MANUFACTURING PROCESS OF STILL WINES

 Harvesting
 Grading
 Weighing
 De Stalking
 Crushing Or Pressing
 Chaptalisation
 Sulphuring
 Fermentation
 Cellaring
 Second Pressing
 Racking
 Finning
 Filteration
 Blending
 Maturing Wines
 Bottling
 Pasteurization
 Storage
HARVESTING: Grapes are plucked when the density of the bloom or natural yeast on
the skin taken from a number of bunches is constant so that the grape is fully ripened and
has nothing to gain more from the plant. Dry weather is chosen for harvesting. Some
wines are left on the vines (shrub) a little longer to develop a greater concentration of
sugar. From these finest dessert wines are obtained.

Any one method may be followed between two methods: Mechanically (harvesting
machines), manually (Hand- Picked). Hand-picked method is very costly. The
mechanically method is more efficient, cost effective and well suited for large vineyards.

GRADING: Grapes are graded according to the quality which segregates ripe mature
grapes from spoiled grapes.

WEIGHING: Grapes are weighed, to determine the quantity required for fermentation.
DE STALKING/Destemming: Destemming is the process of separating stems from the
grapes. The ripe grapes are plucked off from the stalks. The stalks have a bitter taste due
to the presence of tannin, this process may be undertaken before crushing with the
purpose of lowering the development of tannins and vegetal flavors in the resulting wine,
which should not come in contact with the Juice.
• This process is known as Egrappoir (ig-rup-pua) and the machine used is known as
Egrappoir Fuloir. Destalking is necessary if white wine is made but no destalking
is necessary If red wine is made.
1) Blanc de Blanc- White wine made from White Grapes.
2) Blanc de Noir- White Wine made from black Grapes.

CRUSHING OR PRESSING: Grapes are traditionally crushed with the feet ( Known as
Troddening) by wearing special type of shoes called Zapatos di pisar ( Used in Spain)
or more conveniently by mechanical presses to extract the juice called must.

For this the grapes are placed in a large, shallow tank & the people treading the grapes,
wear boots with spikes, which prevent crushing of pips (as pips contains bitter oils).

At this stage the wine maker uses a hydrometer to measure the specific gravity of
must, which indicates the sugar content and therefore the projected alcoholic strength.

During the crushing stage, if red wine has to be made, then the skin is allowed to come in
contact with juice till it gets color from the skin. In case of White wine, skin in is
removed immediately (if it is made from red grapes). Rose wine is made by allowing the
skin to come in contact for a short while to get the pink color.
Mechanical Press
Mechanical Method of crushing may be of the following types:
a. Baloon Press- The balloon press consists of an expandable balloon which is fitted
in a tank filled with grapes & equipped with an outlet for the must. On being filled
with air, the balloon expands, crushing the grapes against the sides of the tank &
squeezing out the juice.
b. Manual/Hydraulic Press- The manual press works on the principle of hydraulic
pressure. As the central disc descends, it crushes the grapes.
c. Electrical/Cylidrical/Horizontal Press- This press consists of a roller with a plate
fitted all around it. The grapes are crushed between the roller & plate.
For Red Wine
Most red wines derive their color from grape skins and therefore contact between the juice and skins is
essential for color extraction. Red wines are produced by destemming and crushing the grapes into a tank
and leaving the skins in contact with the juice throughout the fermentation (maceration). It is possible to
produce white (colorless) wines from red grapes by the fastidious pressing of uncrushed fruit. This
 minimizes contact between grape juice and skins (as in the making of Blanc de noirs sparkling wine,
which is derived from Pinot noir, a red vinifera grape.)
For White Wine
Most white wines are processed without destemming or crushing and are transferred from picking bins
directly to the press.In the case of White Wine, they are made from Red Colour or red and black grapes
without the skin contact.In some circumstances winemakers choose to crush white grapes for a short
period of skin contact, usually for three to 24 hours. This serves to extract flavor and tannin from the
skins (the tannin being extracted to encourage protein precipitation without excessive Bentonite
addition) as well as Potassium ions, which participate in bitartrate precipitation (cream of tartar). It
also results in an increase in the pH of the juice which may be desirable for overly acidic grapes.
For Rose Wine
In the case of rosé wines, the fruit is crushed and the dark skins are left in contact with the juice just long
enough (usually overnight) to extract the color that the winemaker desires.

