES: tannic structure in wine - Stabilize color

- Enhance structure and aging potential

TANIN GALALCOOL Reactive with protein WHITE and ROSE WINES: Inhibits laccase activity - Improve clarification Complexes with oxidizable molecules - Improve structure preventing browning - Eliminate reduction odors

- Botrytised grapes TANIN GALALCOOL Reactive with protein WHITE and ROSE WINES: SP Inhibits laccase activity - Improve clarification Complexes with oxidizable molecules - Improve structure preventing browning - Eliminate reduction odors

- Botrytised grapes - Enhance mouthfeel TAN’COR Compensates for lack of tannin RED WINES: in finished wines - Stabilize color

- Enhance structure and aging - Inhibit residual laccase activity - Reduce vegetal and musty aromas

- Reduce astringency TAN’COR GRAND CRU Compensates for lack of tannin in RED WINES: finished wines, without the dryness - Stabilize color

that might come from barrel aging - Enhance structure and aging Facilitates aging - Inhibit residual laccase activity Antioxidant - Reduce vegetal and musty aromas

- Enhance fruit character QUERTANIN Strong antioxidant RED, ROSE WHITE WINES: Facilitates aging - Enhance body & structure

- Eliminate storage reduction odors

TANIN PLUS Compensates for lack of structure RED WINES: in finished wines - Improve structure


USE OF TANNINS DURING THE LIFE OF A WINE Additions Before Fermentation Recommended for use on grapes that have botrytis, mold or rot. Inhibits laccase activity. Prevents oxidation and protects against browning. Sprinkle over grapes in the bin or add in solution at the crusher. Grape/Tannin Rate (ppm) Amount Red Grapes- Tanin VR Supra 300-500 30-50g/hl 2.4-4.0lb/1000gal White Grapes-Tanin Galalcool 50-100 5-10g/hl 0.4-0.8lb/1000gal White Grapes-Tanin Galalcool SP 100-300 10-30g/hl 0.8-2.4lb/1000gal Additions During Fermentation Helps prevent oxidation and stabilize color. If using tannin in conjunction with enzymes, add enzymes at the crusher (not directly with SO2) wait 6-8 hours and add desired amount of tannin into the fermenter. More tannin can be added, according to taste, at the first two pump-overs. This will make tannin available for binding with the proanthocyanins as color is extracted, optimizing the efficiency of additions. When cold soaking or using rotary fermenters, add the tannin solution when filing the tank. Grape/Tannin Rate (ppm) Amount Red Grapes- Tanin VR Supra 300-500 30-50g/hl 2.4-4.0lb/1000gal Additions During Aging For color stabilization and protect against oxidation. Additions should be made during the first two or three rackings, followed by an organoleptic evaluation. Dosages of 100-200ppm should be added to a barrel or cask during racking. Grape/Tannin Rate (ppm) Amount Red Wines- Tan’Cor 100-300 10-30g/hl 0.8-2.4lb/1000gal White Wines- Tanin Galalcool 100-300 10-30g/hl 0.8-2.4lb/1000gal White Wines- Tanin Galalcool SP 100-300 10-30g/hl 0.8-2.4lb/1000gal Additions to Finished Wines Tanin Plus is a preparation of oak tannins. They have been lightly toasted and impact slightly softer, more aromatic characters to the wine. Grape/Tannin Rate (ppm) Amount Red Wines- Tanin Plus 50-300 5-30g/hl 0.4-2.4lb/1000gal White Wines- Tanin Plus 50-200 5-20g/hl 0.4-1.6lb/1000gal Quertanin prevents oxidation of the color of red wines and adds to the structural backbone of all wines. For whites, the bouquet is conserved while giving a fuller mouthfeel. Grape/Tannin Rate (ppm) Amount Red Wines- Quertanin 100-200 10-20g/hl 0.8-1.6lb/1000gal White Wines- Quertanin 50-100 5-10g/hl 0.4-0.8lb/1000gal


Choosing the appropriate rate of addition Bench trials should be conducted to decide on the appropriate rate of addition and

tannin additions should be done a minimum of three weeks before bottling.



De-stemming and Crushing Grapes Developed by Liz Christensen and Manbin Khaira Monteverdi December 2002 II Introduction The de-stemmer/crusher is used to separate the stems from grape clusters and can be used to crush the grapes. It is used more frequently for processing red grapes although some protocols may require using this equipment for white grapes.

III Equipment

The de-stemmer/crusher is a piece of electrical equipment comprised of:

The hopper--stainless steel collection basin into which whole grape clusters are dumped.

The rollers--nylon wheels that can be adjusted to crush the berries or leave them whole.

The cage--a stainless steel cylinder containing perforations that allow berries, but not stems, to pass through.

Paddles--designed to move the stems through the cage and out the other side. Switches--one to start the paddles, and one to start the rollers. Also, corresponding

red safety switches that you push or hit to switch off. RPM adjustment lever--to control the speed that the machine turns. This level can be

used only while the machine is running. You will also need: an extension cord, a method for loading grapes into the hopper (a ladder for manual loading or a fork lift truck), and two collection basins such as half-ton picking bins.

IV Preparation

1 The equipment and picking bins should be thoroughly cleaned before use. The

hopper, cage and paddles can all be removed to facilitate cleaning. 2 The equipment and the bin for collecting must should be sanitized before use.

Spraying with Quat, leaving for 15 minutes and then rinsing is recommended. (Refer to the sanitation section of these SOPs).

3 The rollers will need to be adjusted depending on your protocol. They can be opened completely to allow whole berries to pass through or closed to allow for a slight or very thorough crush of the berries. You will need to experiment to get the adjustment right for your protocol.

4 The speed of the machine will also need to be adjusted by experimentation. Too high or too low a speed will result in excessive numbers of jacks (stem bits) falling through the cage.


V Procedure Set-up 1 Place all clean and sanitized equipment near the de-stemmer crusher. 2 Place one picking bin directly beneath the machine to catch the crushed berries and juice

(must). Place another picking bin at the end of machine to catch the stems. Be sure that some type of material (i.e., cardboard) is used to separate the two picking bins since jacks are not desired in the must bin.

3 Pull the rolling platform up to the machine and lock it in place. Place the FYBs full of grapes in close proximity to the rolling platform as it is important that the hopper is fed at a consistent rate. Overfilling the hopper with grapes causes the grapes to jam in the hopper and under filling the hopper results in the accumulation of too many stems in the must bin.

4 To help the must remain cool have dry ice available during the de-stemming crushing process.

5 If intending to add SO2, have it measured and mixed. Add one-half the SO2 mixture into the must bin once one-half of the FYBs have been run through the machine.

Operation

1 Dump 2 to 3 FYBs into the hopper (or enough grapes so that the hopper is at least half full). There should be at least one person at the top of the platform to dump grapes into the hopper and one person at the bottom of the platform to hand full FYBs and take empty FYBs.

2 There are two small black buttons; one for starting the de-stemmer and the other is for starting the crusher. There are two red buttons; one is for stopping the de-stemmer and the other is for stopping the crusher. Once the red buttons have been pushed to stop the machine they have to be pulled out by turning to the right and released prior to starting the machine again. The person responsible for turning the machine on and off should make the whole team working on the machine aware of what is happening.

3 The machine should be set at 420 rpm (roughly the middle of the range) at the beginning of the process and then adjusted as needed. (See Troubleshooting for more details)

4 Press the de-stemmer black button and the crusher black button to start the operation. 5 If your protocol calls for crushing, be sure that the berries are being crushed sufficiently

but not too harshly. A good crushed berry should have its skin broken and the pulp should be able to come out.

Wrap-Up

1 Once all the grapes have been run through the machine add the remaining SO2 and additional dry ice to keep the must cool.

2 If another block is to be run through the machine, be sure to pressure wash the entire machine including the hopper, drum, rollers and the cage inside the drum. If the machine is no longer needed for the day, use the following process to fully clean and sanitize the machine:

3 Open the door on the end of the machine and the door on top. 4 Take out the spindle that contains the paddles and then the cylinder. 5 Pressure wash all the pieces, inside and out and let them dry. 6 The rolling platform should also be completely pressure washed.


7 Pressure wash all FYBs and let them dry before stacking and storing. 8 Remove the picking bin(s) filled with stems, load it on to a truck and take it to the nearby

vineyard. 9 The must bin should be covered and moved into the winery and stored per your protocol. Troubleshooting: Too many jacks?

Adjust the speed Increase the amount of grapes in the hopper Change the angle of the paddles

Berries not being crushed enough? Adjust the rollers



Bleeding (Saignée) Developed by: Bob Mihalovich, Erica Schubert Date: Fall 2002 I Introduction Bleeding is a wine-making technique of ‘running off’, or ‘bleeding’, up to 10% of free-run juice from just crushed red varietal grapes at the time of crush or after a short, prefermentation maceration. The aim of this may be to produce a Rose, or to increase the proportion of phenolics and flavor compounds to juice in the remaining must thus concentrating the red wine made from the juice left behind in the fermenter. If the goal is to produce a Rose, then the juice is fermented and treated like a white wine using controlled cold fermentation temperatures. This procedure typically involves the removal of 5-10% of the juice from the total volume of must. Note that bleeding can reduce the nitrogen level in the remaining must II Equipment

Beaker, bucket or shovel Strainer Funnel* Carboy(s)* Airlock* * For Rose.

III Preparation Determine expected volume to be removed (5 – 10%). Triple wash equipment and containers before use. Note that KMBS is added after this process is conducted. IV Procedure 1. Gently press beaker, bucket or shovel on top of must to remove juice (see photo below). 2. Strain the juice and return any skins to the must. 3. Discard the free run juice or if making Rose, see steps 4 to 6 below. 4. Pour the strained liquid into the carboy using the funnel. 5. Leave enough headspace for fermentation. 6. Add yeast, N and nutrients according to the team protocol (see photo below). 7. Proceed with team protocol on the must. V General Notes


Saignée is a French term commonly used in France for juice drawn from the Pinot Noir fermentation tanks prior to fermentation. VI Procedure Photographs Removing Juice and Skins (note Dry Ice has been added to Must)

Saignée Wine Prior to Fermentation



Cold Soak Developed by James Lee and Sandra Peterson December 2001

I INTRODUCTION Cold soaking the must at 50 to 60F for several days before initiation of fermentation by inoculation with active dry yeast encourages oxidative polymerization of phenols, which may be important in wine color stability (Zoecklin et al., 1999). II EQUIPMENT ½-ton picking bin or macro bin with lid Plastic wrap Spray bottle 100-ml graduated cylinder III CHEMICALS 1% S02 solution CO2 ice KMBS (For moldy fruit) IV PREPARATION 1. Clean bin and lid with a 3-cycle wash (See Sanitation Procedures). 2. Clean crusher/destemmer (See Crusher/Destemmer Procedures). V PROCEDURE 3. If bin cannot be moved after filling, place in cold storage before filling. 4. If used, add SO2 as KMBS dissolved in must (See Additions Procedures for calculations)

and skip step 5. But if mold appears on surface of must on subsequent days, then spray with SO2 as described in step 5.

5. Sprinkle 2 cups (2 x 250ml) CO2 ice into cold soak container. 6. Place destemmed/crushed must into container. 7. Spray top with 15 ml of 1% SO2 solution per ½ ton of fruit. 8. Cover container and seal by wrapping with plastic wrap. 9. Keep refrigerated at 50-55F for two to four days. 10. Sprinkle 2 cups (2 x 250ml) CO2 ice on surface of must every 48 hours.


References

Zoecklin, B.W., Fugelsang, K.C., Gump, B.H., and Nury, F.S. 1999. Wine Analysis and Production. Aspen: Gaithersburg, Maryland, p. 288.



Cold Settling Developed by Elaine Vocelka November 2003 I. Introduction Cold Settling is a clarification process used in white wine production that is carried out after pressing and before alcoholic fermentation. After pressing, the juice will be cloudy due to the presence of vegetative fragments and other suspended solids, known as gross lees. This cloudiness is also known as turbidity. Turbidity can effect wine quality whereby too high of a concentration of suspended solids can cause an increase in vegetal flavors, mask fruity characteristics, produce sulfuric compounds and increase the risk of oxidation and spoilage. Too low of a concentration on the other hand can lead to a stuck fermentation and increase VA. Cold settling separates the sediment from the juice, allowing it to settle to the bottom of the tank under the action of gravity. The time required for this operation varies based on particle size and quantity, but usually requires about 16-24 hours. If necessary, cold settling can be extended a day or two if the juice is still too cloudy to rack off. After cold settling, the juice must be racked to another vessel such as a barrel or a stainless steel tank for alcoholic fermentation. Racking is a wine clarification process as well. It is the process of transporting juice from one vessel to another leaving any sediment or deposit behind. The racked juice is generally free of solids but still may require further filtration. II Equipment

Picking Bin Pump ( if needed for racking) Wooden Pallet 10, 30 or 40 gallon trash can (depending on size needed), with lid 3 or 5 gallon Carboys (for press fraction) 400 Liter Stainless steel tank with lid or temperature controlled tank (size may vary depending upon quantity of juice) Siphon hose Barrel or tank (receiving vessel) Sieve for staining solids Saran wrap Wooden dowel Garbage bag twist ties or other bendable wire

III Chemicals


• Dry Ice (CO2) • KMBS (SO2) IV Preparation 1. Clean settling tank (that best suits your needs for the amount of juice you have pressed, i.e.: 30

gallon garbage can, 400 Liter stainless steel tank, glass carboys) corresponding lids and siphon hose with a 3-cycle wash (see “Sanitation Procedures”)

2. If racking to a barrel, prepare it by cleaning per “Barrel Cleaning” procedure and fill with water overnight to expand the wood.

