The Do’s and Don’ts of Distillery Bottle Filling

February 20, 2025

If you’ve been running a craft distillery for a while, you’ll already know that having a safe, reliable, high quality bottle filling station is essential.

For those just starting out, bottle filling might seem like the simplest part of a distillery’s process. However, to get this wrong is to risk anything from brand integrity, to R.O.I, to the health and safety of your team.

It’s been almost 20 years since Adelphi Manufacturing‘s development of the ATEX Response Benchtop Filler, and since then we’ve been able to observe the fundamental Do’s and Don’ts of distillery bottle filling. From technical insights to best practices, here’s our list of recommendations to help you grow smart and avoid classic bottlenecks.

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The Do’s

Do Invest in ATEX Compliant Equipment:

• In distilleries, safety is non-negotiable. When working with flammable substances like ethanol, cutting corners on equipment can lead to serious accidents, costly downtime, and legal issues. Ensure that your filling machines comply with safety standards such as ATEX, which minimises the risk of ignition in hazardous environments. Regular equipment maintenance, clear employee training, and investing in certified machinery like the ATEX Response Benchtop Filler can protect both your team and your business from preventable risks.
• For growing distilleries, choosing an affordable, space saving filling machine with ATEX certification can be a challenge. Many are not built with the craft industry in mind and have oversized, awkward footprints. As its name suggests, the “Benchtop” is suitable for placing onto a small work station but doesn’t compromise on efficiency, filling up to 40 containers per minute.

Do Focus on Lean Manufacturing:

• Avoiding unnecessary costs can impact your bottom line as much as increasing sales. A ‘low hanging fruit’ option to cut costs is by reducing wastage of your product. We don’t want you to go through the time, money and effort of distilling the perfect product only to loose it during bottling. With the ATEX Response Benchtop filler, two-speed gentle filling means no splash-back. We can also offer hygienic drip-trays to catch droplets. Because alcohol is an even lower viscosity liquid than water, we use double PTFE seals on the three-way valve to ensure no leakage when feeding the product into the hopper.

Do Build Strong Supplier Relationships:

• As a key machinery supplier to the craft distillery sector we understand how crucial reliability is. If your bottling operation breaks down it creates a chain reaction that halts all of production. A supplier like Adelphi, known for their proactive approach to maintenance servicing, ensures that your filling machines remain in top condition, minimising disruptions and extending equipment lifespan. Regular maintenance and timely support keep your production running smoothly, helping you maintain high standards and meet increasing demand with confidence.

Read our case study here: A luxury whisky distillery’s experience of us as their supplier >>>

Do Take Quality Control Seriously:

• Consumers expect consistent quality, even from artisanal brands. This means that everything from the fill level on each bottle to the quality of the label should remain uniform. As you grow and production scales-up, inconsistencies become more noticeable. Standardising your bottle filling process early-on ensures that every bottle meets the same high standards, avoiding issues that could tarnish your brand’s reputation. Reliable filling equipment and a strong quality control system are essential for meeting increasing demand while maintaining the excellence your customers expect.

If you’re interested in the the relationship between filling machines and artisanal brand values, read the article “Is It Really Artisan Vs. Automation?”

 

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The Don’ts

Don’t Overextend Financially

• It’s easy to feel the urge to overinvest in equipment or facilities that exceed your immediate production needs, so a strategic approach to growth is key. Scale only when demand justifies it. With Adelphi’s scalable machinery, you can expand as your business grows, ensuring that your original investment continues to provide value. This flexibility helps you avoid unnecessary costs, making sure you only invest in what you truly need as your production requirements evolve.

Learn more about our scalable filling range.

Don’t Forget Employee Wellbeing

• Your team is the backbone of your distillery’s success. Happy, motivated employees are more productive, creative, and committed to maintaining the high standards your brand is known for. Feeding product into a filling machine can pose ergonomic challenges due to awkward angles and lifting heights. A compact solution can be provided through add ones such as a pneumatic trolley that supports the filler and lowers it to a comfortable working height, making hopper refilling much easier for operators and reducing the risk of Repetitive Strain Injury.

Don’t Be Afraid to Ask for Help

• Seeking advice from experienced professionals is invaluable when making tough decisions. At Adelphi, we offer a free weekly Ask-the-Expert hour with Dean Willis, giving distillers an opportunity to air their pain points and find actionable solutions they can enact that day. These consultations help identify inefficiencies that can improve productivity, reduce waste, and support sustainability. It’s a cost-effective way to gain a competitive edge and drive long-term growth in your business.

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Scaling your distillery and improving your bottle-filling process is a blend of art, science, and smart strategy. By investing in the right equipment—like the ATEX Response Benchtop Filler from Adelphi Manufacturing—and following these Do’s and Don’ts, you’ll set your business on the path to sustainable growth and continued success.

info@adelphi.uk.com   +44(0)1444 472300

 

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