Wine Bottling: Turnkey Design of New Plants
From listening to staff training: our working method
How is the design of wine bottling plants carried out? Everything begins with listening and meeting the Client in order to understand his objectives, production requirements, space constraints, timelines and, of course, the available budget.
Once the key points have been clarified, we proceed with data collection and an on-site inspection of the facility, using automatic, ultra-high-precision laser measuring instruments. The inspection is essential in order to obtain accurate surveys of the existing situation, which are fundamental for correctly setting up a feasibility study and, subsequently, for carrying out a bespoke design of the required plant.
Whether it is an upgrade of an existing plant, a modernisation project or a completely new line, we develop several solutions to be submitted to the Client. For each proposal, we attach a clear and detailed layout, accompanied by a technical report highlighting its advantages and any potential critical issues.
Only after identifying the optimal solution for the Client, we proceed with the detailed design phase, focusing on the final layout, technical specifications, mechanical and electrical interfaces, and format planning.
After selecting the supplier (and deciding whether to use new machines or refurbished second-hand machines), 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;
- Installation at the Client’s facility;
- Commissioning of the plant;
- Validation.
The project concludes with training of the personnel who will operate the plant, delivery of the technical documentation and assistance during the first weeks of production, in order to ensure that the line operates at its best from the very beginning.
Construction of the machine
Preliminary testing
Installation
Commissioning of the plant
Validation
Plants for the entire bottling process
Our scope of action is not limited to filling wine bottles; rather, we oversee the entire bottling process, from depalletising empty bottles to the finished pallet ready to be loaded and transported.
Our task is to support and assist our Clients with complete plants capable of handling all the stages that transform wine from a bulk product into an item ready for shipment and, therefore, for sale.
If you would like to receive more information about how we work, our plants (including our bottling plants for spirits) and our used bottling machinery, please do not hesitate to contact us.
Our plants take care of:
- Final product preparation with microfiltration and dosing of any oenological adjuvants;
- Microbiological stabilisation and sanitisation of product lines;
- Depalletising;
- Bottle conveyor belts with advanced automation systems;
- Rinsing, filling and capping monoblocs;
- Wire hooding for sparkling wines;
- 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) or wrap-around packs;
- Marking and coding;
- Palletising and final wrapping;
- Any automatic storage systems.
Distinctive features of our plants
- Maximum safety during filling
- Reduction of dissolved oxygen in the product
- Preservation of aromas and organoleptic characteristics
- Flexibility in format changeovers
- Maximum compatibility with different types of bottles and closures
- Integration of sanitisation solutions
- Efficient and rapid quality controls
Design of wine bottling plants: key factors to consider
The design of each individual bottling plant arises from the meeting point between product requirements and the Client’s needs. The bottling plant must always be custom-designed to suit the winery’s specific requirements, taking into account its history, products and services.
When designing wine bottling plants, the following factors must be considered:
- Type of wine (still, semi-sparkling or sparkling);
- Bottle formats;
- Closure systems;
- Required level of flexibility in production changeovers;
The filling phase is of paramount importance. Those few seconds during which the wine flows and fills the bottle are crucial, because months of work that began in the vineyard may be jeopardised. This is why the plant must guarantee the utmost delicacy in handling the wine, control of dissolved oxygen and effective sanitisation.
In addition to product characteristics, the design of a bottling plant must also take into account other more common aspects such as the space available in the facility, utilities, any integration with existing lines, the budget and, of course, the internal procedures developed by each company.
Our strength lies precisely in our ability to combine all these factors and transform them into a tailor-made bottling plant, capable not only of meeting the Client’s requirements, but also of evolving together with the company.
Upgrading and modifying existing plants
Production and business needs may change over time: new lines, new products or new markets may emerge. In such cases, it becomes essential to upgrade or modify the plants already installed in the facility, so that they can adapt to the company’s evolution.
At Villardi, we also deal with plant upgrades, and it is precisely here that the value of sound initial design becomes evident. From the outset, our objective is to propose solutions that can be modified even years later, open solutions designed to accommodate future upgrades and to evolve over time.
Flexibility and adaptability are essential aspects in the business world, and our plants must reflect these values by adapting to different formats, increases in production capacity, new regulations or market changes.
When the design and development of the line are carried out properly from the very beginning, it becomes much easier to intervene on the plant years later. In such cases, we work alongside the Client to understand and analyse new requirements, study possible integrations and propose modifications that allow the plant to grow together with the company.
Customisation of bottling plants: your needs always at the centre
All the plants we design at Villardi are highly customised and developed with the Client’s needs at the core. Every winery has its own history, with specific production requirements, habits and procedures, making each reality unique and unrepeatable.
The most important phase is the development of the layout, as this is where we put to use the experience gained over more than 25 years of working alongside very different Clients. Thanks to this wealth of knowledge and know-how, we are able to propose solutions already tested in other contexts, adapting them to the specific needs of those who entrust us with their project.
Constant dialogue and the ability to build empathy with the Client form the foundation of everything. Without the Client’s valuable and essential feedback, it would be impossible for us to design a plant truly capable of meeting business requirements, because only Clients fully understands their own needs, machinery, products and the daily challenges they face. It is as if Clients were another designer.
So, what is our role? To translate our Clients’ requests into reality, making their aspirations come true. Each plant therefore originates from a shared journey in which technical expertise, experience and the Client’s vision merge.
The customisation of wine bottling plants mainly concerns the management of different formats, flexibility in production changeovers, attention to gentle product handling and preservation of organoleptic characteristics.
Warranty for new and used bottling plants
We always ensure:
- Constant after-sales support;
- Spare parts supply;
- Technical assistance to all our Clients.
In Villardi, we strongly believe that the true warranty lies in having a plant that continues to operate efficiently over time, ensuring production continuity. This is our philosophy!
We would nevertheless like to emphasise that all our plants are covered by warranty, specifically:
- New bottling plants: in this case, the manufacturer’s warranty applies, which is generally 12 months from commissioning (or 18 months from delivery), with the possibility of extension;
- Used bottling plants: in this case, the warranty depends on the level of overhaul agreed with the Client. We can supply fully refurbished and tested machines, or machines offered in a more economical “as seen and approved” formula.
Our Partners
With Whom We Collaborate
Over more than 25 years in business, we have had the pleasure of working with a number of leading companies in their respective sectors, companies that guarantee quality and professionalism, reflecting our own Values.
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.
Are You Looking for Advice or a Quote?
If you would like to receive a personalised quote, professional advice or simply arrange an appointment to discuss the future of your winery, please do not hesitate to contact us.
