Copper Cane Wines & Provisions recently hosted over fifty (50) wine industry professionals at their bottling facility in Rutherford, California to view a variety of innovative factory automation solutions from EMS Group. Participants also sampled wine and discussed how they could improve their wineries’ efficiency with the implementation of automation.
The tour began with a demonstration of a unique wine-filling line consisting of a fully automated, EMS Group, bulk depalletizer and bottle aligner (single-filer) inside the facility. Empty bottles continue traveling on conveyor through an opening in the wall of the building to a mobile truck outside, where they are filled, labeled, capped, or corked. EMS Group also supplied the equipment needed to complete the packaging process, including conveyors, carton erector, case packer, partition inserter, and case palletizing equipment.
The tour also consisted of a demonstration of a fully automatic line EMS Group designed to dip full bottles into wax to create a visually appealing, high-end finish. The line consists of six (6) robots, including a robotic system to dip bottles into melted wax then into a chilled water tank, a robotic case depalletizer/ case palletizer combination, a robotic case packer, and other equipment required to fully automate the line.
Joe Wagner founder of Copper Cane Wines & Provisions told the visitors: “I don’t think we would be able to break the 100,000 case mark (on Belle Glos) without a system like this. (EMS Group) put in a line that met our needs at the time and very good percentage above that. We have actually outgrown this line, so we are doing a bit of hand waxing again, which is a great problem to have but nonetheless, the vast majority of what we do is here at this line running 24 hours per day. We don’t need to worry about it going down because it gets good service.
When it comes to reprogramming, it is a very easy process. It’s just amazing what automation can do. Having companies like (EMS Group) bring (their) technology here (to the USA) really help us go to the next level, I think it’s phenomenal.”
The tour finished with tastings in the barrel room, as well as a hand-dipping station where guests were able to manually apply wax to their own bottle of Copper Cane’s Belle Glos, which they kept as a gift.
About: EMS Group USA
EMS Group USA is the American subsidiary of EMS Group S.p.A. the company founded in 2018 from the merger of five leading companies with decades of experience in the handling, palletizing, and storage sectors: Emmeti, Mectra, Sipac, Logik and Zecchetti. The EMS Group is recognized as a world-leading supplier with a reputation for engineering expertise in a wide variety of industries. EMS Group USA, located in Tampa, Florida, serves and supports customers’ new projects as well as more than 400 existing installations.
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For more information, visit emsgroup.com or email Beth Zarnick-Duffy, Executive Sales Director, at beth.zarnick@emsgroup.com.
Cost Saving Solutions: Proven Accelerated ROI
EMS Group has been assisting wineries with Product Handling Projects for more than three decades. Automation and technology have changed significantly during this time, while our commitment to providing customers with reliable products, service, and support has remained constant.
AFFORDABILITY: Work directly with the manufacturer; avoiding middleman markups
RELIABILITY: Rugged high-quality systems designed to provide years of high-efficiency service backed by award-winning USA-based service and support
NO PROPRIETARY PARTS
3D MAINTENEASY SOFTWARE: Ask for a demo and make maintaining your machines a virtual ease.
ENGINEERING SERVICES: EMS will engineer your project or line at no cost.
EQUIPMENT BUILT TO YOUR SPECIFICATIONS
AFTERMARKET PARTS & SERVICES WITH 24/7/365 SUPPORT
Packaging automation increases production and improves line efficiency. Almost two-thirds of consumer-packaged goods (CPG) companies have automated their packaging and processing lines, but wineries have been slower to adopt these technologies. Many winery owners know they will benefit from automation and both cartesian and robotics but have difficulty making progress on implementing automation — and the pandemic only exacerbated the decision-making process.
Wineries worry that they don’t have the internal knowledge, skill or expertise to identify the best solution for their needs. With labor shortages already an issue, managers are concerned that it will be difficult for their labor force to adapt to the change. And, perhaps most critical, winery owners want to know that the return will justify the investment.