3. If racking into a tank, proceed to a 3-cycle wash (see “Sanitation Procedures”). 4. If using the pump for racking, proceed with a 3-cycle wash as well. 5. Take a wooden pallet and place a picking bin up side down on it. Place your cleaned receiving

vessel on top of the picking bin. This will allow the juice to be at the correct height to rack the juice by gravity after cold settling.

VI. Procedure 1. Press grapes (see separate procedure). 2. If necessary, place the receiving vessel that you will be using for cold settling the juice at a

height suitable for using gravity to rack the settled juice. Settling and Racking from a Trash Can: 1. Transfer the juice into the vessel can using a pump or siphon tube. 2. Add proper amount of SO2 to juice. (see “Adding SO2 at Crush” procedure) 3. Add 250 ml of Dry Ice pellets to juice and stir gently. Record the starting temperature. 4. When using a 10, 30 or 40 gallon trash can, place the corresponding lid on top of the can. Using

a roll of saran wrap, completely seal the lid to the garbage can itself by wrapping the saran tightly around the edges of the lid at least 3 times. This will help keep any air from getting into the juice.

5. Using the pallet jack, place the pallet with the can on it into the barrel room and set the 6. Temperature of the barrel room should be 50-55 F. Leave the juice for 16 to 24 hours. 7. If the juice is not clear enough after 16 to 24 hours, allow it to cold settle for another day. 8. Attach the 1in tubing attached to a 11/2 tri-clamp fitting to the racking valve of the tank. Direct

the other end into a (properly prepared) barrel placed below the tank. A funnel may be required. Open racking valve and fill barrel to 6” down.

9. If racking the juice to a barrel from a container with no racking valve, take a siphon hose and secure it to a wooden dowel using a metal twist ties. Make sure the end of the hose is about 2 inches from the bottom of the dowel. This will keep the hose off of the bottom of the vessel and prevent it from picking up any settled lees. Note: When racking white juice DO NOT use a dowel that has previously been used to stir Red juice/wine. Always use a dowel that is clean with no signs of red on it for white wine making.

10. If racking to a tank, use a pump and follow the racking procedure (see Tank Racking Procedure) 11. After juice transfer is complete, discard the lees and clean the emptied tank (be sure to remove

all tartrate crystals) and other equipment by rinsing with hot water. 12. The juice is now ready to be inoculated (see “Alcoholic Fermentation” procedure)


13. Make sure to clean the floor and surrounding area of any spilled juice when you are through, as well as any and all equipment used (see Sanitation Procedures)

Settling and Racking from the 400 liter Stainless Steel Tank: 1. Transfer the juice into the 400Liter Stainless steel tank using the siphon hose. 2. Add proper amount of SO2 to juice. (see “Adding SO2 at Crush” procedure). 3. Add approximately 2 x 250ml of Dry Ice to juice and stir gently. Record the starting

temperature. 4. When placing the lid to the tank make sure you have at least three people to help. two people to

hold the lid in place and balanced while a third person manually pumps the inflatable lid into place.

5. Using a pallet jack, wheel that tank into the barrel room and set the temperature of the room to 55 degrees. Leave the juice for 16 to 24 hours. Check temperature and reload with dry ice as needed.

6. If the juice is not clear after 16 to 24 hours, allow it to cold settle for another day. 7. If the juice is ready for racking to a barrel, take a siphon hose and secure it to a wooden dowel

using a metal twist ties. Make sure the end of the hose is about 3 inches from the bottom of the dowel. This will keep the hose off of the bottom of the vessel and prevent it from picking up any settled lees. Note: When racking white juice DO NOT use a dowel that has previously been used to stir Red juice/wine. Always use a dowel that is clean with no signs of red on it for white wine making.

8. If racking to a tank, use a pump and follow the racking procedure (see Tank Racking Procedure).

9. After juice transfer is complete, discard the lees and clean the settling tank, siphon hose and dowel using a 3- cycle wash. If using a pump, clean it as well.

10. The juice is now ready to be inoculated (see “Alcoholic Fermentation” procedure). 11. Make sure to clean the floor and surrounding area of any spilled juice when you are through, as

well as any and all equipment used (see Sanitation Procedures). Settling and Racking from a glass carboy or jug: 1. Transfer the juice into the correct size carboy or jug needed using a siphon hose. 2. Add the proper amount of SO2 to juice (see “Adding SO2 at Crush” procedure). 3. Add proper amount of dry ice and stir gently. Record starting temperature. 4. Using saran wrap, make sure that the opening to the glass vessel it securely covered to prevent

any air from getting to the juice. 5. Place the glass vessel up on to the wooden ledge inside of the barrel room. Making sure that the

temperature is set to 50-55F and let settle 16 to 24 hours. 6. If the juice is not clear after 16 to 24 hours, allow it to cold settle for another day. 7. If the juice is ready for racking to a barrel, take a siphon hose and secure it to a wooden dowel

using a metal twist ties. Make sure the end of the hose is about 2 inches from the bottom of the dowel. This will keep the hose off of the bottom of the vessel and prevent it from picking up any settled lees. Note: When racking white juice DO NOT use a dowel that has previously been used to stir Red juice/wine. Always use a dowel that is clean with no signs of red on it for white wine making.

8. After juice transfer is complete, discard the lees and clean the glassware, siphon hose and dowel using hot water.


9. Make sure to clean the floor and surrounding area of any spilled juice when you are through, as well as any and all equipment used (see Sanitation Procedures).


Alcoholic Fermentation Developed by James Lee and Sandra Peterson December 2001 I INTRODUCTION Alcoholic fermentation is the process of yeast metabolizing sugars and producing ethanol and other compounds. This section covers fermentation from the addition of rehydrated yeast and nutrients to completion of alcoholic fermentation, which is usually achieved when the must/juice reaches 0-0.5% residual sugar. For information on measuring and preparing the yeast and nutrient additions, refer to section on adding nutrients after crush.. For white wines, harvest, crush, press, and inoculation are done the same day (or two) then fermentation takes place in barrels/carboys at 55-60˚F. For red wines, harvest, crush, possibly cold soak, inoculation, and fermentation are done before pressing to ensure maximum extraction of color and flavor compounds from skins and seeds. Fermentation takes place in covered bins at 70-85˚F. II EQUIPMENT Prepared yeast and nutrients (see section on adding nutrients after crush) Punchdown tool in a bucket of acidified SO2 Plastic tub with lid located in a secure, accessible place to hold the following: Thermometer Plastic thief 1-liter plastic pitcher Sieve 2 x 1L beakers Plastic graduated cylinder Hydrometer set 5-25˚ and -5-5˚ Brix (store with care) Paper towels for drying equipment Folder containing

Tracking sheet per varietal (template attached) Copy of winemaking protocol Ink pen that won’t smear when wet


III PROCEDURE Inoculate

Red in half ton bins (75% full with must or less) 1. Carry out any nutrient additions (according to the appropriate SOP). Stir in lightly with

punchdown tool. 2. After following appropriate SOP, pour the yeast preparation into the middle of the must and

gently press to just below the surface. Do not mix throughout the must.

White in barrels (6” head space) or carboys (filled to where neck starts to curve in) 1. Carry out any nutrient additions (according to the appropriate SOP) to the barrel/carboy. Stir

lightly into juice. 2. After 10 minutes, pour the yeast preparation in and do NOT mix it in.

Monitor

Red in covered bins Punchdown 2-3 times per day depending on the stage of fermentation. Punchdown procedure:

1. Get any fruit flies out of the bin. 2. Put the thermometer in the middle of the bin to determine temperature of must. Record on sheet. 3. Clean and sanitize punchdown tool with acidified SO2 and rinse. Don’t let it touch the ground. 4. Punch down vigorously (but not to the point of squishing berries on the bottom). The goal is to

wet the cap with the underlying juice. Ensure to get into all the corners and that there is no dry cap present on top. If bins are different (varietal, yeast…) then rinse/sanitize/rinse between bins.

5. Rinse and return the punchdown tool to the bucket of acidified SO2. 6. Fill one 1L plastic beaker with ~1 liter of must. 7. Filter through the sieve into the other 1L beaker. 8. Fill the graduated cylinder (fill line will vary—you can start with two-thirds full). 9. Gently depress and spin the hydrometer in the juice (do NOT drop it in). Read the Brix and

record on the tracking sheet. 10. Pour some juice into a wine glass and do a sensory analysis (appearance, aroma, taste, bitterness

and astringency). 11. Note sensory info, fermentation observations, date, time, your name on the tracking sheet. 12. Return remaining must/wine to the bin. Clean all materials and place them back in the plastic

tub.

White in barrels or carboys Monitor daily throughout fermentation (15-30 days) as follows:

1. Get any fruit flies away from the area. 2. Insert the thermometer to determine temperature of juice. Record on sheet. 1. Clean wine thief with acidified SO2 and rinse. Don’t let it touch the ground or other surfaces. If

containers are different (varietal, yeasts…) then rinse/ acidified SO2 /rinse the thief between container samples.

2. Using the thief, fill the graduated cylinder (fill line will vary—you can start with two-thirds full). 3. Gently depress and spin the hydrometer in the juice (do NOT drop it in). Read the Brix and

record on the tracking sheet. 4. Pour some juice into a wine glass and do a sensory analysis (appearance, aroma, taste, bitterness

and astringency).


5. Note sensory info, fermentation observations, date, time, your name on the tracking sheet. 6. Return remaining juice/wine to the bin. 7. Clean all materials and place them back in the plastic tub. Clean the bung/closure if dirty.

Determine dryness The wine is dry when residual sugar is 2g/L or less. If the style calls for a sweet style, then the Fermentation may be arrested at a higher sugar concentration (e.g. the rose) 1. Place 1ml of wine into a test tube 2. Drop in one Clinitest tablet and wait 30-60 seconds. Note color and compare to the Clinitest key

to determine the result. Record the resulting measurement. Notes As the ˚Brix drops closer to 0 as measured by hydrometry, the measurement is distorted due to

the presence of alcohol and can actually measure negative ˚Brix. Clinitest is needed for better accuracy at this point.

It is highly recommended to publish a monitoring schedule and ensure all those involved have

the schedule and each others’ contact information. Clearly identify all lots to be monitored, right down to the carboys. Number and label them

clearly. Stuck Fermentation: If ˚Brix stops dropping before reaching the desired residual sugar, the

fermentation may be “stuck.” This means the yeast population has essentially died off or ceased metabolism. The cause of the stuck fermentation must be determined and remedied before fermentation can be restarted.


Fermentation Tracking Sheet

Date/Time Name Lot# ˚Brix ˚F Notes (color, aroma, bitterness, astringency, fermentation, etc)




Punchdown Developed by Anne Arns, Eduardo Avalos, Myles McMonigle December 2003 I Introduction Punching down is the process of periodically submerging the cap of seeds and skins of red grapes into the fermenting juice. The anticipated results are improved color and extraction of phenols, aeration of the fermenting must, limited growth of spoilage organisms in the cap and equalization of the temperature throughout the fermenting must. II Equipment Punchdown tool(s) (Size or kind of tool is dependent on container or process) Sanitizing agent (either acidified SO2, quat or alcohol) Paper towels Alcohol Thermometer (no mercury) 1 liter pitcher (or necessary equivalent) Strainer Graduated cylinder (large enough to accommodate hydrometer) Hydrometer (set at 5-25 or –5-5 Brix)

Important Safety Procedure!!!: Be cautious when entering the winery during fermentation!

Always open the roller door for air circulation (open/close/stop buttons are located to the right of the door)

Be aware of shortness of breath and an acrid smell The carbon dioxide monitor turns on automatically when levels in the winery are

dangerous

Sanitation:

Sanitation procedures should be strictly followed or employed. Punchdown

procedures require constant contact with the fermenting must. The contact is an excellent opportunity for the introduction of spoilage yeasts and other undesirable organisms, such as fruit flies. Always ensure that equipment is sanitized before coming into contact with the must and container. Always ensure that the container is properly cleaned after performing punchdown procedures. III Procedure Note:


The punchdown procedures employed are determined or limited by equipment, container, personal availability, and stylistic goal. The punchdown interval may change with stylistic goal, container, and/or rate of fermentation or extraction. The following procedures may change depending on unanticipated circumstances.

