Bottling of Spirits and Liqueurs: Tailor-Made Projects
From the Client’s request to a bespoke design
When we talk about bottling plants for spirits and liqueurs, we refer to truly customised systems, designed to place the Client’s specific requirements at the very centre and to respond perfectly to business needs. At Villardi, we therefore do not start from standard designs: we start from listening.
Listening is undoubtedly the first step towards effective design, because only in this way can we gain a thorough understanding of the Client’s requests, business requirements, distinctive features and any production issues that need to be addressed and resolved.
Exactly as with wine bottling plants, the process also begins here with a meeting with the Client, aimed at understanding not only business needs, but also space constraints, timelines and, of course, the available budget. This is followed by an on-site inspection at the facility, during which we carry out surveys using automatic, ultra-high-precision laser measuring instruments: together with other data, these measurements enable us to set up the feasibility study.
Depending on the requirements, we develop various solutions (ranging from a simple upgrade of an existing plant, to the introduction of a new format, through to the creation of a completely new line), and for each of them we prepare a clear and detailed layout, accompanied by a technical report outlining advantages and potential critical issues.
Thanks to our professional consultancy, the Client will be able to decide which solution to adopt, allowing us to proceed with the development of the final design (layout, technical specifications, interfaces and format plan), always with the Client’s support, because no one knows the company better than they do.
Once the supplier has been selected (new machinery or refurbished used equipment), we take care of all subsequent phases:
- Construction of the machine at the supplier’s premises, or overhaul in the workshop in the case of used plants;
- Preliminary testing;
- On-site installation;
- Commissioning;
- Validation.
The project is considered complete only after staff have been trained in operating the plant, the technical documentation has been delivered, and assistance has been provided during the first weeks of production, to ensure that everything functions in the best possible way.
What our spirits bottling plants cover
Villardi’s scope of action encompasses the entire bottling process, from the handling and preparation of empty bottles through to the preparation of the finished, wrapped pallet, ready for transport. We therefore do not limit ourselves to filling alone or to individual stages, but take full responsibility for the entire process, right up to preparing the finished product for dispatch.
Specifically, our plants cover:
- Final product preparation;
- Microbiological stabilisation and sanitisation of product lines;
- Depalletising;
- Bottle conveyor belts equipped with advanced automation systems;
- Rinsing, filling and capping monoblocs;
- PVC and poly-laminate capsuling;
- Labelling;
- In-line quality control systems;
- Software integration with SCADA systems and traceability;
- Machines for packing in Regular Slotted Containers (RSC / FEFCO 0201) or wrap-around packs;
- Marking and coding;
- Palletising and final wrapping;
- Any automatic storage systems.
Design of plants for spirits and liqueurs: between business needs and regulations
During the design phase, we always take into account production requirements, the Client’s needs and, of course, the characteristics of the product.
Key determining factors in the bottling of spirits and liqueurs certainly include the alcoholic strength, which is significantly higher than that of wines and therefore requires specific materials and technical solutions. Other factors to be considered, in addition to much stricter safety regulations, include:
Dosing
High precision and accuracy in dosing, particularly for high-value products.
Bottle design
Spirits bottles often feature highly distinctive and refined shapes and designs.
Bottle closures
Packaging sophistication is reflected in closures like wooden stoppers, caps, and security seals.
There are, however, other factors that must also be taken into account and that are shared with the design of wine bottling plants, namely the space available within the facility, utilities, any integration with existing lines, the available budget, and the company’s internal procedures, which must be respected and not disrupted.
Design excellence lies precisely in the ability to combine all these elements, resulting in tailor-made bottling plants for spirits and liqueurs, capable of growing and evolving together with the Client.
Distinctive features of our bottling plants for spirits
Our bottling plants for spirits and liqueurs incorporate precise distinguishing characteristics.
