RTFM: Big & Small Bottle Bottlers, Counter Pressure Bottle Fillers

Welcome to the Bostonapothecary Bottle Bottler series of counter pressure bottle fillers. You have just purchased a very unique tool, unlike any bottler on the market, from a very tiny Boston workshop.

Purchase: Large Bottle Bottler ($190USD)
Purchase: Small Bottle Bottler ($115USD)

This series of full enclosure bottle fillers is ingeniously built around very specific design revisions of commercial water filters. The incredibly durable filter sumps form a high pressure seal all the around the bottle instead of just with the mouth so that a wider variety of bottles can be used and the negative space can hold chilled water to cool the bottles. The heads are carefully machined to integrate Cornelius quick release fittings and bleeder valves. No other bottle filler in its price class can transfer at pressures high enough to effectively bottle sparkling wines or carbonated cocktail creations.

•The Small Bottle Bottler handles bottles sizes from 100 mL bottles to popular 200mL bottles all the way to Champagne 375’s.
•The Large Bottle Bottler handles bottles from 22 oz. beer bombers to Champagne 750’s.

Both designs operate on the same principles. To operate:
1. Put in your bottle of choice and securely screw the top onto the sump with the down tube sticking down the center of the bottle (refer to pictures).
2. Connect the gas hose and release the side valve to flush the bottle of Oxygen. Close the side valve which also brings unit to the same pressure as the keg. Disconnect the gas line (you are probably only transferring at 20-30 PSI).
3. Connect the liquid line from the keg and slowly release the side valve to create a low pressure system drawing liquid into the bottle. Close the side valve at your desired fill level.
4. Disconnect the liquid line and let the bottle bond for 30 seconds so that it does not foam upon releasing pressure (at this time you could start working on another unit).
5. 30 seconds later… Release pressure using the side valve. Remove the bottle and promptly cap it.
6. Start a new bottle!

RTFM: Keg to Champagne Bottle Manifold, Bottler, Bottle Filler

Welcome to the Bostonapothecary Keg-to-Champagne counter pressure bottler. You have just purchased a very unique tool, unlike any bottler on the market, from a very tiny Boston workshop.

[Purchase]

SAFETY DISCLAIMER: USE THIS HIGH PRESSURE PNEUMATICS PRODUCT AT YOUR OWN RISK. WE ARE NOT LIABLE FOR ANY INJURY INCURRED BY THE USE OF OUR PRODUCT. ALWAYS WEAR SAFETY GOGGLES WHEN USING THE MANIFOLD. USE ONLY BOTTLES RATED FOR THE PRESSURE YOUR REGULATOR IS SET AT. DO NOT SET YOUR REGULATOR HIGHER THAN 60 PSI OR RISK WILL ESCALATE. BEWARE OF OUR SEDUCTIVE DESIGN AND MARKETING, THIS PRODUCT IS DANGEROUS AND SHOULD ONLY BE USED BY THOSE THAT FULLY UNDERSTAND THE RISKS. DO YOUR DUE DILIGENCE BEFORE YOU OPERATE THIS PRODUCT.

This device is convertible between acting like the original Champagne Bottle Manifold and performing as a counter pressure bottle filler. When acting as a plain bottle manifold, the long down tube will be removed and a shortened one inserted in its place to help create a seal with the top Cornelius fitting. A Guinness silicon check valve (from their keg couplers in case you need to source a replacement) will be inserted into the food safe silicon seal so that when agitated, liquid cannot enter the gas line. When converting to counter pressure transfer operation, the Guinness valve is removed and a down tube is inserted through the very top fitting straight down the body of the manifold. The Cornelius fitting will create a seal so that no liquid will enter the inner cavity of the manifold. The cavity stays open so that air can be directed upwards to vent through it out the side port reducing pressure so that liquid is slowly drawn from the keg filling the bottle. The silicon bottle seal contains a tiny slit which air can move through when the down tube is inserted. The slit is closed when the Guinness valve is inserted.