A. In Stainless Steel Tank:

1. Remove cover from tank and set aside. 2. Fill the plastic pitcher with 250ml of must from the sample valve 3. Put the thermometer in the pitcher and measure the temperature of the must. Record

on fermentation card. 4. Fill the graduated cylinder with must (start with two-thirds full). 5. Gently depress and spin the hydrometer in the juice (do NOT drop it in). Read the

Brix and record on fermentation card. 6. Pour some juice into a 250ml beaker and do a sensory analysis (appearance, aroma,

taste, bitterness, astringency). Record on fermentation sheet. 7. Return remaining must/wine to the tank. 8. Clean punchdown tool with acidified SO2 and rinse. Don’t let it touch the ground. 9. Punch down, wetting the cap with the underlying juice. Scrape all around the edge of

the tank, ensuring that there is no dry cap present in top. Be careful not to touch the punchdown tool with the sensors located on the inside

bottom of the tank-they can snap off and cause the tank to leak. 10. Rinse and return the punchdown tool to the bucket of acidified SO2. 11. Replace the cover on the tank. 12. Clean all materials and return them to their place.

Punchdown in a stainless steel tank


B. In Plastic Covered Bins (MacroBins) 1. Clean and sanitize punchdown device with water and acidified SO2. Clean and

sanitize pitcher, thermometer, strainer, graduated cylinder, and hydrometer with water and acidified SO2.

2. Remove lid. 3. Punch down vigorously, wetting the cap with the underlying juice. Scrape all around

the edge of the tank, ensuring that there is no dry cap present in the top. Be careful not to squish whole berries on the bottom of the bin.

4. Remove punchdown tool, rinse, and store. Be careful not to spill must on floor or container. If procedure must be repeated with bins containing alternate yeasts, varietals, or bacteria, be sure to properly rinse and sanitize between operations.

5. After must has been homogenized by punchdown procedure, prepare to take oBrix and temperature readings.

6. Fill pitcher with ≈250ml of juice. Strain if necessary in order to remove solids. 7. Put thermometer in pitcher and measure the temperature of the must. Record

measurement. 8. Fill graduated cylinder with juice (≈ 2/3 full). 9. Gently depress and spin the hydrometer in the juice. Do not drop it in. Wait for

hydrometer to equilibrate and measure the oBrix. Record measurement. 10. Taste and smell juice. Record sensory analyses. Pay attention to off-flavors or off-

aromas. The punchdown interval may change if the must has become adequately extracted.

11. Note the condition of the cap. The punchdown interval may change when the cap (cake) begins to fall, become short, or when the skins become soft.

12. Return remaining juice to container. 13. Rinse and store equipment. 14. Wipe down sides of container with sponge, paper towel, or scrub pad in order to

remove excess juice or encrusted seeds or skins. Use alcohol if necessary. 15. Replace lid loosely on top of container. Do not replace lid tightly. Remember there

is evolving CO2.

C. In Stainless Steel Milk Kegs 1. The stainless steel milk kegs require the potato-masher as the punchdown tool

because the mouths of the milk kegs have a small diameter. 2. Clean and sanitize punchdown device with water and acidified SO2 or alcohol.

Clean and sanitize pitcher, thermometer, strainer, graduated cylinder, and hydrometer with water and acidified SO2 or alcohol.

3. Remove lid.

Above is an example of using a potato-masher to punchdown the cap in a plastic 55 gallon trashcan.


4. Punch down vigorously, wetting the cap with the underlying juice. Scrape all around the edge of the tank, ensuring that there is no dry cap present in the top. Be careful not to squish whole berries on the bottom of the keg.

5. Remove punchdown tool, rinse, and store. Be careful not to spill must on shoulders, sides, or water bath. If procedure must be repeated with jugs containing alternate yeasts, varietals, or bacteria, be sure to properly rinse and sanitize between operations.

6. After must has been homogenized by punchdown procedure, prepare to take oBrix and temperature readings.

7. Fill pitcher with ≈250ml of juice. Strain if necessary in order to remove solids. 8. Put thermometer in pitcher and measure the temperature of the must. Record

measurement. 9. Compare the temperature of the must with the temperature of the water bath. These

two temperatures should be the same or within a couple of degrees. 10. Fill graduated cylinder with juice (≈ 2/3 full). 11. Gently depress and spin the hydrometer in the juice. Do not drop it in. Wait for

hydrometer to equilibrate and measure the oBrix. Record measurement. 12. Taste and smell juice. Record sensory analyses. Pay attention to off-flavors or off-

aromas. The punchdown interval may change if the must has become adequately extracted.

13. Note the condition of the cap. The punchdown interval may change when the cap (cake) begins to fall, become short, or when the skins become soft.

14. Return remaining juice to container. 15. Rinse and store equipment. 16. Wipe down sides of container with sponge, paper towel, or scrub pad in order to

remove excess juice or encrusted seeds or skins. Use alcohol if necessary. 17. Replace lid loosely on top of container. Do not replace lid tightly. Remember there

is evolving CO2.




Pumpovers Developed by Greg Siewert December 2003 I Introduction Pumpovers are the most common type of cap management used in the wine industry. It is a simple and very effective method of wetting the cap and facilitating the extraction of color and tannins. It is often more practical to implement than punch-downs when working with larger volumes and it has the additional advantage over punch-downs that it de-stratifies the tank, mixing the yeast and sediment from the bottom of the tank into the cap. On the negative side, some people feel that pumpovers are harsh on the wine and run the risk of extracting undesirable bitterness from crushed seeds and stems. These risks can be minimized by selecting the proper pump and using good technique. II Setup 1. Connect a 2” hose to the inlet of the air pump and another one to the outlet. 2. Connect the air hose to the pump and sanitize the setup as appropriate for the condition of the

equipment. 3. Remove excess water from the lines and connect the inlet hose from the air pump to the racking

valve on the tank of must to be pumped over. 4. Put the outlet hose through the man-way at the top of the tank so that about 2 ½ feet of hose are

inside the tank. 5. Tie this hose down securely with rope or bungee cord. Do not rely on the weight of the door

because the hose might kick out when pump starts. If performing the operation with 2 people, one person can stay on top to hold the hose.

III Procedure Executing the pumpover: 48. Open the racking valve on the tank as well as the valve on the pump if there is one. 49. Open the air valve to the pump and begin pumping the must. Make note of the time or start a

timer if one is available. 50. Holding the end of the oulet hose securely, methodically hose down the cap of the wine, making

certain not to neglect areas at the back of the tank. If the pressure is insufficient, put your thumb over the hose to increase pressure.

51. Continue the operation for the full time allotted by the pumpover schedule. (See below). IIII Breaking down the setup

1. Make sure the hose is secure and shut the door on top of it. 2. Shut the air valve to the pump.


3. Shut the racking valve on the tank. 4. Unfasten the hose from the man-way, shake out as much must as possible into the tank, then

bring the hose down from the top of the tank. 5. Put any remaining must from the hoses into buckets and pour into the top of the tank. 6. Rinse pump setup with water. Also rinse off the racking valve on the tank. Return fittings

and shut the man-way on top of the tank. IV Determining the pumpover schedule

1. Determine the volume of the tank. 2. Determine the flow rate of the pump. (The air pump has a flow rate of approximately

gallons/minute) 3. Choose between two daily pumpovers or three. 4. Determine the length of pumpover required so that the full volume of the tank will be

pumped over once per day. This may be increased to 1 ½ times the volume of the tank at the end of log phase down to about 10 brix in order to increase extraction.

5. Example: The pump moves thirty gallons per minute. The tank contains 1000 gallons of must. It is early on in the fermentation so you want to pump 1 ½ times the volume of the tank. You’ve chosen a schedule of 3 pumpovers per day.

a. 1000 gallons X 1.5 volumes = 1500 gallons b. 1500 gallons / 30 gallons per minute = 50 minutes c. 50 minutes / 3 pumpovers per day = 17 minutes per pumpover


Napa Valley College - Viticulture & Winery Technology Standard Operation Procedures

Rack and Splash Developed by Diane Cannon, Darrel Grosul, & Russell Van Dewark December 2003 I. Introduction The purpose of cap management is to insure aeration and increase grape skin contact in the must. The benefits of the punch-down or pour over methods in cap management help to: provide essential oxygen (O2) for productive and extended yeast activity in order to complete

the fermentation process, control/release build-up of hydrogen sulfide (H2S), deter development of volatile acidity by releasing CO2 in the must and increase the polymerization of phenols which binds and softens the phenols and, ultimately, aids

in stabilizing the color in the juice. Rack and Splash is an optional red wine aeration technique that can be employed as an adjunct procedure to the pour- over method. If cap management calls for three scheduled pour-overs to occur throughout the day e.g., 8 a.m., 4 p.m., and 10 p.m., the Rack and Splash (R&S) technique can be substituted for the 4 p.m. pour-over. R&S can be initiated when the cap begins to noticeably emerge from the must. R&S can continue until the cap begins to shows signs of decline i.e., less formation in the top of the must. The decline in cap activity generally indicates the near completion of fermentation. The procedure requires the minimum of two attendants. II Equipment

30 gallon food-grade fermentation tank (fgt) with a 2" hole drilled on the side of the fgt approximately 24" - 30" from the foot of the tank.

1 2" - 2" Stainless Steel (SS) pipe reducer, 2" 90 SS elbow, 2" SS tee, 2" SS 8 A extension pipe, butterfly clamps, air pump and hoses to transport juice in and out of the fermentation tank, sieve or large screen basket SS punch down tool or SS plate to produce the splash, wooden dowel and camps.

III Procedure 1. Three cycle wash all equipment (except air pump) prior to use. Use alcohol spray in the

interior of the butterfly valve.


2. See attached diagram for the set-up i.e., the connection of the 30 gallon fgt to the racking valve located on the stainless steel primary fermentation tank

3. Put the sieve or screen basket into the 30 gallon fgt; use four wire hangars (one on each

corner of the sieve) to suspend the sieve under the 90SS elbow and below the round surface of the punch down tool to insure maximum flow and screening of the juice to remove berry skins, seeds, etc. .

4. Place the round surface of the SS punch down tool at a 90 angle to collide with the flow of

juice as it emerges from the 90 SS elbow. Span the top of the fgt with a wooden dowel and secure the handle of the punch down tool to the dowel with a clamp. This eliminates the need to manually hold the tool through the 15 minute aeration procedure. See attached diagram.

5. Refer to Tank Cleaning procedures (IV Equipment Setup) to set up the delivery and return hoses and

air pump. Note: substitute the fgt for the 5 gallon bucket and eliminate the use the spray ball. The juice will be directly returned to the tank via the return hose. Prime the pump using procedures under Tank Cleaning - Priming the Pump.

6. When ready to splash the juice, open the butterfly valve to begin the flow of juice to provide

sufficient juice in the fgt for suction. The pump should be set at a low flow rate and turned on. The racking valve will be initially used to control the flow rather than the pump. When a strong flow of juice begins, increase the speed of the pump.

7. In order to maintain a steady flow of juice, it may be necessary to periodically open and close the

butterfly valve several times to release the skins and seeds that are impeding the flow of the juice. 8. Continue the aeration process for 15 minutes and monitor the flow of juice. 9. When skins and seeds accumulate in the sieve or screen basket, remove and clean for flow

capacity. 10. As the juice returns to the primary fermentation tank, it should be aimed to equally and

thoroughly cover the entire cap.



Barrel Heat Exchanger Developed and Designed by Todd Lees December 2002

I Introduction

1. Read and understand all procedures and instructions necessary for safe and productive

operation.

2. The Barrel Heat exchanger uses water temperature flowing through a stainless steel tube loop inserted into a vessel of wine or juice to raise or lower the temperature of the product. This tubing’s loop has its source and discharge well away from the wine or juice so no dilution can occur.

II Preparation Dress properly for winery work and keep safety in mind

Sanitize Barrel Heat Exchanger, See Sanitation Procedure Ensure clean environment around bunghole and work area

Understand operation to be carried out

III Equipment for Cooling

Barrel Heat Exchanger Winery water hose w/quick coupler Dry Ice Bucket Small submergible water pump Long thermometer

IV Equipment for Warming

Barrel Heat Exchanger Winery water hose w/quick coupler Long thermometer

V Procedure for Heating

1. Insert Heat exchanger in bunghole using a back and forth motion-allowing spiral tubing into

the barrel until sufficiently submerged in product. 2. Attach winery water hose quick disconnect to Heat Exchanger water fitting 3. Ensure water valve on Heat Exchanger is closed 4. Slightly open hot water source 5. Slowly open valve on Heat exchanger until adequate water flows out discharge side


6. Use Caution as element heats up from hot water flowing through unit 7. Monitor temperature of wine or juice with thermometer 8. Rotate Heat Exchanger on occasion or rock barrel to have even heat distribution to all liquid

in vessel 9. When the temperature is reached in wine or juice switch the winery water mixer to cold 10. Allow cold water to flow just long enough to make handling Heat Exchanger safe 11. Disconnect water hose at quick disconnect on Heat Exchanger 12. Remove Heat Exchanger using a simple back and forth motion verse rotating unit 13. Rinse and clean Heat exchanger (see cleaning procedure) 14. Properly replaces equipment used to their assigned storage area

VI Procedure for Cooling

1. Insert Heat exchanger in bunghole using a back and forth motion-allowing spiral tubing into the barrel until sufficiently submerged in product.

