Purchasing packaging equipment is a decision that will impact a winery’s operations for the next 10 to 20 years — the life expectancy of most packaging machinery. In the 1990s, empty bottles arrived at wineries in cases for manual unloading and placement on the filling line. Converting to bulk bottles and depalletizing machinery increased automation levels and reduced costs throughout the industry.

 Beth Zarnick‑Duffy
Area Sales Manager / Clevertech North America, Inc. “A big reason wineries changed from manual to automated depalletizing of bottles was to increase production efficiency while improving worker safety and reducing labor costs,” explains Beth Zarnick-Duffy, who worked on many of these conversions. “Wineries continued to automate because finding and retaining qualified workers became even more difficult in the past few years. Companies also began factoring COVID-19’s negative impacts on the workplace into their decisions about when to increase the level of automation for their filling and packaging lines.”

During her 30-year career, Zarnick-Duffy also watched wine consumption rise, which increased the need for more highly automated capital equipment. As consumption grew, more wineries reached a production capacity level that justified the CapEx to move from manual labor to automated machinery.

Zarnick-Duffy recently joined Clevertech North America as a sales manager. This family-owned business offers a range of machines that includes palletizers, depalletizers, case erectors, packers and sealers, strapping systems, stretch wrapping machines and pallet labeling systems for the consumer packaged goods industry.

“We gladly work with customers to engineer and produce equipment customized to meet their application requirements, layout constraints, technical specs and future expectations”

“I realized that Clevertech’s equipment was well suited for the wine industry,” says Zarnick-Duffy, “ and I believe many wineries will choose to work with Clevertech because it designs equipment that is as future-proof as possible.”

Fortune 500 companies around the world have trusted Clevertech equipment and support teams to efficiently and reliably package their products for over 25 years. In the past few years, it has expanded that success to US wine producers on both coasts, and Zarnick-Duffy is confident that its leading-edge technology will lead to more wine industry projects.

Differentiating features and benefits

Transferable skills: All Clevertech equipment have human-machine interfaces (HMI), electrical cabinets and parts in common. When a customer trains plant personnel on one machine and then purchases a different one, such as a carton erector, packer and palletizer, for a new or existing line, this commonality lets the operators use the shared system management language to control any machine and restore systems during malfunctions without additional training.

Better decision-making: Clevertech designs its equipment with Industry 4.0 capabilities that allow them to integrate production operations data with data from the plant’s Enterprise Resource Planning (ERP), Warehouse Control System (WCS) and Warehouse Execution System (WES). The combined database delivers visibility, insights and predictive analytics that increase machinery value, improve maintenance, maximize efficiency and minimize downtime.

Packaging Machinery Language (PackML): Clevertech machines rely on PackML to collect data from different lines, shifts, plants and business units, as well as other suppliers’ machinery that use the same language. The standard look and feel reduces learning curves, simplifies integration into business systems with Open Platform Communications (OPC), enhances productivity through initiatives such as Overall Equipment Effectiveness (OEE) analysis and simplifies Manufacturing Execution Systems (MES) functions.

Total Productive Maintenance (TPM): Clevertech has incorporated TPM into its machine designs since 2012. This proactive and preventative maintenance minimizes disruptions, defects and accidents while maximizing efficiency. Machines have modular belts instead of chains, which reduces the time between repairs or replacements. See-through Lexan covers give plant personnel the ability to quickly and easily see and assess problems, and parts are fully accessible for easy maintenance and easy operability. The result is a boost in product quality, reduced downtime and longer equipment lifespans.

Designed for innovation 

Clevertech’s unique modular approach to machine design enables it to provide out-of-the-box solutions. It offers complete simulations of proposed packaging lines and 3-D renderings so customers can visualize machines and identify potential bottlenecks while defining the project scope.

“We gladly work with customers to engineer and produce equipment customized to meet their application requirements, layout constraints, technical specs and future expectations,” says Zarnick-Duffy. “Clevertech’s range of beginning and end-of-line equipment is the largest in the market and includes high-level, ground-level, robotic, conventional and hybrid solutions, which allows it to offer the best technical solution.”

Clevertech’s dedication to after-sales service is a critical component in its success with some of the biggest US brands. Its Florida support team uses knowledge gained on the factory floors of packaging plants to help customers, and experienced personnel throughout North America join them to deliver best-in-class support service to customers.

