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Co-Packer Dramatically Expands Wine Canning Capacity

In just two years, Free Flow Wines increases its wine-canning capabilities from one semi-automated line to three, adds a fully automated 300-can/min line, and triples its production space.

Cover shot
Free Flow Wines President Rich Bouwer (l.), Chief Commercial Officer Heather Clauss, and VP, Operations Rob Perman

Making its debut in 2003 with The Family Coppola’s Sofia Blanc de Blancs Mini California wine in a 187-mL can with straw, the canned wine market took more than a decade to take hold. But taken hold it has, with a 69% increase in sales from mid-2018 to mid-2019, representing nearly $80 million, according to data from Nielsen. And the category is showing no signs of slowing down. Year over year, wine in cans is on track to grow at least 10%, increasing from 1% of the $70 billion wine market in 2019 to 10% in 2025.

That last prediction was from Rich Bouwer, President of Free Flow Wines, who spoke to The Wine Industry Advisor in December 2019. Bouwer’s Sonoma, CA-based company is on the forefront of the canned wine industry, co-packing 73 SKUs of canned wine for 30 wine customers, among them some of the top wineries in the country. In mid-2017, Packaging World magazine visited Free Flow Wines at its former facility in Napa, CA. At that time, the company, which had until then been solely focused on filling wine in kegs, had just begun operation of a semi-automated 40-can/min Codi can-filling line for wine.

During the visit, Jordan Kivelstadt, co-founder and then CEO of Free Flow Wines (he serves on the company’s Board of Directors now), shared that the company was already struggling to keep up with an overwhelming demand for canned wine. β€œIn the world of being a CEO, you wish you had a crystal ball so you could clearly see what things look like a year down the road, because it would be a lot easier to plan. But we don’t have that,” he said. β€œWhen I made the request to the board in August 2016 to install a wine canning line, cans had just taken their first little surge forward, but there still wasn’t a lot of product on the market. We only had a few customers banging our door down to can their wines right then and there. But we’ve just seen that grow, grow, grow. The response we’ve seen from the industry has been astounding. We’re just scrambling to keep up.”

Had Kivelstadt had a crystal ball, he would have seen that Free Flow was on the cusp of incredible growth. After just one year, the company was producing two sizes of canned wine on two Codi counter pressure fillers and was looking for a new and much larger facility to accommodate its rapidly expanding business. In January 2019, it began operation in a new, leased plant thatβ€”at 58,000-sq-ftβ€”is three times the size of its former Napa facility and is equipped with $10 million of new machinery. Housed in the new Sonoma plant are three Codi fillers and the crown jewel of the new operation: a fully automated 300-can/min filling line anchored by a state-of-the-art Krones Craftmate filler coupled with a Ferrum Canning Technology can seamer.

Consumers driving canned wine

Portability, health consciousness, novelty, sustainability, approachability, and fun: These are some of the factors driving the popularity of canned wine among consumers, says Heather Clauss, Chief Commercial Officer for Free Flow Wines. β€œThe approachability of a can is engaging a whole new set of consumers,” she explains. β€œAnd so, those who might be intimidated to pick a bottle of wine up off the shelf are much more apt to pick up a can and try that. We believe cans are helping to grow the wine consumer base as a whole.

β€œAnd then of course there is the millennial interest in something new and interesting. The products we’re putting into cans are all new and a little bit different. A lot of the spritzers are new and unique in their format. We just did a coconut rosΓ©β€”we’ve never seen anything like that.” Lower in calories and in alcohol content, wine spritzers also align with the growing wellness trend among the younger generation, which is increasingly making the switch to more healthy beverages and those with lower alcohol content.

β€œThere’s also the sustainability piece. So many beverages are currently in PET, and we’re seeing a huge trend where consumers are choosing more sustainable packaging. These cans, if you see them in the recycling bin today, will be new cans in 60 days. That’s incredible. Aluminum has the highest recycling rates of any material.

β€œI think there’s also a fun factor to it as well. Look at the designs. They’re fun, they’re hip. You feel cool with one of these, right? There’s no pretense.”

This lack of pretense may have been what caused the slow adoption of this format, as wine drinkers were skeptical of the quality of wine in a can. But Clauss notes that there are some very good-quality canned wines. β€œAlthough I don’t think people are looking for high-end red wine in a can, per se,” she adds. β€œI think they’re looking for a more approachable wine, one that’s easy to drink. If they’re looking for an ultra-premium wine, they’re not going to choose a can. That’s a different use occasion.

β€œThe use occasion for canned wine is, β€˜I want something that’s easy to drink, tastes fresh and delicious, and I can take it anywhere in my backpack and crush the can when I’m done and have no waste.’”

Another factor propelling wine in a can is the stagnation in the beer industry, which has driven some companies, including large beer producers, to branch out into wine. One example is Anheuser-Busch, which purchased canned wine brand Swish Beverages in mid-2019.

But the growth of canned wine is not the only reason for Free Flow’s success in this area. β€œI think across the board, you can speak to any of our customers or anyone we’ve worked with, and they can attest not only to the level of wine-focused quality that we provide, but also our service,” says Clauss. β€œWe never say no. We always work with customers to achieve their goals. I think we’re well-respected for understanding how to package wine.”

Adds Free Flow Vice President, Operations Rob Perman, β€œAll the wine-making services we offer prior to packaging, such as the addition of carbonation and blending, you can’t find anywhere else.”

Quality comes first

To design the new filling line for its Sonoma facility, Free Flow worked with Altamira, a firm that specializes in engineering and project design for beverage processing and packaging lines. Altamira helped Free Flow select the best equipment for its requirements.

According to Perman, although flexibility, speed, and ease of changeover were very important considerations, β€œthe main goal of the line is to produce the highest quality products.” He adds, β€œSo first and foremost it was quality, and then we backed into everything else from a quality standpoint. We really needed to look at how we could ensure that once the package is palletized and gets to the end user that it’s at the highest quality it can be, eliminating any loss or damage.”

Krones Craftmate fillerThe new line is anchored by a fully automated 300-can/min Krones Craftmate filler, engineered specifically for lower-output needs of craft brewers.For the filler, Perman wanted a volumetric fill, so that Free Flow could control the volume of the product going into the can. Developed specifically for the lower-output requirements of craft beer producers, the Krones Craftmate can filler uses 24 electro pneumatically-controlled filling valves with an inductive flow meter that can determine the fill quantity to the exact amount. Ensuring the correct fill is an under/over fill detection system, part of the Filtec Intellect+ inspection platform.

The second most-important piece of equipment was the can seamer. Free Flow chose a four-head rotary seamer with four seaming stations, the F404 from Ferrum. β€œWe did a lot of due diligence on which was the best company to work with from a seaming perspective, and Ferrum was the one that kept coming up,” says Perman. β€œWe’ve seen the quality that the Ferrum produces, and it allows me to sleep at night, knowing we’re getting a really consistent seam.”

Confirms Free Flow QC Manager Chad Morgan, β€œThe Ferrum was tested with all can sizes, and it consistently stays in-spec. We check everything before we start, and then every hour. So we are still doing the same number of quality checks. But on the Codi fillers, throughout the day, we might have to do some finite adjustments to keep it in-spec, whereas with the Ferrum, it just stays.”

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