2. Connect submersible pump to poly hose of Heat Exchanger 3. Place pump in bucket 4. Place bucket on a surface at similar height as bunghole to reduce pumping force needed 5. Place discharge valve of Heat exchanger over bucket 6. Using winery water hose fill bucket to about ¾ full of cold water 7. Replace winery water hose, no more water will be needed 8. Start pump by plugging it into wall socket (110v) 9. Water flow should circulate from the pump that is in the bucket of water through the tubing

and out the valve side back into the bucket 10. Using proper handling procedures for dry ice. Carefully add a cup of dry ice to the

circulating water in the bucket 11. Monitor the wine or juice temperature as needed 12. Add small amounts of dry ice as needed to keep circulating water cold 13. Pay attention to the flow of water. To much dry ice can freeze up or clog pump 14. Rotate Heat Exchanger on occasion or rock barrel to have even cooling distribution to all

liquid in vessel 15. When the desired wine or juice temperature is reached unplug the pump 16. Carefully remove the poly hose and pump out of the bucket of water 17. Discard water from bucket 18. When hose and pump are warm enough separate and put away pump 19. Remove Heat Exchanger using a simple back and forth motion verse rotating unit 20. Rinse and clean Heat exchanger (see cleaning procedure) 21. Properly replaces equipment used to their assigned storage area



Extended Maceration Developed by Ralph Ewing, Ron Louis and Claudia Mahan December 2002 I Introduction Extending the time that red wine must remains on the skins, up to five weeks after completion of primary fermentation, may enhance the extraction of tannins and cause greater color stability for long aging. Some color may be lost in the process, but it should reduce total astringency and improve flavor by reducing bitter phenols. II Equipment 1. Airtight container, i.e., tank, keg, carboy, etc. 2. Punchdown tool 3. Shovel/scoop III Chemicals 1. Nitrogen, CO2 or Argon gas 2. Sanitation solution IV Preparation 1. Clean container, punchdown tool and shovel/scoop with a 3-cycle wash (See Sanitation Procedures). V Procedure

1 If using only a portion of the batch for extended maceration, be sure that the ratio of skins and seeds to juice is proportionate to that of the main tank from which the new batch is being taken. This may require draining of the main tank of its free run juice prior to pressing and scooping the right amount of pomace from the main tank into the extended maceration container. If the entire contents of the main tank are to be used in extended maceration, ignore this step.

2 Using the punchdown tool, insure that the cap is completely submerged. 3 Taste the wine, and record its progression and your flavor impressions. 4 Inject enough CO2 or Argon gas to fill the space in the tank above the must after

punchdown. 5 Close the container using an airlock or device that will not allow oxygen into the container. 6 Repeat the above steps at least every other day.

Notes___________________________________________________________________ 1. Malolactic fermentation may proceed concurrently with extended maceration. 2. Not all wines will benefit from extended maceration. Varieties and growing conditions can affect the results, and in some cases more bitterness may be extracted. For example, if there are a significant amount of unripe seeds and/or underdeveloped phenols in the grapes, these flaws might be more enhanced. If the must has any of these traits, a smaller proportion can be left on the skins for an extended period for experimental reasons, thus ensuring the quality of the bulk of the wine.


3. Another precaution is to understand the taste patterns that the must exhibits while macerating. Between 14-21 days, the must may taste more bitter and astringent and the color might decrease slightly due to chemical changes in the phenols and anthocyanins. After this period, these flavors should start to decrease and the color will become more enhanced. A commitment should be made to continue the extended maceration through this awkward stage to ensure the benefits (softer tannins, reduced bitter compounds and increased color stability) are achieved. 3. Do not press the must if it is tasting bitter. This process will stop any additional maceration and

the result will be a bitter wine.


Napa Valley College, Viticulture and Winery Technology Standard Operation Procedure

Pressing off from a Picking Bin Developed by Dennis Przybycien and Michael Parmenter November 2003 I Introduction Fermented red wine must is separated into Free Run wine and pomace (skin and seeds) to be pressed for further extraction of wine or Press Fraction. It is desirable to barrel and age the free run separately from the press fraction. The press fraction can be used for topping or blending later. When fermentation is performed in large picking bins, free run can be directly transferred to the aging container or barrel without going through the wine press. This procedure describes a devise that was successfully used for free run transfer. III Equipment Stainless Steel juice collector Air pump Barrel wand 1” Lines for pump Metal mesh strainers (2) Barrel Carboys - 5 gal Funnel Forklift Wooden blocks Picking bin, 1/2 ton containing fermented wine must IV Cleaning Materials Cleansing solutions / caustic soda and citric acid plus SO2 Pressure hose with hot water source (180F) V Preparation 1. Clean and sanitize the juice collector, pump and lines and other equipment VI Procedures Pumping Free Run from Picking Bin: 2. Tilt picking bin, using a fork lift to raise one end and support with the wooden blocks to hold

the raised end approximately 62 inches off the ground. 3. Attach barrel wand to the line on the inlet side of the pump. 4. Place funnel in barrel bunghole and place mesh strainer in funnel. 5. Ready outlet tube from the pump at the strainer. 6. Submerge the SS juice collector into the must at the lowest end where the juice should be

collected after tilting the bin. 7. Place barrel wand into the SS juice collector.


8. Start pumping at a slow rate to prime pump. 9. Continue pumping slowly; avoid air bubbles in the line. 10. At the outlet end the strainer will collect any skins and pulp pumped out with the free run.

Exchange clean strainer as needed. 11. Pump until free run flow has stopped. Pressing Must: 1. Prepare press according to NVC Procedure “Pressing Operations - Ratchet Basket Press for Red

Wines” or “Pressing Operations - Moving Head Press”. 2. Transfer must to press with 5 gallon buckets. 3. Allow additional free run juice to flow from the press. 4. Combine the additional free run from the press with the previously barreled free run, using a

strainer to remove any skins or seeds. Top Barrel. 5. Use carboys for the balance of free run. 6. Cap barrel with pressure release barrel bung; cap carboys with water filled air locks Must Pressing / Press Fraction: 1. Press must according to Press Procedures. 2. Collect and strain wine. 3. Transfer to carboys and label as “Press Fraction”. 4. Cap carboys with water filled air locks.



Malolactic Fermentation Developed by James Lee and Sandra Peterson December 2001 I INTRODUCTION Malolactic Fermentation is the conversion of malic acid to lactic acid by malolactic bacteria, resulting in a decrease in titratable acidity, an increase in pH, and an increase in microbial stabililty. It also can modify the flavor of the wine. II EQUIPMENT Inoculation with Malolactic Bacteria: Scale 50-ml beaker or plastic weighing tray Plastic spoon Monitoring Malolactic Fermentation: 50-ml beaker 10-ml graduated pipette III CHEMICALS Inoculation with Malolactic Bacteria: Malolactic bacteria Monitoring Malolactic Fermentation: (See Paper Chromatography Standard Operating Procedure)


IV PROCEDURE Inoculation with Malolactic Bacteria: 1. Weigh out the appropriate amount of malolactic bacteria (at a rate of 0.038g/gal) according to the following table: Container Volume Weight MLB

59 gallons 2.23 g 15 gallons 0.57g 5 gallons 0.19g 3 gallons 0.11g 1 gallon 0.04g 2. Pour malolactic bacteria into container, being careful not to allow any of the bacteria to adhere to the sides of the container. 3. Reseal the container. 4. Stir the container once a week. Monitoring Malolactic Fermentation: (To be done once a week until malolactic fermentation is complete) 1. Using a 10-ml graduated pipette, withdraw a 5-ml sample of the wine from as close to the middle of the container as possible and place into a 50-ml beaker. 2. Follow Standard Operating Procedure for Paper Chromatography.



Pressing Operations - Bladder Basket Press for White Grapes Developed by Darrell Scarlott, Art Fichtenberg, Maria Baldwin & Gerry Ritchie December 2001 & 2002

I INTRODUCTION

Presses are used in white winemaking to separate the juice from the skins and seeds. The stronger the pressure that is exerted upon the fruit, the greater the extraction of those components that concentrate near or in the skins, as well as those near the seeds. Therefore, each variety will be pressed to different extents depending on the desired wine style. With white varieties, caution should be utilized to avoid crushing the skins and seeds, as they can release undesirable bitter and astringent characteristics into the wine. There are many types of presses, but these procedures describe the use of a bladder basket press.

II EQUIPMENT

Bladder Press 400L Stainless steel, variable volume Tank and lid 30-50gal trash cans with lids (for smaller tonnages of grapes or press fractions) 3-5gal carboys (for press fractions) 5 gal Buckets- 5 Strainers-3 FYB’s-16 Large Funnel Shovel Water Hose-2 Dry Ice Cleaning Materials Cleansers & Sanitizers (Quat, soda ash, citric acid and water) Brushes Sanitizers Hose Nozzle

III PREPARATION

1.Thoroughly clean all equipment. 2.Three cycle wash all plastic & stainless steel equipment, which may come in contact with the

juice or wine. Refer to sanitation procedures section for three cycle wash instructions


3. Use cold and hot water to clean the wooden parts of the press. Once it is clean, spray Quat on the wooden slats of the basket press. Wait 15mins and then rinse off with water.

4. Assemble the press. Place the two halves of the basket on the metal drain pan and connect them together with the pins. Caution should be utilized in the placing of the pins into the basket bracket holders. They should fit into place without undue pressure. The pins for opposite sides of the basket need to put in simultaneously by two people. If there is resistance, the two halves of the basket are either not aligned properly to the brackets and should be readjusted, or the pins have slight imperfections and should be relocated to another bracket.

5. Close the lid and make sure it also fits securely in the basket. Once the lid closes with no problems then secure with the butterfly nut.

Note. Always make sure the lid closes and pins are fitting properly before filling the press with

grapes / must.

6. Initially, it is advisable to partially fill the bottom of the bladder slightly prior to the placement of fruit into the basket, so as to more evenly distribute the pressure once the bladder is inflated. Otherwise, there is a tendency to over inflate the top of the bladder, especially for the second and third press. Once you feel comfortable using the press, you might not always need to inflate the bladder partially.

IV PROCEDURE

For white wine making the grapes may be whole clusters or de-stemmed and crushed fruit. The fruit is placed into the press to separate the juice from the stems, skins and seeds. 1. Place all cleaned and sanitized equipment near press. 2. Place one bucket under drain spout of press to receive juice. Place two or three spare buckets

and strainers next to spout to replace full bucket. 3. A cleaned and sanitized settling tank should be prepared for juice. The 400L stainless steel,

variable volume tank is often used. It must be placed on a pallet after sanitizing and before filling so that it can be moved easily into the barrel room. Ensure that the bottom valve of the tank is closed but accessible. A large funnel may be used depending upon tank or container used.

4. For whole cluster pressing, dump full FYB’s into the press. Press down clusters by hand and distribute evenly around center pole.

5. For pressing crushed fruit, bucket fruit out of the bin into press, pouring evenly around center pole.

CAUTION. With crushed fruit, juice will immediately flow out of press.

6. Make sure you have enough buckets or clean FYB’s. 7. When press is full of either whole clusters or crushed fruit, it is now time to press to separate

the juice from the skins and seeds or pomace. 8. Hook up water hose to spigot at the bottom of the press. With the handle in the off position,

turn on water at source. Slowly turn on water at press to fill the bladder, using caution not to go too fast. As juice flows out, slow down water input because the buckets can fill rapidly.


Never go past 2.5 bar on the pressure gauge. Too much pressure can cause the bladder to rupture and can result in ruining the juice in the press.

9. Juice flowing from the press should always be run through a strainer. The strainers must be

cleaned often since they get sticky. It is a good idea to have a bucket nearby with water for rinsing the strainers, or make sure you hose them down, if necessary. When a bucket is nearly full, replace bucket quickly so as not to lose any juice. Timing is key. Block flow from press with hand if necessary. Teamwork is necessary so always have plenty of buckets you can use so you don’t have to block with your hand and possibly lose any juice.

10. Strain the juice while you pour it into the settling tank / container. When the first juice has been added to the settling tank, add dry ice to the settling tank to minimize oxidation and keep the juice cool. Add more dry ice as needed during the entire process.

11. Continue pressing until juice stops flowing. Remove pressure from fruit by draining water from bladder. Carefully remove sides of the basket. Place empty , clean FYBs around the prees pan. Remove the press cake from the press pan and put into clean FYB’s. This action breaks up the cake without causing undue damage to the marc.

12. Reassemble the press and put the marc in the FYBs back into the press. 13. Repeat the steps 4-10. Press until the desired amount of juice has been extracted from the

fruit. You can do this by tasting the juice, measuring the pH or the quantity of juice / ton (called the “yield”) and by feeling the dryness of the skins. It is recommended to keep the different press fractions separate by setting in different containers.

14. Once the pressing is complete, then break down the equipment. Remove pressure by draining water from the bladder. Remove the baskets, empty out the pomace and discard in the proper receptacle (usually a ½ ton picking bin).

15. Label all vessels using masking tape. Label should include Lot number, fraction and date. 16. Put in barrel room to settle overnight at 55 °F. 17. Take a sample from each container and measure the Brix, pH and TA. Add tartaric acid or

water if necessary (see Acid Additions procedure). 18. Add SO2 if it is part of the winemaking protocol for that lot (see SO2 Additions procedure) 19. Clean and put away all equipment.