In a final, personal note, Zarnick-Duffy adds that she is excited to once again work with Fausto Savazzi, who joined Clevertech’s Sales Team a few years before her. 

“Fausto was the first person from a packaging machinery supplier I ever met,” she explains. “Since then, we have worked together on and off to serve the wine industry for more than 20 years. We have partnered with many wineries to help improve their level of automation and efficiency. I am confident that we will be doing the same for many more years as Clevertech continues to expand its wine industry business.”

Traditionally, the cost of purchasing a bulk glass depalletizer for bottling has been out of reach for many wineries. However, current market pressures bring bulk glass into reach for many wineries as the industry grapples with rising costs.

In addition, fuel, labor and corrugated packaging costs have escalated, making cased glass increasingly expensive. According to data from the U.S. Bureau of Labor Statistics, glass prices have escalated 44% over the past decade and have risen steadily at an average annual rate of 6% since 2020. These expanding costs have transformed what was once a 5 to 6-year ROI for the bulk conversion into an 18-month to 3-year ROI.

Given today’s economic challenges, it may be time for producers to reevaluate their math.

Market Pressures Amplify the Case for Bulk Glass
Transitioning from cased glass to bulk glass is not only cost-effective but also offers long-term benefits in efficiency, sustainability and competitiveness.

“The numbers have changed,” says Marty Sychowski, a 30-year packaging industry veteran, “with many medium-sized and larger wineries seeing the cost of glass increase up to 50% in the past few years. Using bulk glass can save money in several ways, and those savings make it much easier to justify the equipment purchase.”  

“Now that the numbers have changed, wineries can offset equipment cost with their savings from buying bulk glass. The ROI for equipment is better than it’s ever been; with wineries able to regain their ROI in 3 years or less,” Sychowski emphasizes.

Clevertech, a global leader in automation solutions, can make the transition not only feasible but highly advantageous to wineries. by producing packaging machinery yielding a faster return on investment (ROI) while providing long-term competitive advantages that enhance operational efficiency, reduce environmental impacts and lower costs. 

Cost Advantages of Bulk Glass Containers
Bulk glass containers provide significant cost reductions in multiple areas:

• Reduced Packaging Costs: Unlike cased glass, bulk glass eliminates the need for costly materials like partitions and cases[1] . This change lowers purchasing costs and minimizes waste disposal fees.
  

• Shipping Savings: Palletized bulk glass maximizes transport efficiency. Without cases, more bottles can fit on a pallet, reducing shipping weight and fuel costs while minimizing storage needs.
  

• Streamlined Operations: Bulk glass simplifies logistics by eliminating the need for manual handling of cases, reducing labor costs and freeing up resources for other production areas.

Optimized Storage and Shipping
Switching to bulk glass improves storage and shipping efficiency:

• Maximized Space: Bulk glass uses less packaging, allowing producers to store more bottles within the same footprint and reduce warehousing expenses.
  

• Lower Freight Costs: The denser and lighter design of bulk glass pallets reduces transportation costs, further enhancing margins and sustainability.

Environmental Benefits Drive Consumer Appeal
Adopting bulk glass also supports sustainability goals:

• Reduced Waste: Less packaging material means fewer resources consumed and less waste generated.
  

• Lower Carbon Footprint: Improved shipping efficiency reduces emissions across the supply chain.
  

Consumers increasingly prefer brands with eco-friendly practices, and switching to bulk glass helps wineries align with this growing demand. 

Clevertech: Delivering ROI and Long-Term Success
Clevertech’s automated machinery is engineered for efficiency, flexibility, and reliability. Additionally, the equipment is designed so that it can be easily adjusted to handle different bottle sizes, operating speeds, or packaging formats so that it not only meets today’s needs, as well as the evolving market needs of the future.

Clevertech’s bulk glass depalletizers options seamlessly[2]  integrate with other automated machinery, drastically reducing manual labor requirements. Clevertech can provide a single machine – depalletizer only - or an entire bottling line.

Conclusion: A Strategic Investment for the Future
Transitioning from cased glass to bulk glass is not only cost-effective but also offers long-term benefits in efficiency, sustainability, and competitiveness. In an industry where cost pressures and sustainability are paramount, switching to bulk glass is more than a financial decision—it’s a strategic move toward long-term success.