Beth Zarnick-Duffy understands these concerns after almost 30 years at EMS USA, the leader in the product handling, palletizing equipment and automated warehousing sectors. As the Executive Sales Director, she focuses on packaging operations at wineries and food & beverage companies, as well as the can and glass container manufacturers that supply these industries.
“I work with companies to improve their line efficiency, reduce their labor costs and automate their plant or improve their existing automation processes,” she says. “I do this with the confidence of knowing that EMS Group produces the leading capital equipment that utilizes the latest technology. My goal is to help these companies find the best product-handling solution at a competitive price.”
In a world bombarded with supply shortages, wild weather, and other uncertainties, top wine manufacturers need a trusted partner they can rely on. EMS USA works with you to engineer and design the right solution for your business — at no cost to you! Whether it’s bulk or case depalletizers, carton erectors, partition inserters, case packers, conveyors, palletizers, shuttle cars or automated warehousing systems, EMS USA has the automation equipment you need.
In the end, no matter how straightforward or complex your integrated solution, your investment in automation will yield faster production, greater line efficiency and accelerated ROI.
Wineries know that they can rely on EMS USA to design flexible solutions for single systems and complete lines for everything from new installations to upgrades, and even revamping and relocating existing systems. These automation solutions and the associated digital infrastructure that governs your plant can be fully integrated with your management software.
Winemaking is as much an art as it is a science, which is why partnering with the right OEM is critical to the process. You need an OEM that has in-depth knowledge of the wine industry and can work with you to improve your manufacturing process. To that end, here are the 5 things you need from your original equipment manufacturer:
QUALITY: Your OEM should ensure their equipment is compliant with all international standards in addition to offering UL and CAL OSHA compliant (Industry 4.0). EMS USA is proud to say that we meet and exceed those expectations.
RELIABILITY: You need an OEM partner that works with you to ensure your manufacturing line is optimized and running smoothly. This should be evident from the early design phase through installation, and beyond. EMS provides advanced engineering and design with expert 24/7/365 support. Plus, our innovative 3-D interactive manual and no Proprietary Parts makes maintenance easy and worry-free!
FLEXIBILITY: Your wine-making facility and process is unique, and you need an OEM that works with you to provide flexible solutions that support your business goals. Whether you need just a single machine or a full line, working with an OEM that provides innovative solutions is critical to your success. With EMS, you get our equipment designed, built, and commissioned to meet your needs.
AFFORDABILITY: When you invest in new equipment, working directly with the equipment manufacturer eliminates the increased costs charged by a 3rd party representative of an OEM. Such investments should readily produce improved efficiencies that positively impact your bottom line. Our clients can attest to the fact that their investment in EMS USA equipment results in proven, accelerated ROI and a lower total cost of ownership.
SUPPORT: Avoid frustrations of unanswered questions and unsolved problems by choosing to work with an OEM that provides excellent customer service. Look for an OEM that offers sales, service, and customer support through USA-based offices. That way, your operation can quickly get the assistance they need. EMS USA provides exceptional stateside sales, service, and support. You get the benefits of premier product handling equipment designed in the heart of Italy’s ‘Packaging Valley’ with the promise of USA-based sales staff, technicians, spare parts, and more.
Is now the time to invest with so many supply chain issues?
EMS USA understands the concerns wineries are facing in a post-pandemic world. With bottlenecks in almost every supply chain, how do wineries ensure that their investment in automation won’t cause more problems or introduce new issues?
“We expanded our staff of stateside technicians and representatives at our EMS USA headquarters in Florida” says Zarnick-Duffy. “We knew it was vitally important for our customers to have 24/7/365 service, parts and support in the face of supply chain issues stemming from the pandemic. We want them to be confident that we won’t leave them waiting for production, equipment installation, or service because of the pandemic. Our engineers and technicians are available to support them in every step from design to installation and maintenance because we know it is critical for the peace of mind they need for long-term success.”
