The entire process of bottle making is almost fully automated. An automated
feeder separates a stream of molten glass into individual gobs
by cutting it with what is,effectively, a giant scissors. These gobs
are then dropped through tubes in a moving track. The gob is shaped
into what looks like a short bottle with thick walls and is called a
parison. The parison is transferred
to a final mould made of iron, which moves up and clamps around the
glass. Air is blown into the glass until it acquires the final shape
of the mould. This procedure involving expansion is called blowing.
The bottle is then released from the mould and annealed.
Annealing is done by reheating the glass and gradually cooling it. This
process removes the stresses and strains in the glass after shaping.
This is a most important step and if not done the bottles can explode
on contact with a hard object (like another bottle) as a result of the
build up of tension caused by uneven cooling. After the bottles have
cooled to room temperature, they are inspected and finally packaged.
Glass
Glass is made by melting together several minerals at very high temperatures. Silica in the form of sand is the main ingredient and this is combined with soda ash and limestone and melted in a furnace at temperatures up to 1700oC. Other materials can be added to produce different colours or properties. Glass can also be coated, heat-treated, engraved or decorated.
Shirdley Sand is a vast swathe of sand deposited by wind since the last glaciation. It spreads from the Sefton Coast several kilometres inland, and can create dunes up to 75m (246ft) tall.
The sand, centred around the hamlet of Shirdly Hill was an invaluable resource as an ingredient in glassmaking hence the location of the UK major glassmaking facilities in St Helens. As late as the 1970s the fields around Bickerstaffe and Lathom were still being excavated for the pure Shirdley Hill sand by the Pilkington Brothers Glass Company whose international research facility is situated at Lathom.
Shirdly Hill, situated about 5km (3 miles) south-east of Southport is now flat !
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Split or Piccolo |
1/4 bottle |
187 ml |
Half or Demi |
1/2 bottle |
375 ml |
Bottle |
1 bottle |
750 ml |
Magnum |
2 bottles |
1.5 l |
Jeroboam |
4 bottles |
3 l |
Methuselah |
8 bottles |
6 l |
Salmanazar |
12 bottles |
9 l |
Balthazar |
16 bottles |
12 l |
Nabuchadnezzar |
20 bottles |
15 l |
Melchizedek |
40 bottles |
30 l |
Piccolo (1/4 bottle) 187ml
Italian for ‘small’. 187ml is approximately two glassfuls – Champagne
glasses usually hold around 125ml but it is not usual to fill them.
Demi (1/2 bottle) 375ml
French for “half,” and also known affectionately as a ‘Fillette’, or ‘little
girl.’ At 375 milliliters, 4 glasses, the equivalent of half a bottle.
Magnum (2 bottles) 1.5 litres
Latin for “great,” this describes a bottle that is twice the standard
size and yields 16 glasses.
The names of the six largest Champagne bottles are of
Biblical origin:
Jereboam (4 bottles) 3 litres
Jeroboam (actually Jeroboam II), was the King of Israel during the year
of Rome's founding (753 BC)
Rehoboam (6 bottles) 4.5 litres
A son of Solomon, Rehoboam (meaning "the clan is enlarged"
according to Willard Espy) became king of Judah in 933 BC.
Methuselah (8 bottles) 6 litres
Methuselah was an antediluvian patriarch described in
the Old Testament as having lived 969 years and whose name is synonymous
with great age. He may well have evolved from a character of earlier Sumerian
legend who lived for 65,000 years.
Salmanazar (12 bottles) 9 litres
Shalmaneser (alternatively spelled Salmanazar) was an Assyrian monarch
who reigned around 1250 BC.
Balthazar(16 bottles) 12 litres
Balthazar ("King of Treasures") is the traditional
name of one of the Three Wise Men, the other two being Melchior ("King
of Light") and Caspar ("The White One"). Many scholars
nowadays tend to characterize the trio not as kings but rather as Zoroastrian
priests, while others speculate that at least one of them was a king --
namely Azes II of Bactria who reigned from 35 BC to 10 AD. Whatever their
occupations, legend and German tourist brochures have it that the Three
Wise Men -- or at the very least their skulls -- lie buried in a golden
shrine at Cologne Cathedral.
Nabuchadnezzar (20 bottles) 15 litres
Nebuchadnezzar, originally nabu-kudurri-usur meaning
"Nabu protect the boundary," became King of the Chaldean Empire
in 604 BC. He was actually the second Nebuchadnezzar; a less celebrated
Nebuchadnezzar I preceded him by 500 years.
Melchizedek (40 bottles) 30 litres
is an enigmatic figure twice mentioned in the the Old Testament. Melchizedek
is mentioned as the King of Salem, and priest of God Most High, in the
time of the biblical patriarch Abram. He brought out bread and wine, blessed
Abram, and received tithes from him, [Genesis 14:18-20]. Reference is
made to him in Psalm 110:4 where the victorious ruler is declared to be
"priest forever after the order of Melchizedek." This size bottle
should yield around 320 glasses.