CHAPTALISATION: If incase the must shows the insufficient amount of sugar, then
the sugar is added to enrich the must. This process is called chaptalisation.

SULPHURING: Sulphur dioxide is added early in the fermentation process to prevent

air from oxidizing the juice and converting the alcohol into vinegar. Sulphur dioxide takes
up all the oxygen to let the wine yeast which is anaerobic (able to work in absence of
oxygen) to convert grape sugar into alcohol. Sulphur dioxide forms a coating on the
surface of juice to prevent the air from entering the juice and thereby letting the wine
yeast to do its work. It is also used to kill the wild yeasts present on the skins of grapes
that may cause premature or uncontrolled fermentation.

VATTING- After all the must is taken out it is transferred to the vats, where they are fermented .The Vats,
once upon a time used to be made from wood, but now a days stainless Steel Vats, Concentrate Vats and
Glass lined container are used. The wooden Vats are soaked in water to seal the pores.

FERMENTATION: Fermention is the process of adding wine yeast (technically termed

as Saccharomyces Ellipsoideus) to fresh grape juice to convert the natural sugar in the
grape to ethyl alcohol. The fermentation is done in stainless steel vats nowadays against
the traditional wooden vats. In this process carbon dioxide is simultaneously released
making fermentation violent at first and then slows. The yeast added is 3-5 % of the
volume of juice. The fermentation process two days to two weeks. Fermentation occurs
only as long as there is sugar to ferment or when the alcohol content rises to 14% because
at this point alcohol kills the remaining yeast. If sugar remains with alcohol content then
the wine tends to be sweet. A wine is considered sweet when it has 2% sugar content.
During the process the temperature is maintained between 64-70 degree F for red wines
and 44 degree to 59 degree F for white wines. The wine maker may control the acidity
caused by grape acids by adding water acidifying agents such as gypsum. The process of
fermentation takes about 3-4 (Max-14 Days) days.

To prevent excessive heat(which would inactive the yeast & thus halt fermentation), cold
water is run through pipes (Known as Attemperators) embeded in the tanks; this has a
cooling effect. If the temperature is too low, hot water is run through the pipes.

Sometimes Sulphur Di Oxide (SO2) is added to the must/juice to check the rate of
fermentation or special yeast culture is added to accelerate fermentation. The wine maker
 may control the acidity caused by grape acids by adding water or acidifying agents such
as Gypsum.

Attemperators- These are pipes entering into the vats in zigzag motion and coming out,
which carry Cold water in them continuously and helps in maintaining the temperature
below 36Degree centigrade. These pipes are called as attemperators. They are used only
in Case of wooden vats. In case of stainless Steel tanks, the tanks are sprinkled with Cold
water to maintain the temperature.

The fermentation stops for 3 reasons.

1)Temperature increase or decreases.
2)The alcoholic percentage increases or decreases.
3)Addition of Sulphar Dioxide.

MACERATION- Maceration is the winemaking process where the phenolic materials of the grape—
tannins, coloring agents (anthocyanins) and flavor compounds—are leached from the grape skins, seeds and
stems into the must
CELLARING: Once fermentation is complete the running wine‘ or vin de goutte is
run off into the casks for maturing. The casks are filled to the full to exclude air. The
filled casks are put in cellars for the wine to mature. This is called Cellaring. The
suspended particles are allowed to settle to the bottom of the cask as sediments or less.