Notes 1. Our bladder press can take approximately 13 FYBs per run. 2. Always be prepared for fast flowing juice or wine. Press flow can change from slow to fast

rapidly without warning. 3. It is advisable to partially fill bladder press prior to loading to ensure even pressure on fruit

during pressing. 4. Free run, first press and second press should be kept separate for fermentation and/ or aging.

Different press fractions may be blended together in the future. 5. You may place an FYB under buckets at drain spout to help catch overflow or spilled juice or

wine. Mark all containers clearly to avoid any confusion.



Pressing Operations-Ratchet Basket Press for Red Wines Developed By Maureen Donegan and Gerry Ritchie November 2002 I Introduction Draining is the process in which the fermented must (juice, skins, seeds and pulp), now wine, is removed from it’s fermentation tank or ½ ton bin, by draining the wine that runs freely from the skins and seeds (called marc or pomace). This wine is refered to as Free Run. Pressing is the process of removing the pomace to a press and exerting pressure on the skins and seeds to extract the wine that is trapped in the pomace. Different qualities of wine are produced from various press levels and these are called called Press Fractions. The harder the pomace is pressed the greater the level of strong tannins and undesirable phenols become in each press fraction. The amount of pressure you use will determine the dryness of your press cake that comes out of the press. It is always best to keep free run and any subsequent level of press fraction separate until their quality and appropriateness for the wine style have been established. II Equipment 400 L stainless steel, Variable volume tank and lid (for holding and settling of free run wine) Ratchet Basket press of appropriate size Barrel and/or Kegs and bungs Carboys (3 and 5 gallon) (2-3) Gallon jugs and 750ml bottles (2-4) 5gal buckets (3-5) Strainers (3) FYB’S (lug boxes) (3+) Funnel (1) Plastic shovel (1) Clear, plastic hose (1) Forklift III Cleaning Materials Cleansers / Sanitizers (Soda ash, Citric and Quat) Brushes and scrubbers 2gal hand held Quat sprayer Pressure hose with hot water source (180 °F ) Ozone IV Preparation

1 Thoroughly clean all Drain and Press equipment (except forklift). 2 Three Cycle Wash all non-wood equipment (see Sanitation procedures). 3 Spray the wooden basket slats with Quat and leave for 15 min. Rinse with water thoroughly. 4 Assemble the press near the tank that is being emptied or outside if the quantity is small (e.g.

the contents of a 15gal keg). Place the two halves of the wooden basket on the metal press pan and make sure it is centered. Connect the two halves with the pins and check that they are


securely in place. Do not put wood blocks or metal top on press until basket is filled with pomace and ready to press.

5 Place cleaned and sanitized tank on a wood pallet near fermentation / supply tank for free run juice.

6 Make sure all openings on the receival tank are closed or have closed valves attached. 7 Place buckets with strainers and FYB’S at lowest fermentation tank spout and at press drain

spout. 8 Place barrel or keg on a metal pallet outside and rinse with Ozone (see Ozone Operation

Procedures) for two minutes. Let drain and dry with bunghole at approximately 6 O’ Clock for at least ½ hour.

9 Place two each 3 and 5 gallon carboys as well as jugs, bottles and funnel beside the press. IV. Procedure

Draining of the Free Run

1 Place a bucket and strainer under lowest outlet on supply tank. 2 Open valve slowly and let free run flow through the strainer into the bucket until ¾ full. Close

valve and replace with clean strainer and empty bucket, open valve again. 3 Empty first free run bucket into receival tank 4 ,Dump pomace into pomace bin (usually a ½ picking bin) 5 Immerse strainer in a 5gal bucket of water and clean thoroughly. 6 Repeat steps 2-5 until all the free run is out of the supply tank 7 The free run will be settled overnight and then racked into barrels or another tank. Removing the pomace from the supply tank 1 Place or hold an FYB under the fermentation tank door. 2 Slowly open the tank door and catch any pomace that falls out in the FYB. Place FYB on

ground and start shoveling pomace out of tank into FYB until full. Have backup FYB waiting to move into first FYB’S place. Continue until most of the pomace is out of the tank.

3 There will be a lot of seeds in the bottom of the tank. Do not transfer them to the press so as to minimize extracting bitter and astringent phenols

Pressing the pomace 1 Make sure a bucket with a strainer is under press drain spout. The pomace is full of juice and

the press will start runnng juice as soon as you put pomace in the basket. 2 Start filling the press evenly with the pomace from the fermentation tank until the press is

“full”. How much you fill the basket for each press is a decision you will have to make based on how dry you want to press your cake, and subsequently how many press fractions you want.

3 Finish assembling the press by placing two wooden half circles on top of pomace and then building up the wood blocks going first one direction then the other forming a pillar for stability. Screw rachet machanism down tightly on top of pillar. Make sure metal directional pins are placed correctly on top of ratchet for pressing direction. The opposite direction is for removal of the rachet. Put metal rod handle into rachet and make sure to secure it with the metal bolt. Push the handle back and forth to press the rachet down onto the pomace.

4 While pressing, it is important to watch the juice flow and determine exactly when you want to change your bucket and strainer. A new set can be moved right into position as you are moving the “full” bucket out of the way. This juice is called your first press and should be funneled in an appropriate sized bottle (filled to the top) and labeled with masking tape. The varietal, press number, date and wine group it belongs to should all be noted.

5 To remove the press cake after pressing, adjust the metal directional to the opposite direction and push handle back and forth until the ratchet is loose enough to remove all wood blocks,


pins and one half of the basket. At this point you can pick the press up or tip it so that the cake spills out into an FYB, and then rotate FYB’S dumping the cake into a container to take out to the compost pile later.

6 Continue filling the basket, pressing, and bottling until all the pomace has been pressed. 7. Label all vessels using masking tape. Label should include Lot number, fraction and date. 8. Put in barrel room to settle overnight. 9. Take a sample from each container and measure the alcohol, Residual sugar, pH and TA.

10. Clean and put away all equipment. 12 Remove the last press cake from the basket press and seeds from tank and place in the pomace

container (usually a ½ ton picking bin kept outside. Racking the wine after settling overnight 1 Carefully move the tank of free run on the pallet out to crush pad and place close to the barrel

to be filled. 2 Adjust barrel so that the bung hole is vertically up and the barrel is centered and in line with the

other barrel on the rack. 3 Tape one end of a 1” siphon tube to a three or four foot stick to help keep the plastic tubing

vertical in the settling tank. 4 Use the forklift to raise the pallet about five feet above the ground. The end of the tubing

attached to the stick should be carefully lowered into the settled wine by a person standing on a ladder and held in place during the racking process.

5 Another person, holding the other end of the tube by the barrel must start the flow of wine by sucking on that end. Once the wine is flowing in the tube, the open end is put into the barrel to fill it. Watch the barrel carefully if you have more than one barrel of wine. As long as the end of the hose in the tank stays submerged, the wine will flow.

6 To stop the flow at any time, simply remove the tank end of the hose. If there is not enough of the free run to fill your barrel, use some of your first press wine. Always fill and/or top off with the best quality wine that you can.

7 Seal barrel/s with a bung and label with all of the important information; varietal, date, wine group, etc. Clean any spilled wine off of the barrel and move it into the winery for malolactic fermentation and/or ageing.

8 Clean and sterilize all equipment and put it back in it’s place. Clean the winery. 9. Record all operations and changes of alcohol volume and container on Record sheet



Topping Developed by Tane Yamamoto December 2001 I INTRODUCTION:

1 Definition: Refilling any container to replace wine that has been lost through use-up or evaporation.

2 Objective: Eliminate head space in wine container to prevent oxidation by acetobacter. 3 Frequency: At least monthly, in general. Determine specific need based on speed with

which head space is created, and establish a regular schedule. II EQUIPMENT

1 Topping wine – to be of same provenance as the wine to be topped. 2 Thief or siphon tube, beaker, funnel. 3 Clean rag.

III PREPARATION

1 Sanitize equipment to be used with quat and water rinsing. 2 Ensure clean environment, especially around bung hole. 3 Establish ranking of wines to be used for topping in descending order. Start with the best, or

of quality closes to the wine to be topped. 4 Principal interference is contamination from foreign material, and from cross-contamination

between different wines or yeasts through equipment. IV PROCEDURE

1 Draw appropriate amount of topping wine using a thief or siphon into a beaker. 2 Fill the container to be topped to about an inch below the bug hole. 3 Replace bug. 4 Wipe clean the area around bung hole of any spillage. 5 Call back 15 minutes later to check if any entrapped air has subsequently increased the head

space. Repeat topping if required. 6 Record date, topping volume, and any other significant observations. 7 Repeat the procedure in turn for the topping wine by with the next ranking wine. 8 Sanitize equipment before moving on to another wine of different provenance.



Stirring Developed by Tane Yamamoto December 2001 I INTRODUCTION:

1 Definition: Thorough mixing of lees with wine 2 Objective:

a Extraction of compounds that enhance body. b Aid MLF c Avoid formation of hydrogen sulfide.

3 Frequency: Weekly. Also, take advantage of topping occasion to do it at the same time. II PREPARATION

1 Sanitize equipment to be used with quat and water rinsing. 2 Ensure clean environment, especially around bunghole. 3 Principal interference is contamination from foreign material, and from cross-contamination

between different wines or yeasts through equipment. III MATERIALS

1 A stirring stick designed with a crescent shaped head in order to fit the curvature of the barrel side, or any suitable substitute.

2 Clean rag. IV PROCEDURE

1 Start with non MLF white wines. 2 Insert the stirring stick and stir well. The bottom of the barrel should be gently scraped so

that all the lees become suspended throughout all of the wine. 3 Replace bung and record date of stirring and any significant observation. 4 Sanitize stirring stick before moving on to a wine of different provenance. This is

particularly important for wines that are non MLF.



Barrel Racking with a Wand Developed by Darrell Grosul, Reese Wilson, and Gerry Ritchie May 2003

I Introduction

Racking wine off lees in a barrel can be accomplished by a wand and can serve the following purposes:

Rack from barrel to temporary vessel, clean barrel, and return to barrel.

Rack from to blending vessel, clean barrel, and return blended wine to barrel or other vessel.

The overall process is depicted on the last page of this procedure using gravity return for return to barrel (alternatively, pump may also be used).

II Equipment

1 General cleaning equipment (see Sanitation

Procedures and Three Cycle Wash) 2 Wand 3 1 1/2" Stainless Steel Tri-Clamp (SSTC) 4 Sight glass 5 8 x 1 1/2" SSTC 6 4 x 1 1/2" valve 7 1" line, 10' length (wand to pump)


8 2 x 1 1/2" to 2" reducer 9 2 x 2" SSTC (inlet & outlet of pump) 10 Air Pump 11 1" line, 10' length (pump to tank) 12 Receiving tank large enough to accept wine 13 Barrel washing equipment (see Procedure)

III Materials

1 General chemicals (see Sanitation Procedures)

2 Compressed air (for Air Pump) 3 Water (see Barrel Cleaning Procedures) 4 Nitrogen or other inert gas (if

appropriate)

IV Preparation 1 Sanitize all equipment to be used in the

procedure outlined below (as appropriate) 2 Place equipment in approximate locations to

implement procedure (as appropriate) 3 Remove bung(s) from barrel(s) and smell

wine to check for faults. Set a side any barrels that have faults

4 Connect all equipment as per procedure 5 Test for integrity

V Procedure Transfer Wine to Receiving Tank 1. Carefully read work order (if

appropriate) and clarify as necessary with supervisor

2. Connect site glass to wand 3. Connect 1 1/2" valve to sight glass 4. Connect 10' (or longer) line to valve 5. Connect other end of line to 1 1/2"

valve 6. Connect valve to 1 1/2" to 2" reducer 7. Connect reducer to inlet of Air Pump 8. Connect outlet valve of Air Pump to 1

1/2" to 2" reducer 9. Connect 1 1/2" valve to reducer 10. Connect valve to 20' (or longer) line 11. Connect other end of line to 1 1/2"

valve

12.

