BOTTLING UNDER CONTRACT (COPACKING)

IMPORTANT FOR A HIGH-QUALITY PRODUCT:
FORMULA
Recipes for new products are developed by highly qualified and experienced company specialists with the help of external institutes, and approved by the plant's tasting commission.
ООО Premium Spirits produces vodkas and special vodkas. Our vodkas have an inherently characteristic taste and aroma, while our special vodkas have a subtle taste and an emphatically specific flavor and/or taste. Each of our vodkas has its own "character," its own original, recognizable taste, which sets it apart from other vodkas.
QUALITY INGREDIENTS AND CONSTITUENT MATERIALS
The basic components of vodka, as everybody knows, are alcohol and water.
1) ALCOHOL
For the preparation of our vodka we use only Lux grain (corn wheat or rye) alcohol and
Alfa alcohol.

Every type of alcohol has to meet regulatory standards (GOST) in terms of its physical and chemical characteristics.

We buy our alcohol only from approved suppliers who have passed a strict selection procedure. These are well-known Russian factories whose products have been repeatedly highlighted
in tasting competitions. The company's tasting commission has put together a line of alcohols whose organoleptic properties provide a profile for the company's products.

Each part of alcohol intended for the production of vodka undergoes mandatory quality control for its physical and chemical characteristics at the beginning of the distilling process.
But no analytical apparatus will replace the human sensory organs, so the most important stage
of assessing the alcohol is a taste evaluation, in the process of which recommendations are given for the use of the alcohol for specific vodkas.

2) WATER
Our water is taken from artesian wells with a depth of 160 meters from the Lomonosov geological formation.

Purification takes place in 4 stages: via a sand filter, a carbon filter, a microfiltration filter
and a membrane filter, which holds back particles on a molecular level. This method of reverse osmosis refers to the physical method for desalination of water – filtration through special membranes. Under pressure, predominantly water molecules pass through the membrane, while the dissolved salts are dumped into a drain. The membranes are characterized by their high selective permeability and allow water to be desalinated to 98-99%.

In order to soften the taste and give the vodka individuality, infusions are added,
as well as flavored alcohol, honey and sugar.
3) INFUSIONS
1.1 Alcohol infusions are semi-finished products, derived from plant material by extraction.
This means the removal from the material of aroma, flavor and other components, and is carried out during periodic mixing.


Infusions are made only from natural material, such as fresh oranges and lemons, apples, cucumbers, and cranberry. Wheat grain, sesame, parsley, leaves, birch catkins and nuts are also used. After preparation the infusions are filtered through a 1-micron filter produced in Sweden and kept in storage tanks.

1.2 The infusion workshop also produces flavored spirits, which are produced by distilling the essential oils and other fragrant materials with a water-alcohol solution (infusion). Only natural ingredients are used in the preparation of flavored spirits, such as oranges, lemons, cloves, etc. These flavored spirits are made in an Alambic distillation cube.

1.3 Honey is used in many of our vodkas. We use only natural bees' honey (linden, meadow grass, white acacia – the light grades) which we buy only from certain approved suppliers
(on the whole from Russia's central zone). A honey solution is prepared using special technology for the dissolution of honey in purified water. The liquid honey is stirred and delivered
into a collection container through a filter.


1.4 The sugar syrup is prepared in a tank with a stirrer, into which the sugar is delivered
by a pneumatic loader, boiled, and left to cool. The resulting sugar syrup is then filtered.


There are 30 hermetically sealed stainless steel tanks for storing infusions, flavored spirits
and sugar syrup, with a capacity of 15 to 250 decaliters
, and 22 glass containers with ground lids and a capacity from 5 to 20 liters.


This equipment has been designed and manufactured to our requirements to be relatively compact, which allows us to save on production space and facilitates the storage of a wide range
of semi-finished products.


TECHNOLOGY AND EQUIPMENT
We adhere to classical technologies, especially regulatory standards (GOST) and technical regulations.
Our set of lines simultaneously provides both sufficient capacity and bottling flexibility. We are supplementing our equipment
stock in accord with the demands of the market.