The manifold is carefully designed so that if you lose a component it can be quickly replaced, often from third parties that have expedited shipping.

An optional tool recommended for use during counter pressure bottling operation is a bleeder key with gauge (pictured above). If this tool is not present, an object can be used to depress the Cornelius fitting, venting the bottle. With practice, you can get quite good at it and may not want to use the bleeder. The advantage of the bleeder is that you get consistent bleeding among inexperienced operators and the gauge can be used to measure carbonation levels in a bottle for product development tasks. A bleeder with a gauge can also be used to measure the pressure in the keg to keep carbonation levels consistent.

Counter pressure bottling happens at pressures typically under 35 PSI. If too much pressure is used, the liquid will increase in dissolved gas during transfer while if too little is used the liquid will decrease in dissolved gas. As rules of thumb, without knowing your specific equilibrium pressure or the resistance of your jumper line, sparkling wines and highly carbonated cocktails can be transferred at 35 PSI while beers can be transferred at 20 PSI. Liquid transfer hoses can be as short as 12 inches to reduce resistance and minimize warming of the liquid during transfer.

To start a liquid transfer, the chilled bottle needs to be brought to the same PSI as the keg (your keg pressure may need to be brought down to your transfer pressure). A gas line is disconnected from the keg and connected to the top fitting of the transfer manifold (this single fitting shares both liquid and gas). At this time the bottle can also be vented of atmospheric oxygen. The down tube will flush air straight to the bottom of the bottle, up and out creating a very thorough flush.

When the bottle has the same pressure as the keg, the gas line can be moved back to the keg and the liquid jumper line can be connected from keg to bottle manifold. The liquid will be nearly indifferent on moving between vessels because the pressure is the same. When the pressure is reduced on the bottle by venting the side port, liquid will flow across the jumper line into the bottle. When the bottle is filled, the liquid line can either be disconnected to stop the flow or the gas bleeding can also be stopped.

The manifold seal on the bottle cannot be disconnected right away or detrimental foaming and loss of dissolved gas may occur. Bottles often need to bond for upwards of 45 seconds depending on how cold they are and how much dissolved gas they contain. Chilled kegs and chilled bottles help everything move faster. Bonding time can slowly be reduced by empirical testing to maximize productivity. Once the bottle is released, it must quickly be capped. The inactive time of counter pressure bottling is significant and the transfer manifold is designed modularly so that multiple units can be used to reduce inactive time.

Adding a down tube and a second gas port adds lots of functionality to the transfer manifold beyond classic counter pressure bottle filling or acting like the original bottle manifold. Tubing can be put over the down tube to reach the bottom of a bottle and a gas-in line put on the side port to turn a bottle into a mini keg for research tasks. Chilled uncarbonated liquid can also be put into a bottle, such as a magnum, and gas moved down the down tube and vented out the side port, very much like the mechanism used by a Soda-Stream, to carbonate liquid in a bottle without agitating like is done with original bottle manifold use. All of this versatility means the transfer manifold can be in use 24/7 in your institution.

Congratulations on your smart purchase and thank you for supporting our small workshop.

SAFETY DISCLAIMER: USE THIS HIGH PRESSURE PNEUMATICS PRODUCT AT YOUR OWN RISK. WE ARE NOT LIABLE FOR ANY INJURY INCURRED BY THE USE OF OUR PRODUCT. ALWAYS WEAR SAFETY GOGGLES WHEN USING THE MANIFOLD. USE ONLY BOTTLES RATED FOR THE PRESSURE YOUR REGULATOR IS SET AT. DO NOT SET YOUR REGULATOR HIGHER THAN 60 PSI OR RISK WILL ESCALATE. BEWARE OF OUR SEDUCTIVE DESIGN AND MARKETING, THIS PRODUCT IS DANGEROUS AND SHOULD ONLY BE USED BY THOSE THAT FULLY UNDERSTAND THE RISKS. DO YOUR DUE DILIGENCE BEFORE YOU OPERATE THIS PRODUCT.