The benefits are clear: lower material costs, and streamlined operations translate to rapid ROI—often within three years or less. And as production increases, ongoing savings multiply, further improving profitability.

Clevertech works closely with wineries to determine the best solutions for their needs, ensuring optimal production efficiency and environmental stewardship.

To learn more about Clevertech’s automation & equipment solutions, visit their website or contact them directly at  b.zarnick@clevertech-group.com. 

🍇🍷 The Wait is Almost Over – WIN Expo is Tomorrow!

As the Presenting Sponsor, we are excited to welcome you to Booth #220 on December 5th at the Sonoma County Fairgrounds in Santa Rosa, CA.

Discover how Clevertech’s cutting-edge front and end-of-line solutions can streamline your wine packaging process and help boost efficiency.

Our experts are ready to share innovative strategies tailored to the wine industry’s unique needs.

We can’t wait to meet you and explore the future of wine packaging together!

Certified Origins Block Buster Testimonial Premier!

From streamlined efficiency to accelerated ROI and a long-term OEM & client partnership - watch the full journey unfold.

From Time-lapse installation to successful production, this testimonial highlights the impact of Clevertech’s best-in-class automation, straight from the voice of our client.

 
Hear how our partnership with Certified Origins made a real impact:
• Boosting operational efficiency
• Strengthening supply chain transparency
• Building long-term trust
• Delivering scalable results

This is more than a testimonial; it's a testament to what's possible when vision meets execution.

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? ???? ?? ?? ???? ?? ??? ??????? Let’s act today to preserve tomorrow

WIN Expo was a success - and if you missed it, here’s the big takeaway: Clevertech North America makes bottling automation simple, scalable, and cost-effective.

Our modular approach means you start with what you need now—depalletizer, case packer, or palletizer-and add more as your production grows. Seamless integration minimizes downtime and maximizes ROI.

Wondering how Clevertech’s technology can fit into your space? Schedule a meeting with one of our Sales Managers to see how we can enhance your plant's performance. Whether you run a small winery or a large-scale operation, Clevertech is here to help you overcome labor, space, and budget challenges—one smart step at a time. 

Contact Clevertech today to learn how modular automation can transform your bottling line.

Discover how Clevertech engineered and installed advanced palletizing and depalletizing systems for Certified Origins, a leader in the USA food sector. From streamlined efficiency to accelerated ROI and a long-term OEM & client partnership - view the impact of Clevertech’s best-in-class automation.

Small Steps, Big Gains: Affordable Efficiency with Winery Automation

The wine industry is undergoing a seismic shift. Changing consumer preferences, generational taste evolution, and a surge of lower-cost grapes and bulk wine from global markets are reshaping the competitive terrain.  To stay ahead, wineries are rethinking their operations, streamlining workflows, expanding outreach, and embracing automation as a strategic lever for growth.

Companies facing financial constraints often turn to automation, a proven strategy that can help reduce labor costs and increase production efficiency in packaging and bottling lines. Among these innovations, packaging automation stands out, delivering measurable cost savings, production agility, and scalable infrastructure, empowering wineries to protect margins and adapt swiftly to market demands.

When financial constraints tighten, automation becomes more than a luxury; it’s a lifeline. For wineries, automating packaging and bottling lines can dramatically reduce labor costs and boost operational efficiency, even when capital is limited. That’s where Clevertech North America comes in.

To help wineries navigate automation without the burden of a full-scale upfront investment, Clevertech North America offers a modular solution designed to grow with winery’s production needs. Leveraging decades of automation expertise, Clevertech delivers fully integrated, customizable systems that align with your specific goals, space constraints, and long-term vision. Instead of requiring a complete end-to-end bottling line from day one, wineries can start with a single component that addresses a pressing need and expand seamlessly over time, building toward a fully automated system at a pace and scale that fits their operation. It’s a smarter, more flexible path to automation that delivers both immediate impact and future-proof scalability.

Oak Ridge Winery: A Modular Success Story
Oak Ridge Winery in Lodi, California, was an early adopter of Clevertech’s modular strategy. Under the leadership of Bottling Manager Steven Uline, the winery implemented three key components: a depalletizer, partition inserter, and case erector. These upgrades enhanced bulk glass packaging and integrated smoothly with their existing line.