SECOND PRESSING: The residue of pips and skin (called marc) left in the
fermentation tank or vat is sent for further pressing and the resultant juice, called vin de
presse to which is rich in tannin. The wine maker may decide whether to add vin de
presse to vin de goutte. The left over i.e. pips and skins are sent for a third pressing and
the juice fermented and distilled to produce eau –de –vie- de- marc. Nothing is wasted
and the sugar in the grape is completely utilized.
RACKING: The process of removing pulp & yeast particles from wine is
called racking. The wine must be separated from the dead yeasts which
decompose and give an odd flavor to the wine. The wine is carefully pumped
into another cask without disturbing the lees leaving some wine at the
bottom. This is sent for distilling into eau- de- vie- de- marc. Racking
removes some acidity. The color is brilliant and flavors blend together and
smooth out. After the wine is transferred , the cask is filled to the brim to
eliminate oxidation. This is called Toppling.
Result of Racking:-
1. Racking removes some acidity.
2. The colour is also more brilliant.
3. It is less astringent with the reduction of tannins.
4. Flavours also blend together and smooth out.
5. Glycerin develops, giving more smoothness and body.
6. The process is repeated 3-4 times & so racking can take upto 3-4
months.

FINNING: This is the process of converting the cloudy wine into clear
fine wine.
Gelatin has been used in winemaking for centuries and is recognized as a
traditional method for wine fining, or clarifying. Generally no gelatin
remains in the wine because it reacts with the wine components, as it
clarifies, and forms a sediment which is removed by filtration prior to
bottling.

Besides gelatin, other fining agents for wine are often derived from animal
and fish products, such as micronized potassium casseinate (casein is milk
protein), egg whites, egg albumin, bone char (animal bones), bull's blood,
isinglass (Sturgeon bladder), PVPP (Polyvinylpolypyrrolidone, a dairy
derivative protein), lysozyme, and skim milk powder.

FILTERATION: After fining the wine may passed through fine filters to
get crystalclear wine. The young wine is pumped to the refrigeration unit
to stabilize the wine.

Filtration in winemaking is used to accomplish two objectives, clarification

and microbial stabilization. In clarification, large particles that affect the
visual appearance of the wine are removed. In microbial stabilization,
organisms that affect the stability of the wine are removed therefore
reducing the likelihood of re-fermentation or spoilage.
Stabilization are two types:- Cold & Heat Stabilization.

Cold Stabilization
Cold stabilization is a process used in winemaking to reduce tartrate
crystals (generally potassium bitartrate) in wine. These tartrate crystals
look like grains of clear sand, and are also known as "wine crystals" or
"wine diamonds". They may appear to be sediment in the wine, but they
are not. During the cold stabilizing process (-4 to 0 ⁰ C , 24-32⁰ F), the
temperature of the wine, after fermentation, is dropped to close to freezing
for 1-2 weeks. This will cause the crystals to separate from the wine and
stick to the sides of the holding vessel.

Heat Stabilastion
During "heat stabilization", unstable proteins are removed by absorption
onto bentonite, preventing them from precipitating in the bottled wine.

REFRIGERATION
After fining the wines are pumped into a refrigerated unit in order to avoid
bacterial attack & stabilize the wine.
Preservative-
The most common preservative used in winemaking is sulfur dioxide.
Another useful preservative is potassium sorbate.

AGEING/MATURING WINES:
Once the wine is clear & free of impurities, it is filled in black or white
oakwood casks & kept for maturing. Maturing makes the wine mellow &
smooth & removes harshness. Oakwood is porous & allows enough air into
the wine to make it mellow, but not enough air to oxidize the wine into
vinegar. Prior to maturing the casks are subjected to the process of
‘sulphuring’. This consisting of spraying or gassing the empty casks with
sulphur di oxide, 15-20 days before filling them & then drying them in the
sun. Similarly, bottles & corks are treated with sulphur di-oxide & placed
upside down to prevent microbial growth.

It is natural process by allowing the wine to rest in oak barrels for 1 or 2

years to gain maturity and pick up a soft mellow character from the oak wood.
Maturisation can be induced artificially by agitation, heating, refrigeration and
electrical impulses. During maturation wine tends to evaporate. So the loss of
wine during maturation is called Angels share. There is a stopper (usually
cork ) that fits into the opening at the top of the barrel. The stopper must be
opened from time to time to allow the gas to escape.