[Purchase]

For Sale: Counter Pressure Keg-to-Champagne Bottler ($225USD)

Follow @b_apothecary




Bostonapothecary is proud to introduce a next generation counter pressure bottler inspired by the infamous champagne bottle manifold. The counter pressure bottler attaches to champagne bottles with the same collar system as the original manifold but also includes a down tube and side port with a second Cornelius fitting for venting or pressurizing. The down tube can also be removed and a check valve inserted to revert the bottling head back to the same functionality as the original design for in-bottle carbonating, reflux de-aeration, or counter pressure to preserve sparkling products.

Counter pressure bottling is a fairly advanced procedure and assumes users are familiar with carbonating in Cornelius kegs. There is not much hand holding here so this product is designed to fulfill the dreams of people who pretty much already know what they want to do and how it will work. This product fills a giant hole in the market. Cheap versions, which don’t handle pressure levels beyond beer (and require two man operation) are available for $70 and then nothing worth a damn is available until $10,000. No other product is available that can give you full control at the smallest possible scales. Though slightly technical, counter pressure bottling is safe and liquid is typical only transferred at under 40 PSI which is a small fraction of the working pressure of Champagne bottles. Transfer pressure, because liquid is only being moved rather than forced into solution, is much lower than the pressures used for in bottle carbonation of the original Champagne bottle manifold and is thus a safer procedure.

setThe down tube has been designed as a standard soda keg down tube to keep all the parts familiar. The accessory check valve (included) is from a Guiness type keg coupler so it is tried and true as well as easily replaceable. The check valve slides comfortably into the specially designed food safe seal which engages the bottle. The functionality of going from down tube for liquid transfer to check valve for various non transfer tasks means the tool can be used around the clock and helps justify owning multiple units. Such versatility is not a feature of any competing product at any price range.

optionsGas can be bled from the bottles with a “key” which is best done with a Cornelius gas quick release fitting with a pressure gauge and bleeder valve (pictured above). This key is not included with purchase but can be acquired affordably from my favorite supplier, the Chicompany. Champagne bottles, such as magnums, can even be turned into mini kegs and a hose can be placed over the down tube to reach the bottom of the bottle. Gas can then be inputted into the side port to move liquid up the hose instead of down. The key can also be used to measure the internal pressure of a keg and when paired with the temperature, can imply carbonation level (a common brewers technique!).

keyinstalledEverything was designed with cleanup in mind which is another major strength over competing designs. The Cornelius fittings hold a seal when only thumb tight so disassembly can be done without tools to maximize productivity. The Cornelius fittings have also been proven to hold a seal for months on end which is the reason for using a second Cornelius post instead of integrating a bleeder valve (yes, I systematically explored and tested every option). As opposed to the bulky, large square footage, standing clamp designs of competitors, the small size and portability of the collar design allows all parts to constantly be dunked in sanitizer for cleaning (parts should never be dish washed at high temp because high heat will weaken the seal of the embedded fittings).

The bottling head features unique over-molding of stainless steel 19/32 fittings for anchoring and an uncompromising seal. This complicated production technique, typically found only in very expensive medical devices, was made possible by developing a new laser cut acrylic mold box & plastic silicon die technique (that I’m very proud of, woohoo!).

molddyes

Production is currently still rather bespoke and all sales are being reinvested into the project to upgrade the designs and manufacturing techniques to take full advantage of CAD, 3D printing & CNC machining (there is finally a legit engineer on the team!). Until further notice, purchasers will be part of an early adopters / patrons of the arts program and entitled to trade in their units towards new versions at the expense of shipping and other greatly minimized expenses (manufacturing techniques allow reuse of the costly stainless fittings). Early adopters will also get the benefit of small amounts of consulting which is basically the ability to constantly pick my brain about product usage and potential applications as well as recipe development.