Our bottling plant consists of four production lines:

- Line 1 – production capacity of 6,000 bottles/hour
- Line 2 – production capacity of 6,000 bottles/hour
- Line 4 – production capacity of 18,000 bottles/hour
- Line 5 – production capacity of 3,000 bottles/hour


Our production lines are fitted with equipment from leading companies: SIDEL, ALFA (labelling machines), AROL (capping machines), STORK, Gernep, SMI, FBT.

VODKA PRODUCTION IS MADE UP OF THE FOLLOWING STAGES:
1) PREPARATION OF ALCOHOL-WATER MIX
The first step is to prepare an alcohol-water mix of a given strength (ABV). The preparation
of this mixture takes place in flux on a German DIESSEL two-component unit. The dosage is accurate to 0.1% ABV.

If necessary, before it is purified the finished alcohol-water mix is passed through heat exchangers, where it is cooled to the optimal temperature for purification with activated carbon. Afterwards
it is pumped into pressured collectors.


2) PURIFICATION OF ALCOHOL-WATER MIX
The alcohol-water mix is processed with activated carbon by one of two formulas: classic or traditional. The type of treatment chosen depends on the organoleptic features of the alcohol
in question.

The modern formula for carbon processing involves treatment by a silver filtration unit
in accordance with a specially developed procedure.

The classic formula involves treatment of the alcohol-water mix with activated carbon in
a filtration battery made up of sand filters and carbon columns. The alcohol-water mix passes
from the pressure tanks into the sand filters for preliminary purification and passes through three layers of sand of different fractions.

From the pre-filters the alcohol-water mix passes upwards through one or two successive or parallel linked carbon columns, fully loaded with charcoal. This is where the alcohol-water mix mysteriously transforms into vodka.

Activated carbon is active charcoal, prepared in a special way so as to have a highly absorbent surface. We use activated carbon from birch wood.

The charcoal absorbs the impurities and simultaneously catalyzes oxidative processes, which have a beneficial influence on the quality of the vodka, and the qualitative composition of the compounds changes, improving the quality of the finished product. The processing of the alcohol-water mix with active carbon is done using a dynamic method in which the mix is constantly filtered through a motionless layer of active charcoal.

The alcohol-water mix is delivered from below, which ensures the balanced filling of the columns. This is one of the ways to maintain the stability of purification.

The purification process is carried out at a certain speed, which is controlled by rotameters installed beyond the carbon columns.

After carbon filtration the vodka passes through sand filters and then into collecting tanks to sit before blending.

3) PREPARATION OF BLEND
After purification the vodka is sent to the Diessel dosing unit, which feeds doses of the ingredients. This unique machine is programmed by a technician. The dosing units are linked to containers for the storage of infusions, flavored alcohol, sugar and honey. The vodka is fed through the dispensers, which drip-feed the ingredients in the necessary quantity. The vodka leaves this unit with its components evenly distributed throughout its volume and does not require further mixing.

Before bottling the vodka is allowed to "relax" for the ingredients to assimilate better.

The vodka is sent for bottling via a 2-stage cascade system of controlled filtration: preliminary and polishing filtration.

The physical, chemical and organoleptic composition of every blend of vodka is checked before bottling and a taste evaluation is conducted.

VODKA BOTTLING
Bottling is carried out on state-of-the-art automated lines.

The bottling process consists of several stages:
- the glass bottles are fed onto a depalletizer
- the bottles are automatically fed onto a transporter
- the bottles are rinsed with vodka
- vodka is dispensed into bottles of various sizes: 0.05 l;0.25 l; 0.375 l; 0.5 l; 0.7 l; 1 l
- the bottles are sealed (aluminum caps, metal-polymer Guala caps, Т-form (Kamyu) polymer corks etc.)
- front, back and neck labels are glued onto the bottles
- the bottles are registered with a special federal stamp or excise stamps (for export)
- the bottles are packed into a box (boxes are filled automatically)
- pallets are assembled automatically (the depalletizer has a program for assembling and wrapping pallets).

- quality control is conducted at every stage of production




LOGISTICS
The company uses a barcode system, which allows it to optimize logistical flows and increase the speed with which documents are processed. The FIFO principle is observed when dispatching the finished product – this is part of the logic system used to manage the warehouses.
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CONTACT US:
River House Business Center, Ul. Akademika Pavlova 5, Building B, St. Petersburg 197022, RUSSIA
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