 The wine also acquires colour from the oakwood casks.

 Oakwood casks, on being repeteadly used become seasoned & after a
certain period of time, also stop imparting colour to the wine.
 Red Wines are generally aged in the wooden cask (Oak) Where as the
White wines are aged in the stainless steel tanks.
 The oak cask contain Tannin in them. The tannin and other extractable
 materials present in the oak casks Gives required complexity and
characteristics to the Red wine where as the white wine Are required
to retain their freshness and hence aged in stainless steel tanks. The
casks Are always kept on their side.
 There is a hole in the cask through which wine is poured Into the cask.
 12. This hole is known as “Bung Hole” The bung hole is stopped by a
Bung .
 13. The cask is then transferred to a Chai (pronounced as shay,
wine storeroom; usually it refers to an aboveground room rather than
an underground cellar).
 14. When the cask are filled, they are filled to the Top and no gap or
space is allowed to be kept between the wine level and the top of the
cask.
 15. If any space remains between the wine level and top of the cask,
the space Is called as Ullage.

1. The Chai is an above the ground arrangement for aging and maturity of the Wine.
2. Chai is a warehouse where the cask are stored. The person incharge of the chai is Called
the “Maitre de chai”
3. He knocks the casks with a stick to find out if a Ullage has Been created. If an Ullage is
created, then the Maitre de Chai fills up the cask with Fresh wine.
4. There are around 5 % evaporation (Known as Angel Share) every year through the
pores of the Casks which causes the Ullage to be created.
 After a certain length of time, wine changes colour. White wine
changes from greenish to golden colour and red wine changes from
purple to garnet colour (Dark Red).
 The maturation period varying greatly for different types of wines.
 Champagne , for instance, is matured while other wines may be
matured for 3, 6 or 9 months or even for a number of years.
 Champagne & other sparkling wines are bottled, gassed & ready to consume after finning
or filteration- the second fermentation takes place in the bottle itself, using the natural
sugars & yeast present in the wine, in the presence of the air in the bottle.
 Once a bottle has been filled , i.e the wine has been glassed, the wine will not mature
further.
 The wine filled casks are kept on rocks in the cellar to age, the period depending upon the
type of wine. White wine are usually matured for 3-6 months & are best consumed when
young.
 The Red Wines are aged for minimum 1 Year and maximum 5-10 Years. 5–10%
of wine improves after 1 year, and only 1% improves after 5–10 years.
 In general, wines with a low pH (such as pinot noir and Sangiovese) have a greater
capability of aging.

Malolactic Fermentation
During the ageing process, a secondary non-alcoholic bacterial
fermentation called malolactic fermentation takes place. In this
type of fermentation, the bacteria convert the harsh malic acids in
the juice into softer lactic acids. This imparts a softer mouth feel
and a more inviting palate. Most red wines go through malolactic
fermentation to reduce their acidity.
BLENDING: Experienced specialist improve the quality of wine by blending
wines of different vineyards and vintage (different years) to produce wine that
is consistent in quality.

BOTTLING: Wine is poured into sterilized bottles during cool and dry
weather. The bottles are closed with corks and sealed with Spanish wax or
foil. The selection of cork is very important as poor quality of cork can spoil
the wine. After 40 years the cork tree develops a thick, spongy, semi hard
bark, several inches thick. Portugal primarily and then Spain and Italy
produces the best cork.
The corks are obtained from bark of tree called
 ‗Bark oak‘. There are different colors of bottles
for different wines.

o Green & Transparent For white wine

o Brown red wine
o Transparent rose wine

PASTEURISATION: Pasteurization is the process to free the wine from

further fermentation. The wine bottles are immersed upright in double boilers
with water, heated to temperatures between 180 degree F & 190 degree F. The
immersion is for 1 to 2 minutes.

STORAGE: Wines are stored in cool conditions at temperatures of 50

degree- 65 degree F. The storage area must be as light can ruin the wine. The
wines must be moved as littleas possible before they are shipped out.

WINE MAKING PROCESS

WHITE WINE