As you move your winery toward smarter product handling solutions with a greater level of automation, your efficiency, reliability and ROI will accelerate. The first step is to identify a knowledgeable partner with the expertise to assess your needs and help you design the system that will deliver the greatest ROI for you.
Discover Why EMS USA is the Preferred OEM
To learn more, visit emsgroup.com/beverage to see our array of Palletizers, Depalletizers, Conveying Systems, Case Packers, Automated Vertical Warehouses, and more. Get the Next Generation Factory you need from the partner you can rely on to help you remain competitive.
Time to check the math; how running bulk glass could be cheaper than cased
Gas prices are surging, inflation is rising, and glass supply chains are in gridlock. The result is escalating glass bottle prices in a market where the consumer demand for wine has outstripped the available supply of glass bottles, making it one of the biggest headaches for wineries and one of the hottest topics in the wine packaging world.
Most mid-size to large wineries use case ware for their bottling process. Traditionally, the cost for purchase and the ROI on buying a bulk glass depalletizer has been out of reach for these wineries. But with the current economic conditions the industry is facing, now is the time for these wineries to redo their math!
"Now that the numbers have changed," says Marty Sychowski, a 30-year packaging industry veteran and packaging consultant to Smart Plastic Technologies, "medium-sized wineries can offset the equipment cost with their savings from buying bulk glass. The ROI for equipment is better than it's ever been; they can regain their ROI in 3 years or less."
Current Market Conditions
Broken supply chain - Consumer demand for wine and spirits has escalated since 2020, which means the demand for glass has increased right along with it. Simultaneously, the supply of glass has decreased by 20 percent, creating the perfect storm for wineries and distilleries. Thirty percent of the glass for our industry comes from China. With the continued shutdowns inside China and massive delays at US ports of entry, the lead time for glass has doubled. Add to that the growing cost of shipping and the wine & spirits industry is facing unprecedented challenges.
Cost of Goods climbing with no end in sight
- Cost of fuel
- Cost of corrugated packaging
- Cost of labor
These are the three main components involved in determining the cost of cased ware, all of which have gone up exponentially in the past year and show no signs of slowing down. That means it’s time to revisit the feasibility of bulk glass.
Sychowski says, "Many of the medium-sized and larger wineries are seeing that the cost of glass has increased up to 50%. Using bulk glass can save money in several ways, and those savings make it much easier to justify the equipment purchase."
This is confirmed by the recent Food Institute report that glass prices have risen 45% since 2019, exacerbating pressures wineries are already feeling from the negative impact of the pandemic, workforce shortages and wildfires.
ROI in 3 years to 18 months – Yes. You read that right. When you do the math, the cost savings, efficiencies and reduction in carbon footprint for bulk glass far surpass the upfront temporary cost of equipment needed to convert your lines from cased glass to bulk. In fact, given the rising costs of goods along the entire supply chain, many companies are finding that what they previously calculated as a 5-6 year ROI is now a 2-3 year ROI! Some wineries have even found it to be an 18-month ROI!
The Big Picture
Converting lines to bulk glass has big benefits the whole way around.
Supply Chain Efficiency - Currently, US glass manufacturers can’t make glass fast enough to keep up with demand, not just because of volume, but because of storage. If more end-users were ordering bulk glass, the production line and fulfillment moves even faster on the manufacturing side. Bulk glass offers the benefits of Reduced Storage space, and the ability to use a common mold for many packages without having to store leftover cased ware in a specific box. All of that takes up time and space on the production floor. If it was all bulk glass going out the door, manufacturing becomes faster and more efficient, which means you have better and faster access to your product - bottles.
Reduction in Your Carbon Footprint - Consumers care about sustainability and social responsibility. Reducing your carbon footprint has big benefits. Bulk glass offers a perfect solution - not only is it responsible, it actually saves you money! Buying in bulk cuts out an entire step in the supply chain and results in a massive amount of reduction in cardboard. Waste reduction is the number one thing all wineries and distilleries can do to positively impact their sustainability. Double handling and in some cases, packing from box to a custom box, can be eliminated along with the waste that these processes create. Imagine being able to reduce your cardboard waste by 50%! That’s what bulk glass vs. cased glass will do for you.