Big bottles can be difficult to handle with the average full Nebuchadnezzar,
for example, weighing in at around 38kg (84 lb) which means that the bottle
itself weighs more than the Champagne it contains. The bottle weighs about
23kg (51 lb)
There are occasionally exceptions to these standard bottle types. Sometimes
bottles of different sizes and shapes are used for special occasions or
for special cuvées. For example, Pol Roger made a 20 fluid ounce/ 60cl.
bottle (imperial pint) specially for Sir Winston Churchill, which his
manservant brought him each morning at 11 am. Extremely rare is the 18
litre, 24 bottle Solomon (Salomon in French), and even
rarer is the gigantic 27 litre, 36 bottle Primat (pronounced
"preemah"), which weighs in at 65 kilos!
Big bottles have a novelty value, but because of the
difficulty in moving such a large mass for riddling and disgorgement (a
full Nebuchadnezzar weighs 38 kilos!), in most houses the secondary fermentation
is carried out in magnums. The wine is then decanted into the larger bottles.
This inevitably results in a loss of pressure. Some would say that there
is a chance of more oxidation as a result of this, and that Champagne
from a giant bottle is inferior to that from the magnum it was fermented
in.
A notable exception to this practice is the house of Drappier, who are
very much the big bottle specialists. They carry out bottle fermentation
in even the very largest sized bottles. Imagine riddling and disgorging
a Primat by hand! Michel Drappiersays that an empty Primat bottle costs
around £400! They have to be specially made, and also pressure tested
so as to withstand more than 90lbs. per sq. inch (6 bar).
Each year well over one billion wine bottles are made
around the world. An explanation of what you may expect from the shape
and color of a wine bottle on your merchant shelves can be helpful.
Bordeaux Style
The
most common type bottle used is the Bordeaux bottle. The bottle shape
is tall with high shoulders and is straight sided. It is a favourite of
almost all wine producing countries. Green glass is used for red wines
and clear glass for whites. This bottle shape represents the classic Bordeaux
soft reds, and dry or sweet whites.
Burgundy Style
A slope-shoulder bottle hints of a full-bodied red wine characterized
by the wines of Burgundy and Italy. These are sturdy, heavy bottles, with
a slightly fatter girth than other wine bottles - although you may only
notice this if stacking them. This shape is also widely used throughout
the New World for Chardonnay and Pinot Noir.
Alsacian
This
bottle is long and slender. It has something frivolous, a bottle with
a lively radiation. The Alsacian bottle is just as the Mozel bottle made
out of green glass. It is used for wines such as Riesling, Gewurtztraminer
and Pinot.
Rhine and Mozel ![]()
The Rhine (Hock) and Mozel bottle is identical in shape to the
Alsacian bottle, slender and fine in form. However, the Mozel bottle is
made with green glass and the Rhine bottle from brown glass. Wine from
the Rhine ('Hock') spends its life in a bottle similar in shape to the
Mosel/Alsace bottle. Once again, however, the style of wine can vary,
and a little label knowledge is required.
Champagne
The
familiar Champagne bottle is the heavy bottomed, thick-lipped, dark green
bottle used for the world-famous beverage. The Champagne bottle shape
is the only one that has a compelling scientific justification behind
it. It has thicker glass that is able to withstand the higher pressure
that is found with Champagne (up to 90 psi).
Fortified Wine Bottle![]()
Fortified wine bottles used for Port and Sherry are sturdy and
typically have a bulge in the neck supposedly in order to help capture
the sediment, as the wine is decanted. Many of these wines, especially
if for drinking young, would be sealed with a cork stopper rather than
a long cork.
Similar
in style to the Burgundy, but not so fat. In addition, some may bear a coat
of arms on the neck, particularly Châteauneuf du Pape. The traditional Côtes
du Rhône bottle is similar in shape, but with more angular sloping shoulders.
New World Shiraz may have a similar bottle, but often this is not the case.
Le Remueur: 1889 engraving of the man engaged in the laborious daily task
of turning each bottle a fraction [Wikipeda.org]
After aging (a minimum from one and a half to three years), the sediment
(lees) must be consolidated for removal. The bottles undergo a process
known as riddling (remuage in French). In this stage the bottles
are placed on special racks called pupitres. This places the
bottles at a 45 degrees with the cork pointed down. Every few days the
bottles are given a slight shake and turn and dropped back into the pupitres
(eventually the angle is increased). The drop back into the rack causes
a slight tap, pushing sediments toward the neck of the bottle. In about
6 to 8 weeks the position of the bottle is pointed straight down with
sediment in the neck of the bottle. This manual way of riddling sparkling
wine is still used for Prestige Cuvées in Champagne, but has
otherwise been largely abandoned because of the high labour costs. Mechanised
riddling equipment called gyropalettes are used instead.
Our last Outback event was a very enjoyable Tutored Whisky Tasting featuring Glenfiddich,
Full details will posted very soon in <News and Events>
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