Materials
Use of materials and components suitable for products with a high alcohol content, in compliance with safety regulations
Hermetic closure
Handling of special closures (wooden, plastic, metal and glass stoppers, capsules, labels and tamper-evident seals)
Dosing
Maximum dosing accuracy, essential for high-value products
Design
Ability to adapt to designer bottles or non-standard formats
Plant customisation: what can we do for your business?
The customisation of plants, just like their design, begins with the Client: with the company’s history, its diverse production requirements, habits and procedures, which vary from one business to another. This is why we do not aim to offer standardised plants, but ensure that every solution we provide is designed around each individual Client.
The most important phase of the entire customisation process is the development of the layout, because this is where we make full use of the experience gained over more than 25 years of activity, during which we have worked alongside Clients with very different backgrounds and needs.
The customisation process of a bottling plant is based on constant dialogue with the Client and the ability to build empathy. Only in this way can we truly understand business requirements, challenges, critical points, distinctive features and everything that makes a company unique. Only the Client truly knows his products, lines, machines and the issues to be solved: our task is to turn his ideas, your ideas, into reality.
Each plant originates from a shared journey, from continuous collaboration with the Client, in which technical expertise, experience and the desire to respond perfectly to business needs come together.
Bottling plants for spirits are customised primarily based on:
- Accuracy in fill levels;
- Safety during the filling phases;
- Resistance to high alcoholic strengths;
- Adaptation to particularly distinctive bottles and closures.
New plants for new business requirements
If production needs change, is it possible to upgrade a bottling plant? The answer is yes, especially if, already at the design stage, an “open” solution has been created, a plant capable of evolving and being modified over time.
Flexibility is essential for businesses, and machinery must be equally flexible, so as to be able to accommodate and support change. At Villardi, we ensure that all the bottling plants we design can, one day, be modified and upgraded to adapt, for example, to different formats, increases in production capacity, market changes and new regulations.
Thanks to well-designed plants, any future modifications become simpler and more immediate, to the overall benefit of the company.
Contact us if you want to upgrade or modify your bottling system!
Plant warranty: our professionalism for your peace of mind
We never leave our Clients on their own, but continue to support them even after the installation and commissioning of bottling plants.
Specifically, for new plants, the manufacturer’s warranty applies, generally 12 months from commissioning or 18 months from delivery, with the possibility of extension upon request.
As for used plants, the warranty depends on the level of overhaul agreed in advance. At Villardi, we can supply fully refurbished and tested machines, or equipment offered under an “as seen and approved” formula, ideal for those who need to adhere to a strict budget.
In all cases, we always guarantee after-sales assistance, spare parts supply and technical support.
The true and best warranty is having a plant that continues to operate flawlessly over time, and we want to help you achieve exactly that!
Compliance with health and safety regulations
All bottling plants, whether for wines or spirits, must comply with precise regulations concerning food safety and worker safety.
From a health perspective, machines must guarantee the use of materials suitable for contact with foodstuffs (EC Regulation 1935/2004 and subsequent amendments), effective sanitisation processes (CIP and SIP) and compliance with HACCP standards. Adherence to these regulations ensures the hygiene of the finished product and consumer protection.
With regard to occupational safety, bottling plants must comply with the Machinery Directive 2006/42/EC (now Machinery Regulation 2023/1230) and the related standards governing protective devices, interlocks, ergonomics and emergency stop systems.
Depending on the product and the substances handled, other regulations may also apply, such as ATEX (for environments with high-alcohol-content atmospheres), noise regulations and electrical safety standards.
Each project is developed with meticulous attention to integrating these rules, ensuring that all plants comply with current legislation, are safe for operators and reliable in guaranteeing high-quality products.
Would you like some advice or a quote?
At Villardi, we’re always on hand to offer you our professional advice, whether you’re looking for a new, bespoke system or one of our reconditioned systems. Contact us for more details!
Our Partners
Who we collaborate with
Over the years, we have had the pleasure of assisting a wide range of national and international companies, providing them with bespoke bottling solutions. Here are some of the companies that have placed their trust in us.