The Silver Lining
Amidst a horizon of storms, there is a silver lining. Mid-size and large wineries have an opportunity to capitalize on the times and pivot, placing themselves in a ready position for growth. "The positive is that now wineries can handle the glass themselves," Sychowski points out, "eliminating the inefficient added handling costs passed along from suppliers. Now, when a winery looks at using bulk glass, the ROI for equipment is almost twice as good as it's ever been."
"The only regret you'll have about converting from re-shippers to bulk is that you didn't do it 5 years ago," says Michael Deltuva, Industrial Development Manager for Copper Cane Wines & Provisions.
Sychowski recommends talking with EMS GROUP USA, the leader in handling, palletizing and storing goods and materials, to understand the equipment needed to bring this process in-house.
“EMS group works with wineries to help them determine if bulk glass is the best solution for them. But whatever their need, EMS has the ability to provide them with equipment that works for bulk or cased glass and improve their efficiencies on their production line. We can even utilize the same depalletizer for both bulk and cased glass.” says Beth Zarnick-Duffy, Executive Sales Director.
By re-evaluating previous costs of ownership for equipment to automate your lines for bulk glass, you can save money while at the same time positioning your winery for increased production capacity to meet consumer demand. That is something to raise your glass to!
Innovative Winery Automation
EMS USA recently hosted over fifty wine industry professionals at Copper Cane Wines & Provisions to witness a demonstration of automated equipment that applies wax onto filled bottles, creating a visually appealing, high-end finish.
Attendees were also able to view a line utilizing EMS USA’s fully automated bulk depalletizer, conveyors, carton erection, case packing, partition insertion, and case palletizing equipment.
The tour included tastings in the barrel room, as well as a hand dipping station where guests were able to manually apply wax to their own bottle of Copper Cane’s Belle Glos, which they kept as a gift. The tour finished with a complimentary wine tasting and hors d'oeuvres.
EMS USA would appreciate the opportunity to discuss your factory automation needs. Please contact Beth Zarnick-Duffy at 814.571.1768 or beth.zarnick@emsgroup.com.
We had the pleasure of hosting tours of Copper Cane Winery & Provisions’ production lines. Visitors saw firsthand how upgrading and automating bottling lines, including the conversion to bulk glass, improved efficiency and accelerated ROI. To learn more about automation options for your facility, visit booth 220 and speak with our experts.
See How Automation Changed the Game for this Winery!
EMS USA is hosting private tours of the bottling lines at Copper Cane Wine & Provisions on Wednesday, November 30th – a perfect way to kick of WINExpo 2022!
See firsthand how Copper Cane and EMS Group partnered together to increase efficiency through INNOVATIVE automation solutions and TALK WITH THE EXPERTS from both EMS and Copper Cane as you tour the bulk glass bottling line and automated Wax-On dipping line.
Get your COPPER TICKET and enjoy the bottling line tour and post-tour happy hour where you will enjoy exquisite Copper Cane wines, delicious hours d'oeuvres, and you even get to take home a bottle of wine– all compliments of EMS USA and Copper Cane. Be sure to REQUEST YOUR TICKET TODAY; this exclusive insider tour has limited availability.
For more information and to register for the tour, visit bit.ly/coppertour
Be sure to visit booth 220 to see why industry leaders choose EMS as their OEM partner for material handling automation.
Learn more about our innovative and flexible solutions for improving efficiency and boosting your bottom line.
EMS USA is proud to sponsor the WINExpo 10th Anniversary Trade Show and Conference- we hope to see you there!
Event Type: Trade Show
Location: Sonoma County Fairgrounds, Santa Rosa, CA
Date: 12/1/2022
Be our guest!
Register to attend the 10th annual WINEXPO using promo code EMS220. Be sure to visit our booth to discover the latest in material handling and warehousing automation.