Tapped Apple Part 3

Canning Day

Part 3 of our series about the Tapped Apple production process finds us back at their warehouse, getting ready to can and label 600 gallons of their First Bite Hard Cider. It’s their most popular hard ciders; dry and not too sweet, and this particular batch first started fermenting over a year ago. 

Their canning process has evolved from self filled and hand labeled to what is now a fully automated process, aside from packing and stacking. 

Empty cans are loaded onto a feeder conveyor belt, which then aligns the cans single file under a series of sprayers that deliver a precise mixture of CO2 and hard cider. The mixture is set and monitored by John IV, who says that he is doing his job right if he doesn’t have anything to do. Meaning everything is set and operating at the right parameters. 

Once the mixture is in the can, a top is pressed on and each can is cleaned and pushed through a labeler. Every aspect of this process has been fine tuned and honed for Tapped Apple’s exact needs. 

The canning system and labeler are two completely different units that John IV connected via a 3D printed plate and bumper. Once it is dialed in, he will have a permanent version machined out of a material of his choice. 

Random selections of filled, capped and labeled cans are pulled out of the receiving tray for weighing and inspection; any irregularities are diagnosed and fixed with as little interruption to the process as possible. 

The Fastest Hands in Westerly

Once the cans are out of the label maker, it’s up to Lori to load them onto cardboard trays and apply the plastic 6 pack can carries. She bartends at their Tasting Room most nights and has some serious moves. 

Once she corralled and clipped the cans together, John V and I would take turns stacking the finished cases on a nearby pallet. The whole operation has been designed to be as close to the starting point and final destination of their cans as possible, so as to improve efficiency and limit physical exertion. It’s loud and impressive. 

I love the ingenuity of well thought out designs. Nothing is wasted during their canning process, and John IV has devised an efficient and iterative approach to all aspects of their operation.

This post is part of a three part series about Tapped Apple’s production process. Part 1 takes a look at how their fermented cider is transported and cared for, while part 2 documents their fermentation process.

Tapped Apple’s tasting room is located at 37 High Street in Westerly, Rhode Island, and their products are available in restaurants and liquor stores throughout the state. 

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