12. Connect valve to inlet of receiving tank (make sure tank is properly vented); blanket with Nitrogen if appropriate


13. Make sure that valves on both ends of discharge line connecting Air Pump outlet to Tank are open

14. Connect air to Air Pump 15. Double-check all connections, fittings, Air pump 16. Blanket the receiving vessel with nitrogen or other inert gas if appropriate 17. Open valves on both ends of suction line connecting Wand to Air Pump inlet 18. Simultaneously start the Pump and lower the Wand slowly into the Barrel until the wine in the

Site Glass becomes cloudy or hazy. Immediately raise the Wand about 1" and maintain this height until the barrel empties

19. Follow the lines to the receiving vessel, checking for leaks and to remove air bubbles from line 20. When barrel is empty, close the valve on the wand and repeat the process to rack wine off the

lees of other barrels as appropriate (making sure that the receiving vessel is large enough to accommodate the racked wine)

21. When all barrels are empty, continue pumping until wine is removed from suction line. 22. Close valve on inlet side of pump and on wand, 23. Close valve on pump outlet and disconnect valve and line from pump. 24. Attach nitrogen or other inert gas to end of line, pressurize line (10-15 psi) and open valve that

was on the outlet side of pump and walk line to the receiving tank. 25. Close tank valve and switch of inert gas. 26. Disconnect inert gas line and carefully reduce pressure by slowly releasing the clamp. Barrel Cleaning 1. Place a stainless steel bowl under the empty barrel and spin (rotate) the barrel until the bung

hole is facing vertically downwards 2. When all the lees have emptied into the bowl, place the bowl contents in a 5gal bucket or bigger

container depending on the size of the lot 3. Place the barrel washer in the barrel and rinse with hot water until the rinse water runs clear

(~1min) 4. Follow with cold / ozonated water if appropriate 5. Let barrel drain, bung down, while emptying others in lot Analyses 1. Take a sample of the wine and analyse for pH, TA and Free sulfur dioxide. 2. Make adjustments as needed (See Additions section of procedures manual) Transfer Racked Wine back to Barrel (Air Pump Method)

1. Connect 10-foot (or longer) 1" suction line to tank (with valve) and inlet side of Air Pump (with valve)

2. Connect 20-foor (or longer) 1" discharge line to outlet side of Air Pump (with valve) and connect filling wand (with valve) to other end of line

3. Make sure that tank is vented

4. Open valves at the tank and inlet and outlet sides of pump

5. Open valve on wand slightly to let air to escape from the lines as they fill with wine from gravity and close the wand valve when lines are full of wine

6. Insert wand into (first) barrel to be filled and open the wand valve


7. Switch on the Air Pump when wine flow under gravity slows

8. As barrel fills, use rubber hammer and tap the sides of the barrel to allow air bubbles to escape

9. As the wine level nears the top of the barrel use the wand valve to slow flow

10. When barrel is completely full, close the wand valve. Raise the wand slowly out of the barrel

11. Insert wand in next barrel to be filled and repeat Steps 8 - 10

12. Turn off Air Pump

13. Top barrels with wine from a jug up to bottom of bung while tapping sides of barrel with rubber hammer

14. Replace bungs firmly

15. Wash down barrels with cold water to remove any spilled wine

16. Label barrels

17. Put any excess wine into "breakdown" vessels as per Topping Procedure.

18. Return barrels to storage area (and stack if appropriate)

19. Clean and put away all equipment Transfer Racked Wine back to Barrel (Gravity Flow Method) 1. Connect 10-foot (or longer) 1" suction line

to tank (with valve) and wand (with valve) 2. Make sure tank is vented. 3. Raise tank with a forklift so the its base is

higher then the top of the barrels 4. Open valve on tank 5. Insert wand into (first barrel) 6. Open valve on wand 7. See Steps 8-11, above 8. See Steps 12-18, above.



Barrel Racking with a Bulldog Pup Developed by Carl Bowker and Didier Jacquet May 2003

I Introduction The purpose of racking is to separate the wine from the lees and other solids present in the barrel. The clear wine can be transferred to a holding tank, a clean barrel or back to the original barrel after the lees have been disposed of and the barrel properly washed. Using a bulldog pup allows for a gentle and clean rack as gas pressure is used to push the wine, as opposed to a pump. The flow rate is approximately 20gal per min so it will take about 3ins to empty a barrel. The flow rate will vary witht the height and length of the run. A small bottle of gas (224cu. ft.) will push 20 –25 barrels.


II Equipment

1 Bulldog pup (see diagram) 2 1 ½ Tri- clamps & gaskets 3 1 ½ in. valve(s) 4 1 in. line (10 to 20 ft.) 5 Barrel wand (if racking to barrel) 6 Holding tank (if racking to tank) 7 Pressure regulator for Nitrogen tank 8 Pressure hose with quick disconnect for Nitrogen tank 9 Flashlight

III Materials 1 Nitrogen gas cylinder 2 General chemicals (see sanitation procedure) 3 Water (see barrel cleaning procedure)

IV Preparation 1 Sanitize the bulldog pup, barrel wand, valve(s), hose/line(s), receiving tank(s), and fittings

with a 3-cycle wash following the sanitation procedure. Then: 2 Connect a 1 ½ in. valve to the outlet of the bulldog using a 1 ½ gasket and tri- clamp. 3 Connect a 1” x 10 ft line to the outlet of the 1 ½ in. valve using a 1 ½ in. gasket and tri-

clamp. Note: Make sure that the attachment of the tri clamp is underneath the valve. This will prevent the operator from scratching his/her hand while operating the valve.

4 Connect the pressure regulator to the Nitrogen cylinder. 5 Connect the inlet of the pressure hose to the pressure regulator through a quick-disconnect. 6 Connect the outlet of the pressure hose to the inlet gas valve of the bulldog pup.

Racking to a barrel

1 Inspect the receiving barrel with a flashlight for cleanliness and possible tartrate deposits. (Clean and sanitize as necessary.)

2 Connect the outlet end of the 1” x 10 ft. line to a barrel wand using a tri-clover clamp and 1 ½ in. gasket.

3 Insert the wand into the receiving barrel for filling.

Racking to a tank

1 Inspect the tank for cleanliness using a flashlight. (Clean and sanitize as necessary.) 2 Connect a 1 ½ in. valve to the drainpipe of the receiving tank using a tri-clover clamp and a

1 ½ in. gasket. 3 Check that the receiving tank is fully vented and that the racking valve and sample port (if

any) are closed.


4 Connect the outlet end of the 1” x 10ft line to the bottom valve of the receiving tank using a 1 ½ in. gasket and tri-clamp.

5 Open the valve on the receiving tank.

Note: If proceeding to a non-aerative racking, blanket the receiving tank/barrel with Nitrogen to avoid wine contact with oxygen.

V Procedure

1. Read and understand the work order. In doubt, always check with a supervisor/cellarmaster/instructor.

2. Identify the barrel(s) to be racked. 3. Lay down barrel(s) in the cellar within reach of the receiving vessel. 4. Remove each bung and smell wine to check each barrel for faults. Set aside any faulty barrels.

Replace bungs until ready to start racking. 5. Loosen the bulldog nut/shaft (tightening) assembly and raise the bulldog shaft. 6. Remove the bung from the barrel to be racket and insert the bulldog pup vertically into the wine.

Make sure that the gas valve on the bulldog is closed both sides 7. Rock the bulldog back and forth to push bung on shaft into bunghole. Then tighten-up the bung

on bulldog so that it is securely positioned on the bunghole so that it is sufficiently airtight. 8. Open the 1 ½ valve on the bulldog. 9. Check that the air release valve on bulldog is closed. 10. Open the valve on the Nitrogen cylinder to pressurize line and adjust the pressure regulator to

12 – 15 PSI. Do not exceed a maximum pressure of 15 PSI or you may “suck” heads off barrel and lose wine!

11. Open the inlet air/gas valve on the bulldog pup to begin flow of Nitrogen and subsequently the wine from barrel.

12. Let the wine flow through the bulldog and the line to intended vessel. 13. Monitor the clarity of the wine through the sight glass. Use a flashlight to shine light through the

wine if working inside or in dark area 14. Slowly lower the shaft of the bulldog until cloudiness appears in the sight glass. 15. With any sign of cloudiness immediately raise the bulldog shaft until the wine becomes clear

again. 16. Secure the bulldog nut/shaft tightening assembly at this lowest level where clear wine is

flowing through bulldog. 17. When all the wine has been racked, close the 1 ½ in. valve on the bulldog. 18. Then quickly close the gas intake valve on the bulldog. 19. Release the pressure in the system by opening the gas release valve on the bulldog 20. Proceed to the next barrel to be racked. Repeat the process (procedures 5 – 19). 21. Place a stainless steel bowl under the empty barrel and spin the barrel until the bung hole is

facing vertically downwards 22. When all the lees have emptied into the bowl, place the bowl contents in a 5gal bucket or bigger

container depending on the size of the lot 23. Place the barrel washer in the barrel and rinse with hot water until the rinse water runs clear

(~1min) 24. Follow with cold / ozonated water if appropriate 25. Let barrel drain, bung down, while emptying others in lot


26. When the last barrel has been racked, close the gas intake valve on the bulldog, then close the valve on the Nitrogen cylinder. Release pressure from the barrel by opening the gas release valve on the bulldog

27. Disconnect all equipment. Thoroughly rinse bulldog, valve(s), gaskets, line(s), etc. with fresh water.

28. Return equipment to the appropriate location in winery. 29. If the wine is to be returned to barrel, follow the procedure given on p.89-90 of the racking with

a wand procedure 30. Label all tanks and barrels following the appropriate procedure. 31. Assure that bungs are tight and that valves on filled tanks are fitted with an end plate and Tri-

clamp to prevent losses.



Tank Racking Developed by Liz Christensen and Ron Louis May 2003 I Introduction Racking, the process of moving wine from one container to another, is used for a number of reasons during the winemaking process. It is most often used to separate the wine from the lees or solids that settle under gravity to the bottom of the tank. It is also used during the blending process and may also be used to move wine to make better use of storage containers. II Equipment

1 Two 1 inch hoses; one approximately ten feet long, the second should be approximately 10-20 feet in length, but as long as necessary to reach the receiving tank(s).

2 Two butterfly valves in addition to those installed on each tank. If valves are not already on both the drain outlets and the racking outlets of both tanks, they must also be installed.

3 1-1/2 inch to 2 inch stainless steel reducer-couplings if necessary. 4 Tri-clamps and gaskets sized for each hose connection. 5 Diaphragm pump. 6 An empty receiving tank or container large enough to hold the wine being transferred. 7 Two to four empty sanitized buckets. 8 Siphon hose. 9 End caps and gaskets 10 Fitting to attach small gas hose to 1 inch wine hose.

III Materials

1 Sanitation chemicals (See Sanitation Procedures). 2 Adequate water supply with hoses. 3 Argon or Nitrogen gas tanks with regulators and hoses attached. 4 Compressed air.

IV Preparation

1 All equipment, including the pump, should be thoroughly sanitized before use, using the three cycle wash (See Sanitation Procedures in the Napa Valley College Winery Procedures Manual).

2 On the supply tank (the one you will be racking from), make sure butterfly valves are installed to both the upper racking outlet and the lower drain outlet. In every connection necessary in this procedure, a tri-clamp and gasket will be necessary.

3 Remove any end caps from the valves, after checking to be sure that the valve is closed. 4 Repeat items 1-3 on the receiving tank. 5 Hook up the hoses in the opposite direction that the wine will be flowing. Attach the longer

hose to the lower, drain valve on the receiving tank. Attach a butterfly valve to the open end of the hose and connect it to the pump’s outlet, the higher portal on the pump.


6 Connect another butterfly valve to the inlet portal of the air pump, the lower portal on the air pump.

7 Connect the shorter hose to the pump’s inlet (see items 2-4 in the Operation section below). 8 Attach the open end of the short hose to the racking (upper) hose bib on the supply tank. 9 Attach the pump to the compressed air line. 10 Make sure all valves are in the closed position. 11 Make sure that all tanks are vented so that air can flow into the tanks.

V Procedure

1 Place buckets at each connection. 2 After checking to be sure that the top of the supply tank is vented, or the cover is removed, a

layer of Nitrogen or Argon gas may be injected to blanket the wine, protecting it from exposure to oxygen. The gas should flow for approximately 5 minutes to insure a protective layer.

3 Close all valves and access doors on the receiving tank. If attached, remove the supply hose from the pump.

4 Inject a layer of Nitrogen or Argon gas into the receiving tank through the drain (lower) valve as follows: Insert the end of the plastic gas hose into the valve tightly, open the butterfly valve on the tank, and slowly open the valve(s) on top of the gas cannister to insure adequate flow. Fill for approximately 5 minutes, then close both valves and reconnect the hose from the pump to the tank.

5 Double check all fittings to be sure they are tight and properly connected. 6 Open the valves in the following order: Receiving tank, pump outlet, pump inlet. Only after

double checking that these valves are open, the tanks are properly vented and all other valves and doors are properly secured, THEN you should open the valve on the supply tank slowly. Observe the flow of the wine (gravity flow to begin with) and make sure there is no leakage. IF THERE ARE ANY PROBLEMS, SHUT OFF THE SUPPLY TANK VALVE IMMEDIATELY! Use the buckets as necessary to save the wine and keep equipment clean.

7 When the gravity flow slows considerably, turn on the diaphragm pump. The pump speed can be adjusted in two ways, either by controlling the air hose lever or by turning the black knob on the top of the pump. Start slowly. You may want to speed up to remove the air from the lines, then slow down again. Continue pumping until the wine in the supply tank is below the racking valve. If you must leave the operation for any reason, shut off everything and close all valves. When ready to restart, repeat the pertinent portions of steps 5 and 6.

8 When there is no wine flowing through the racking valve, close the valve on the receiving tank and immediately turn off the pump . Place a sanitized bucket under the access door of the receiving tank and slowly open the door, catching any wine in the bucket. There will probably still be some wine in the tank, on top of the lees. This can be removed by siphoning the wine into the bucket or if there is a large amount and if it can be retrieved without picking up lees, use the 1 inch hose manually holding it on your shoulder above the level of the lees.

