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Frogmore Bottling Company’s Bottling Process

At Frogmore Bottling Company, every bottle that leaves our facility is a testament to our commitment to quality, precision, and care. Our bottling process is a meticulous journey from raw ingredients to a perfectly sealed product, ready for shipment. Let’s take a closer look at how we bring our products to life.

Ingredient Preparation: We meticulously select and prepare ingredients for every product we craft, thoroughly inspecting them to ensure they meet our exacting standards. Each batch is precisely weighed and carefully loaded into our kettles, marking the first step in our production process.

Glass Loading and Sanitization: On the production line, the first station is where we load our glass bottles onto turntables. These bottles then pass through our bottle sanitizer machine, where they are flipped, rinsed, and air-dried before continuing down the line.

Bottle Filling: This is where the magic happens. At the bottle fill station, our glass bottles are filled with the prepared product at a precise temperature, ensuring both quality and safety. Within seconds, the bottles are filled and immediately capped to retain their heat, setting the stage for the next crucial steps.

Quality Check and Inversion Process: Once filled and capped, each bottle undergoes a quality check to ensure the caps are fully tightened. The bottles are then placed upside down on carts to begin the inversion process. This critical step ensures that the inside of the bottle and the headspace between the lid and the product are thoroughly sterilized. The inversion process is carefully timed to meet the specific needs of each product.

Cooling and Vacuum Sealing: After inversion, the bottles are flipped right side up and moved into the cooling tunnel. This stage is essential for sanitizing the outside of the containers and ensuring the product inside achieves a proper vacuum seal as it cools. By the time the bottles exit the cooling tunnel, they are no longer at cooking temperature and are ready for final inspections.

Final Inspection and Labeling: Every bottle that leaves the cooling tunnel is inspected for proper seals and any potential glass defects. Only those bottles that pass this rigorous inspection move on to the labeling stage. Here, bottles receive their batch number, expiration date, and finally, their label.

Boxing and Palletizing: Labeled bottles are carefully packed into their cases and then sent through an automatic box-taping machine. The sealed boxes are placed onto pallets and then wrapped with stretch wrap to secure them for transportation. Once a pallet is complete, it’s time to load it onto its designated truck for storage or shipment.

From start to finish, our bottling process is designed to ensure that every product that leaves Frogmore Bottling Company is of the highest quality. Each stage, from ingredient preparation to final inspection, reflects our dedication to delivering excellence to our customers. We’re proud of the work we do and the products we produce, and we’re excited to continue bringing you the best of what we have to offer.