The design features many advantages over competitors and the number one is portability and the potential to be used 24/7 for a variety of tasks followed by affordability. Counter pressure bottling requires significant amounts of inactive time (due to physics) so it is not exactly the fastest process. The affordability of the design allows users to own multiple heads for the price of a one head system from competitors. This allows users to purchase more heads at their own pace to reduce inactive bottling time. As one bottle is coming to equilibrium and “bonding” so the manifold can be removed without detrimental foaming, another bottle can be filled and maybe yet another can be capped.

Another unique feature is the usage of only Cornelius gas fittings instead of both gas & liquid fittings. Liquid can run through the gas quick release so what this means is the same input at the top of the bottling head can be used to both pressurize the bottle, bringing it up to the same pressure as the keg (as well as flush it using the key), and then be used for the liquid line. The liquid jumper cable going from the keg to the manifold will have a liquid disconnect on the keg side but a gas disconnect on the manifold side. This breaking of the rules means the bottler requires less fittings to function and the force to attach the main fitting presses straight downward over the center of the bottle so as not to stress the seal.

With enough early adopters, new tools will be introduced such as a collar to hold 25 mm beer & soda bottles. Working prototypes already exist but need to be scaled upwards to safe, consistent, mechanically precise, and economically viable production.

Distant projects are proposed for affordable but limited production runs of equipment for bottling carbonated water in old fashioned soda siphons. Also a flexible bottling plant has been conceived for eco-hotels and other programs in far flung areas who need bottling heads that can handle the assortment of miscellaneous bottles recycled in their area.

PATENT PENDING

SAFETY DISCLAIMER: USE THIS HIGH PRESSURE PNEUMATICS PRODUCT AT YOUR OWN RISK. WE ARE NOT LIABLE FOR ANY INJURY INCURRED BY THE USE OF OUR PRODUCT. ALWAYS WEAR SAFETY GOGGLES WHEN USING THE MANIFOLD. USE ONLY BOTTLES RATED FOR THE PRESSURE YOUR REGULATOR IS SET AT. DO NOT SET YOUR REGULATOR HIGHER THAN 60 PSI OR RISK WILL ESCALATE. BEWARE OF OUR SEDUCTIVE DESIGN AND MARKETING, THIS PRODUCT IS DANGEROUS AND SHOULD ONLY BE USED BY THOSE THAT FULLY UNDERSTAND THE RISKS. DO YOUR DUE DILIGENCE BEFORE YOU OPERATE THIS PRODUCT.




Follow @b_apothecary

Green Apple Soda as De-aeration Color-Indicator-Test

Acmeapple soda

For a while I’ve been trying to dream up a test that could illustrate the effectiveness of reflux de-aeration with the champagne bottle manifold.  Of course you can smell the absence of oxidative aromas in de-aerated lemon juice but not everyone smells so well, not even experienced culinary professionals.  A better test would be something visual which made me think of apples.

Apples are subject to oxidative browning which many people are well aware of.  The juice starts out pale and fairly clear like white wine then slowly turns brown before your eyes.  My hope was that de-aeration could remove enough oxygen to prevent any visible browning.  This might be achieved without even adding any ascorbic acid as anti-oxidant.

Using only reflux de-aeration, the juice of green apples stays green and the highly carbonated product is delicious even by itself with no added sugar or acid.

Of course it is even more delicious in a cocktail:

5 oz. highly carbonated green apple soda (probably 8g/L dissolved gas)

1 oz. gin (something burly and high proof)

.5 oz. lime juice

2 g. non-aromatic white sugar

The green apples were juiced with an Acme centrifugal juicer.  The juice was then quickly funneled into a champagne bottle (a clear bottle!) and reflux de-aerated at 65 PSI.  Centrifugal juicers are known to whip a lot of air into the juice accelerating browning but miraculously reflux de-aeration takes the oxygen right out.  Once the oxygen was vented, the juice was carbonated to 8 g/L of dissolved gas which gives it quite the sparkle.