9 Remove the supply tank hose from the racking valve. Attach a properly sized adapter to the hose which can be attached to the nitrogen gas line. Turn on the gas to about 12 psi and gently push or displace the wine through the hoses and the pump into the tank. Walk the supply tank line , and when all wine is in the pump, displace the wine in the pump using nitrogen and opening the valve to the receiving tank at the same time. Walk the shorter (receiving tank) line, and displace the remaining wine in the hose, forcing it into the receiving tank as you quickly open and close the valve on the tank.


10 Place end caps on the butterfly valves of the receiving tank and clean up. VI Clean-Up

1 Cold or warm —NOT HOT—water rinse all lines or hoses while still connected to the pump the pump.

2 Hot rinse the supply tank thoroughly, including the sample valve and both racking and drainage valves, keeping everything open for good water and air circulation.

3 Rinse the fittings and gaskets and store them on the fittings board. 4 Store the lines so that they will drain and so that no liquid can accumulate in them (open

ends pointing down). 5 Coil and put away the air hose, water hose, and store the pump and the gas cannisters in

their proper places. Helpful hints 1. Have some clean buckets around as you start the process. They can be useful as a place to put

the ends of lines rather than having them on the floor. They can also be used to collect wine that may otherwise spill during parts of the process.

2. If you have to leave the area for any reason, make sure that all valves are turned off. 3. When you attach the tri-clamps, keep the thumb screw on the side or the bottom—they will be

easier to remove and not be in the way.


Tank-to-Tank Racking with Pump




Filtering (mini scale) Developed by Todd Lees April 2005 I Introduction The method of filtration is used to separate the wine from the lees which ensures bright wines and minimizes or stops microbial spoilage. This method has been specifically designed to filter small volumes quickly (e.g. 750ml bottles). It is the method used to filter the fining trials set up in VWT 281 prior to bottling the wines. The mini Buon Vino pad filter is designed for filtering small lots of wine less than 10 gallons when all three plates are used. One single plate may also be used when smaller volumes are being filtered (e.g. 750ml bottles). Consideration must be used in proper pad selection to prevent premature plugging do to its small surface area. If filtrate has a potential of excess matter (suspended particles) multiple runs will need to be done with decreasing tighter pads.

II Materials and equipment: Mini Buon Vino Pad Filter Receiving vessel to hold appropriate volume being filtered (1.5L jug for 750ml bottles) 150ml beaker for collecting the initial 120mls of filtered wine that is discarded(for single pad)


Small bucket for water soaking filter pads Filter pads (Coarse Filter pads are used for filtration of fining trials) Filter pad #1 Filter pad #2 Filter pad #3 2.0 micron 0.8 micron 0.5 micron Coarse Polish Sterile III Procedure Cleaning and setting up the Pad Filter Machine: 52. Based upon turbidity of the wine choose the first filter pad number to be used, i.e., > opacity of

wine > porosity of pad. Sterile pads are always used as the last step before bottling. If you cannot see through the wine start with filter pad #1. If wine is hazy you may start with #2. Never use sterile filter before polish.

53. Rinse pad filter and plates with warm water. 54. If some cleaning is required do not allow water in motor area. Only plug pump in when ready

to operate to reduce shock do to wet working environment. 55. Immediately before use, submerge filter pad in warm water in the small bucket until air bubbles

stop emerging out of the pad. 56. Place pad between plastic plates. While putting the pads in place, make sure the holes in pads

are lined up with the holes in plates and the “rough” side of the pads is facing outwards. Tighten frame plates down firmly and evenly. Be careful to tighten the screws little by little to assure an even distribution of pressure. Alignment of all parts in required before turning on filter.

57. Tilt filter over sink to drain excess water from drain pan. 58. Situate filter on counter top next to sink.

All hoses are of different diameter sizes to be used in a specific place on the filter. 59. Attach short hose to drain pan and loop around to sink or up high to act as a stop so liquid can

be saved if necessary. 60. Connect pump discharge hose to filter frame. (lower port) 61. Connect filter discharge hose to filter frame (upper port). 62. Place pump suction hose in filtrate. 63. If the apparatus needs sanitization, circulate a KMBS/Citric Acid solution through the pad filter

for fifteen minutes (see small filtration procedure). 64. Flush KMBS/Citric Acid solution out with warm water, until water tastes non-acid.

Sanitization is not necessary if the wine being filtered is to be used within 24hours


Operation: 1. Have the 150ml beaker and a container ready at the drainage end to receive filtered wine.

2. Place intake tube into unfiltered wine. 3. Turn on pump. It is recommended to try to limit the starting and stopping of the wine flow the least amount of times as possible. Surge

or pulse action of the starting and stopping can force particles through the pad unnecessarily. 4. Quickly move to discharge side and place filter discharge hose over small beaker to measure out 120mls. When the

120mls is reached quickly move hose to receiving vessel that is large enough for volume to be filtered. The first 120mls of filtrate must be discarded because it is either diluted with water (at the start of filtering) or with the

previous wine if one filters several different wines with the same pad 5. When the container of wine being filtered is empty, turn off pump when air begins to exit discharge port of filter. 6. Disconnect discharge hose from filter frame and raise to allow gravity to recover filtered product that still remains

in hose to receiving vessel. 7. Repeat all necessary steps to compete all wines to be filtered. 8. Once filtering is complete place discharge hose from filter in sink and pump a minimum of 2 cups of clean water

through system. 9. Break down filter. Discard filter pad and rinse carefully the Buon Vino filter with water under the tap. Use great

caution not to get water in motor area. Drain and wipe dry with towel. 10. Rinse and drain all hoses. Changing the pad: 1. When the filter starts to leak excessively and the flow rate slows down, it is time to use a new pad of the same

number until all of the wine has passed through. 2. Repeat steps 2 through 13 as necessary. Breakdown and Clean-up: 1. Once you have completed you filtration, place discharge hose from filter in the sink and pump a minimum of 2

cups of clean water through the system 2. Break down filter 3. Discard filter pad 4. Rinse the filter body with water under the tap, being extremely careful not to get water in the motor area 5. Drain and wipe dry with paper towels, checking for any missed wine residues 6. Rinse and drain all hoses 7. Return all equipment to storage.




Filtering (small scale) Developed by Rachel Martin and Ludwig Hussong December 2003 I Introduction The method of filtration is used to separate the wine from the lees which ensures bright wines and minimizes or stops microbial spoilage. II Materials and machinery to be used: Large Buon Vino Pad Filter 1 40 gallon trash can 3-5 five gallon buckets 2 tbl KMBS (potassium methabisulfite) 1 tsp Citric Acid Filter pads Filter pad #1 Filter pad #2 Filter pad #3 2.0 micron 0.8 micron 0.5 micron Coarse Polish Sterile III Procedure Cleaning and operating the Pad Filter Machine:

Wine must be racked or decanted at least once before filtering. 65. Based upon turbidity of the wine choose the first filter pad number to be used, i.e., > opacity of

wine > porosity of pad. Sterile pads are always used as the last step before bottling. If you cannot see through the wine start with filter pad #1. If wine is hazy you may start with #2. Never use sterile filter before polish.

66. Rinse pad filter and plates with warm water. 67. Place filter in plastic FYB for any leakage that will occur. 68. Fill a five gallon bucket with 4 gallons of water, add 2 tbl KMBS, 1 tsp Citric Acid, dissolve by

stirring. 69. Fill another five gallon bucket with warm water. 70. Submerge filter pads in warm water before placing them in the pad filter. 71. Each pad is placed between plastic plates. While putting the pads in place, make sure the holes

in pads are lined up with the holes in plates and the “rough” side of the pads oriented towards the motor. Screw the metal plate finger tight against the end plate. Be careful to tighten the screws little by little to assure an even distribution of pressure. Alignment of all parts in required before turning on filter.

72. To sanitize the machine and also to remove a “paper” taste from the pads circulate the KMBS/Citric Acid solution through the pad filter for fifteen minutes.


73. Flush KMBS/Citric Acid solution out with warm water, until water tastes non-acid. 74. Pour wine to be filtered into 40 gallon trash can or whatever size container is appropriate for the

volume of wine. 75. Have a container ready at the drainage end to receive filtered wine. 76. Place intake tube into unfiltered wine. Once all of the water has been pumped out of the pad

filter through drainage tube (taste for wine), place drainage tube into the container you have allocated your filtered wine.

77. While operating machine you must monitor the pressure gage it should not pass level 20 pounds.

78. When the pressure is too high, adjust flow valve located on the suction tube that may be manipulated to slow the flow to the filter, decreasing the pressure.

79. When the pressure is still too high and the valve is almost completely shut, it is time to use a new set of pads of the same number until all of the wine has passed through.

80. Every time new pads are used they must be sanitized with KMBS/Citric Acid solution following steps #8 and #9.

81. Now that all of the wine has passed through the first size of filters it is time to move on to the next size, of a finer porosity.

82. After the wine has been through each stage of filtration it may now be transferred into carboys and other appropriately sized containers.

83. Once you have completed you filtration, you must allow 10 gallons (45litres) of clean, fresh water to flow through your pump. This is simply done by placing you intake tube in clean water, start the motor and allow the water to flow through.


Napa Valley College Winery Procedures Manual Standard Operating Procedure

Wine Filtration using a Pad Filter Developed by: Phil Horta, Tony Kolonie, Daniel Stasko and Gerry Ritchie May 2003 I Introduction Filtration is used to clarify wines (when the filter pads have a nominal pore size > 0.45micron (u)) and sterilize them by removing unwanted micro organisms (<0.45 u). It is not intended to replace racking or fining, since even the most coarse filter pad will readily become blocked, slowing filtering progress, by requiring frequent backwashing. Not all wines need to be filtered e.g. if the wine is clear, healthy (low VA), has had no microbially induced problems and has completed MLF. However, if any of the above conditions have occurred, the wine needs to be filtered within 2-4 days of bottling In the pad filter used here we have the capability to run two sizes of pad filters at the same time which helps maintain the integrity of the wine by not having to pump it more than once. Pads with a nominal pore size of 1u are utilized in the first section of the filter to remove coarser particles. Then the wine is passed through pads of a nominal pore size < 0.45u which removes finer particles and micro organisms and helps to sterilize the wine. This prevents microbial growth in the bottle once it has reached the consumer. The method describes how to set up the filter, clean and sterilize it, use it for filtration, back flush the pads so they can be used again after they have plugged and then how to finish a filtration once all the wine has passed through the filter. II Equipment The equipment is listed in the order that it is put together, starting at the sump cart / supply tank end of the chain of equipment. See the ensuing diagrams and photo to get an overall feel for the set-up

. 1 General cleaning equipment (see Sanitation Procedures and Three cycle wash. 2 Sump Cart (100 gallon) 3 2” stainless steel tri-clamp (SSTC) 4 2” x 1-1/2” reducer 5 1-1/2” valve 6 1-l/2” SSTC 7 l” line l0’ to 20’ length (sump cart to pump inlet) 8 l-1/2” SSTC 9 2” to l-1/2” reducer 10 2” SSTC 11 2-1/2” to 2” reducer 12 2-1/2” SSTC 13 Variable volume gear or positive displacement pump, 2-1/2” x 2-1/2” 14 2-1/2” SSTC 15 2-1/2” to 2’ reducer 16 2” SSTC 17 2” Tee


18 2” SSTC 19 2” blow cap fitting 20 Nitrogen/argon supply with regulators and hose 21 2” SSTC 22 2” x 1-1/2” SSTC 23 l” line, 10’ to 20’ length (pump discharge to pad filter inlet) 24 l-1/2” SSTC 25 l-1/2” tee 26 l-1/2” valve 27 l-1/2” SSTC 28 l-1/2” SSTC 29 l-1/2” x l-1/2” portable pad filter with cross flow plate 30 ¾” Hot water hose 50’ 31 l-1/2” quick connect spray nozzle 32 Supply vessel – 400L 33 l-1/2” SSTC 34 l-1/2” valve 35 l-1/2” SSTC 36 l-1/2” SSTC 37 2” x l-1/2” reducer 38 2” SSTC 39 2” valve 40 l” line, 10’ to 20’ long (wine supply tank to pump suction) 41 l-1/2” SSTC 42 l-1/2” line 15’ to 20’ (Pad filter discharge to receiving tank) 43 l-1/2” SSTC 44 l-1/2” tee 45 l-1/2” SSTC 46 l-1/2” valve 47 l-1/2” SSTC 48 l-1/2” valve 49 Holding vessel –400L 50 l-1/2” SSTC 51 l-1/2” valve 52 Barrel washing equipment (see procedure) 53 l-1/2” closure caps 54 l-1/2” closure gaskets 55 gallon plastic buckets (minimum 5)

III Materials

1 General chemicals (see Sanitation Procedure) 2 180ºF hot water 3 Water 4 Nitrogen or Argon 1 1 micron filter pads (8-10 minimum) for Filtrox filter 5 0.45 micron / EK filter pads (8-10 minimum) for Filtrox filter


IV Jargon Intake Drain Valve: This consists of a Tee with a valve attached to the drain exit on the Tee. V Preparation

1 Carefully read work order (if appropriate) and clarify as necessary with supervisor. 2 Sanitize (3 cycle wash) the receival tank using the pump and lines to be used in the

procedure outlined below. Displace the air in the receival tank with nitrogen. 3 Place equipment in approximate locations required for the procedure 4 Place hose ends in sanitized buckets to prevent contamination during the hook-up phase and

during filter back washings and sparging. VI Procedures Set-up (see photos at end of procedure)

1 Load pad filter, being careful to position pads and filter plates to create a continuous flow path through the filter. Starting with the rough side of the first filter pad against the front stainless steel screen plate which is positioned directly behind the front end plate, alternate direction of pads rough and smooth, while sliding each filter plate forward to hold the filter pad in place. Use the correct silicone rubber gaskets between each plate port. Take care to center the filter pad so that filter pad is showing outside of the entire filter plate.

