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]