At this point the unadulterated juice is turbid and has some sediment which might irk some neurotics, but the settled juice could easily be racked before carbonation to remove most of the particulates.

To clarify the unadulterated juice within reason on the larger scale (gallons), I bet the juice could be de-aerated in a 3 gallon keg, allowed to settle, then racked off by use of a floating down tube.

Production is pretty quick, low foot print, and economical. No enzymes, no agar clarification, no centrifuges (even though I love those techniques!). Just plain old raw juice, reflux de-aerated.

Measure Carbonation with your Kitchen Scale!

Follow @b_apothecary

[This is a very old post and I’ve learned so much since. I’d either explore the Carbonation time line or jump to taking a look at the Champagne Bottle Manifold.]

A few months back in the summer I wrote a post called new ways of thinking about carbonation where I started to explore carbonation in terms of grams per liter of dissolved gas instead of pressure and temperature. I set up quite a few projects and so far have been slowly crawling through them.

The first project to be tackled asked this question: Can I easily weigh the gas I add with my car valve carbonator to know how sparkling I am?

I was turned onto the car valve carbonator by the folks at the Milwaukee Maker Space. It is basically a soda bottle with a hole drilled in the cap and a replacement tire valve affixed to the hole.  It is an astoundingly cheap and easy way to carbonate.  you then a get a tire filler and attache it to your gas supply.  set your regulator to 50 PSI and then inject some gas and shake to facilitate dissolving. [it turns out these valves have lead in them and I abandoned using them. I now only use the tap cap and my Champagne Bottle Manifold.]

We used 20 oz. soda bottles that were filled with 500 mL of liquid.  The filled bottle was placed on a kitchen scale and zeroed then we weighed after each injection.  We were easily able to add 3.5 grams (7 grams per liter!) to our bottle.  We then put it in the fridge to rest and come to equilibrium so it didn’t gush when opened too quickly. [I think when I did this I was not accounting for what was in the head space which has a significant weight that can be accounted for by zeroing. Newer things I’ve written explain the process much more clearly.]

What is awesome about this is that you don’t have to taste as you go, you can learn what 7 g/L tastes like and then keep all your numerous bottles consistent. A jigger for carbonation and its as simple as a kitchen scale!

What I’m really bent on is doing this with champagne bottles or those tiny San Bitter soda bottles. I won’t be impressed until I get perfect carbonation and an elegant delivery.  Luckily my champagne bottle manifold works well now that my plastic foundry skills have grown.  I also discovered a stainless 19/32-18 to 1/4MPT thread adapter that will allow me to put Cornelius quick release fittings on top of my manifold! The same link also has a 19/32-18 adapter that goes on a 1/4 male flare fitting so you can combine it with a draft tail piece and put a Cornelius quick release on a soda siphon (I know a picture would be worth a thousand words). For a busy bar, the fittings will pay for themselves in a few weeks!

The next thing I wanted to tackle is how much gas actually goes in a soda siphon when you charge it with a 8 gram cartridge.  I’m equipped to do this.  I’ll have to charge up the siphon, zero the scale, then unscrew the cartridge but leave it on the scale and see how much weight was left trapped in the cylinder. Then I can unscrew the top of the siphon and see the weight of the gas that escapes. Then I’ll know how many g/L of gas made it into the water. I should probably also weight the cartridge to actually see how full it was.

This information will let us know how much dissolved gas we should put in our soda if we want them to compare to classic siphon made versions.

We can also see how much gas is lost to the turbulence of going through the siphon.  For that I’ll use the Carbodoseur tool that my new favorite commenter Julia mentioned. They are typically expensive but I was lucky enough to acquire a new one very cheap on ebay.

There is more to be done but I’m off to work.

[I never followed through with exploring the soda siphon because the Champagne bottle manifold was so successful. I eventually even built cradles that allow me to fill 100 mL San Bitter bottles as well as 187 mL & 200 mL bottles. Ideas developed quickly from here and I recommend checking out my Carbonation time line.]

Follow @b_apothecary