2 Once the first stage filter pads have been installed, place the heavy stainless steel cross-flow plate against the last filter plate. Slide it forward to make sure it is flush against the filter pads and plates already in position.

3 Install the second stage filter pads and plates as installed on the first stage. Install the stainless steel screen plate in front of the rear head.

4 Tighten the ram against the rear head making sure the spacer bar is in place or removed as needed. Check to see that there are no crimped gaskets or places where the filter pads could leak.

5 Using a water hose, run water over the top of the filter pads to ensure uniform wetting up. Extend the ram until it is difficult to turn the Hand wheel. Do not tighten further until hot water has been run through the pads.

6 Open the pad filter intake valve (1) and pad filter discharge valve (2). Close intake tee drain valve (3) and receiving tank line valve (4). Slightly open receiving tank tee drain valve(5), and all the bleeder valves (6) of the pad filter, top, bottom and rear.

Valve

Drain exit of Tee

Flow exit of Tee

Flow exit of Tee


Figure 1 7 Attach a 1 ½” valve to the lower opening on the sump cart and then attach a 10 ft, 1”

diameter hose from the suction side of the pump to the valve on the lower opening on the sump cart.

8 Attach a 1” hose line from the discharge side of the pump to the tee on the intake side of the pad filter (see photos at end).

9 Connect a similar line from pad filter discharge to the receiving tank, putting a 1 ½” tee (with a valve on the drain exit) between the tank and the hose (Fig. 1 and photos).

Sterilizing the Pad Filter 1. Fill the sump cart with a known amount of cold water. Add citric acid to the cold water at a

rate of 0.05% and KMBS at a rate of 0.1% %(see Table 1 at end). Ensure that both chemicals are thoroughly dissolved before circulating through equipment. Open the sump cart valve and start the pump on slow speed. Circulate through all hoses and the pad filter and back to the sump cart. Regulate flow of SO2 / citric solution into the pad filter with the pad filter intake valve so that solution will be flowing from the discharge hose and all bleeder valves without exceeding two bar pressure on the discharge pressure gauge. Circulate solution for fifteen minutes.

2. Stop pump and drain pad filter by opening bottom bleeder valves. After pad filter is empty of solution, re-close bottom bleeder valves, leaving them slightly open. Drain sump cart at the end of the circulation period.

3. Refill sump cart with cold water and pump through pad filter, as above, for ten minutes, refilling sump cart as needed. Stop pump, and drain pad filter and sump cart.

Removal of water from the filtration system 1 Connect N2 regulator and hose to N2 supply. Connect other end of hose to a blow cap.

Connect blow cap to intake tee drain valve on pad filter ((1) in Figure One). Open intake tee drain valve and bottom, front and rear discharge bleeder valves ((6) in Figure One). Close all other valves on the pad filter. Open receiving tank tee drain valve ((5) in Figure one).

2 Turn on N2 supply and slowly increase pressure to 40psi until all water has been blown out through the bottom, front and rear bleeder valves and receiving tank tee drain valve ((5) in Figure one). Turn off N2 supply. Open all valves on pad filter and tee to drain any residual water.

3 Close pad filter inlet valve, remove blow cap from intake tee drain valve. Leave intake tee drain valve open.

4 Remove suction hose from sump cart and connect blow cap to it.

(5) Receiving tank tee drain valve

(1) Pad filter intake

valve

(2) Pad filter discharge

valve(6)

Bleeder valves

Hose line (3)

Intake tee drain valve

(4) Receiving tank

line valve

Pad Filter

Tank


5 Turn on N2 supply and slowly increase the pressure to no more than 40psi. Blow water out of suction hose, pump and the discharge hose between the pump and the pad filter. Walk water out of hoses to pad filter intake drain valve. Turn off N2 when all water has been blown out. Remove blow cap from suction hose.

Starting the wine flow through the filtration system The next step is to start pumping the wine into the filter without diluting it with any water left in the system.

Read the next section very carefully as the actions have to be completed swiftly but carefully so as not to dilute the wine with water.

1 Connect suction hose from pump to the supply tank as shown in connection picture for the supply tank. If you are certain that the wine at the bottom of the tank is not different from the wine at the racking valve, then you may come off the bottom valve to start, otherwise start at the racking valve.

2 Connect N2 supply to sparger attached to a tee on the discharge side of the pump. Do not turn on N2 supply until wine is flowing.

3 Check that the pad filter intake valve is closed ((1) in Figure One) and the intake tee drain valve is open ((3) in Figure One).

4 Open the valves at the supply tank and let the wine flow through the lines. 5 Start the pump. This will push any air and or water from the line going to the pad filter, out

of the drain valve on the tee on the intake side of the pad filter. Wine will be following very closely behind the water.

6 As soon as wine reaches the pad filter, simultaneously open the pad filter inlet valve and close the pad filter inlet tee drain valve. With white wine, this must be assessed by continuously tasting the liquid that comes out of the inlet tee drain valve.

7 Continue to evacuate air and water from the pad filter, closing each top bleeder valve as soon as wine that comes out the bleeder valves tastes undiluted.

8 On the receival tank, continue to bleed air and water from the tee drain valve attached to the receival tank until wine is pure to taste.

9 Simultaneously close the tee drain valve and open the tank line valve as soon as pure wine is detected by tasting. Catch any pure wine in sanitized buckets.

10 Do not stop the pump or cause sudden flow or pressure changes while performing pad filtration operations. The surge created will disturb filter media and allow filtered particles to escape entrapment and reenter the filtered wine stream and require re-filtration of the entire wine lot including re-sanitization of all equipment beyond and including the pad filter.

11 Check the hose lines and connections frequently for leaks during the entire filtration operation.

12 Turn on the nitrogen supply to the sparger attached to the tee on the discharge side of the pump.

13 Monitor the pressure differential and if it reaches l.33 bar stop the filtration pump, close the valve on the supply tank and close the valve on the pad filter inlet.

14 Prepare to back flush the filter pads according to the next step. If the supply tank is emptied before reaching 1.33 bar differential pressure, proceed to ending filtration.

Back Flushing Filter Pads When the pad filter differential pressure reaches 1.33 bar prior to completing the filtration, the filter pads will require back flushing.


1 Shut off pump, close the valve on the supply tank and close the valve on the pad filter inlet. 2 Connect blow cap of N2 supply to the pad filter intake drain valve. Open pad filter intake

valve and intake drain valve. 3 Turn on N2 supply to no more than 40psi. When as much wine as possible has been blown

through the pad filter, to the receiving tank, close the receiving tank line valve while simultaneously opening the receiving tank tee drain valve. Turn off the N2 supply and close the pad filter discharge valve. Close the intake valve and disconnect the hose at the pad filter discharge valve. Catch the wine in a sanitized bucket. Open the pad filter intake drain valve. Disconnect N2 supply blow cap from the intake drain valve. Remove the pad filter intake hose at the pad filter tee, catch the wine in a sanitized bucket.

4 Drain any residual wine from the pad filter into a sanitized container by opening all bottom bleeder valves and the pad filter discharge valve. Return wine to supply tank.

5 To back flush the pad filter, run warm water (not more than 120ºF) through the pad filter in the opposite direction of flow compared to during filtration. Attach a water hose to the pad filter discharge valve. Cap the pad filter intake line tee (that previously had the hose attached to it). Open the pad filter intake valve. Open all bleeder valves to approximately one half. Close pad filter intake tee drain valve to ½ - ¼ to create sufficient back pressure to cause water to flow out from the top bleeder valves.

6 Turn on the water supply and set mixer valves to run 120ºF water through the pad filter for twenty minutes.

7 Turn hot water off to allow cool down for the last five minutes. To aid in dislodging filtered material from the filter pads, pulse the discharge flow by occasionally closing and opening the pad filter intake valve, while observing changes in cloudiness through the intake line sight glass. When no further cloudiness takes place, back flushing is complete.

8 Shut off water supply and disconnect water supply from pad filter discharge valve. Close pad filter discharge valve. Open pad filter intake tee drain valve and connect N2 supply using the blow cap.

9 Close all top bleeder valves and open all the bottom ones. 10 Turn on the N2 supply and slowly increase pressure to 40psi until all water has been blown

out through the bottom bleeder valves. Turn off the N2 supply. Disconnect blow cap from intake drain valve.

11 Open all bleeder valves to allow any residual water to drain from the pad filter. Close bottom bleeder valves and open top bleeder valves approximately one half.

12 Reconnect discharge hose to pad filter discharge valve. Open receiving tank tee drain valve to direct flow to drain.

13 Open pad filter discharge valve. Close pad filter intake drain valve. Remove cap from the pad filter intake tee and reconnect hose from pump and supply tank.

14 Open pad filter intake valve. Open supply tank valve. 15 Start the pump with the pad filter intake valve opened less than one half to control wine

flow. Regulate flow of wine with the intake valve so that the pad filter will fill slowly and residual water will be pushed out the top bleeder valves, rear discharge bleeder valves and receiving tank tee drain valve without exceeding two bar pressure on the discharge pressure gauge.

16 Close each bleeder valve as pure, undiluted wine is detected by taste to be flowing out of each valve.

17 When undiluted wine is detected at the receiving tank tee drain valve, simultaneously close the drain valve and open the receiving tank line valve.


18 Adjust the flow of wine (by closing or opening the pad filter intake valve) so that the pressure on the pad filter intake pressure gauge never exceeds 3 bar, and the differential pressure between intake and discharge pressure gauges never exceeds 1.33 bar.

19 Continue filtering. 20 Regenerate the filter pads as needed by repeating the back washing procedure. If the pads

become so plugged that regeneration is not effective, they will have to be replaced. Follow procedure as described in Procedure Part I.

Ending the Filtration

4. When supply tank and suction hose are empty, stop the pump. 5. Replace the sparger on the tee on the discharge side of the pump with the blow cap that is

connected to the N2 supply. Turn on N2 supply to no more than 40psi. Walk the lines from the discharge of the pump to the pad filter and from the pad filter discharge to the receival tank until the line is empty of wine. Simultaneously, close the line valve on the receival tank and open the drain valve on the tee attached to the receival tank

6. Turn off the N2 and remove the blow cap. 7. Drain the discharge side of the pad filter by opening the bottom bleeder valves and draining

into a sanitized bucket and return to the receiving tank. 8. Maintain the N2 blanket on the receiving tank. 9. Disconnect the hose from the empty supply tank and connect it to the valve on the sump

cart. 10. Wash the supply tank with hot water. 11. Remove the drain valve and tee from the receival tank valve. Sanitize the latter by rinsing

with water and then spray with alcohol. Cap the receiving tank valve. 12. Fill the sump cart with a known amount of cold water. Add citric acid to the cold water at a

rate of 0.05% and KMBS at a rate of 0.1% %(see Table 1 at end). Ensure that both chemicals are thoroughly dissolved before circulating through equipment. Open the sump cart valve and start the pump on slow speed. Circulate through all hoses and the pad filter. Regulate flow of SO2 / citric solution into the pad filter with the pad filter intake valve so that solution will be flowing from the discharge hose and all bleeder valves without exceeding two bar pressure on the discharge pressure gauge. Circulate solution for fifteen minutes.

13. Stop pump and drain pad filter by opening bottom bleeder valves. After pad filter is empty of solution, re-close bottom bleeder valves, leaving them slightly open. Drain sump cart at the end of the circulation period.

14. Refill sump cart with cold water and circulate through pad filter, as above, for ten minutes, refilling sump cart as needed. Stop pump, and drain pad filter and sump cart as before.

15. Release ram pressure on pad filter. Remove ram spacer and pull end plate back as far as possible. Remove each filter pad by sliding each plate backwards to allow removal of each pad. Wash plates of pad filter to remove cellulose residue. Close filter and properly dispose of filter pads.

16. Disassemble the rest of the equipment and store properly.


Table 1. SO2 and citric acid quantities for Routine Sterilization and taste removal from pad filters

Routine Sterilization Routine Sterilization Taste Removal

Water Volume

KMBS (g) (0.1%)

Citric Acid (g)

(0.05%)

Citric Acid (g)

(0.01%)

1 gallon

7.56

1.89

0.38

1 Liter

1.996

0.499

0.1

5 gallons

37.8

9.45

1.89

15 gallons

113.4

28.35

5.67

30 gallons

226.8

56.7

11.34

60 gallons

453.6

113.4

22.68

80 gallons

604.8

151.2

30.24

NOTES: Filter Data: Manufacturer: Filtrox AG Type: NOVOX 400 Max Pressure: 4 Bar Max Temperature: 110ºC Gauges: 0-6 Bar Year Built: 2000 Order: Y-0132


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