Uline says, "These upgrades are part of a larger goal to improve how we handle bulk glass packaging and ensure everything operates seamlessly with the speed and flow of our existing line. Clevertech was able to meet our tight installation deadline without interfering with our production schedule, and their systems offered the advanced diagnostics we needed to eliminate downtime and simplify troubleshooting."

When a winery client engages Clevertech to evaluate its bottling line, the process begins with a collaborative evaluation.

Clevertech's North American Sales Manager, Beth Zarnick-Duffy, explains, "We work with customers to engineer customized equipment that meets their requirements, layout constraints, technical specs, and future expectations."

Clevertech engineers conducted an on-site assessment at Oak Ridge to observe operations, measure line speeds, and identify bottlenecks, and flag safety concerns. The resulting solutions included a depalletizer capable of handling full bulk pallets - reducing forklift reloads and enabling rejection of entire stacks without halting production. The upgraded case erector featured an expanded magazine, allowing operators to load knockdowns more efficiently.

Results That Speak for Themselves
“Since installing the new Clevertech equipment,” adds Uline, “we've seen major improvements in efficiency. Changeovers are faster, and we can diagnose and resolve machine downtime more efficiently. It's made the entire line more productive and easier to manage. The benefits go beyond just speed. Clevertech was committed to coming up with solutions that worked for us. Their team was extremely responsive and really took the time to understand our specific needs. Would I recommend working with Clevertech again? Absolutely!”

Zarnick-Duffy adds that CleverTech's support doesn't stop at installation. "Our clients know that Clevertech is their first point of response and will always answer their call, at any time of the day or night, to help them get their systems up and running. If it can't be done remotely, we'll send someone to fix it."

Clevertech Is Helping Wineries Thrive Amid Industry Disruption
For more information about Clevertech’s modular automation solutions, contact Beth Zarnick-Duffy at b.zarnick@clevertech-group.com to start the conversation.

In today’s fast-paced production environments, space is a luxury and efficiency is non-negotiable. That’s why Clevertech introduces the Small Footprint Depalletizer: a compact, high-performance solution designed to transform your line without taking up unnecessary space.

Whether you’re working with bottles, cans, or cartons, this depalletizer is engineered to handle a variety of formats with speed, precision, and care. Its modular design allows for seamless integration into existing lines, minimizing downtime and maximizing throughput.

Despite its reduced footprint, it doesn’t compromise on performance. With advanced motion control technology and a user-friendly interface, it delivers consistent, reliable operation shift after shift.

Operators love the simple, smart controls designed for ease of use and fast changeovers. And with built-in diagnostics and remote support capabilities, maintenance is quick and cost-effective.

From startups with limited space to large facilities looking to optimize every square foot, the Small Footprint Depalletizer is the right fit for businesses that refuse to compromise.

Clevertech – where smart engineering meets real-world needs. The future of compact automation is here.

Curious about how to streamline Your Winery's Post-Production Process?
Is your winery ready to boost efficiency and overcome labor challenges through automation?

Learn how Clevertech, a family-owned leader in automation solutions, is bringing its expertise to the wine industry with fully integrated systems that boost efficiency, reduce downtime, and foster lasting partnerships.

Stop by our Unified Symposium Booth #A2304 to Learn more!

Fuel your mind over lunch! 

Want to learn how your winery can increase efficiency with leading capital equipment?
Curious as to why so many wineries are choosing to partner with Clevertech?

Clevertech invites you to schedule a Lunch & Learn session! This is a great opportunity to enjoy lunch on us while learning how bulk & case depalletizers, case packers, carton erectors, partition inserters, case palletizers, and more can help your company improve the bottom line. If you have thought about the next step for your winery or want to explore your possibilities to increase efficiency but need to know where and how to start, this type of session is for you!

Our lunch & learn sessions are limited to 2 per month for the wine industry, so schedule your date asap with Beth Zarnick-Duffy, a 30-year industry veteran. 

b.zarnick@clevertech-group.com / 814-571-1768

www.clevertech-group.com

We hope to see you soon!

After an successful experience at the Simei Trade Show in Milan, we were thrilled to welcome so many California winery customers to our headquarters in Cadelbosco di Sopra.

It was a pleasure to connect, discuss ongoing projects, explore new opportunities, and share ideas on how to enhance and optimize bottling and packaging processes.

Your trust, collaboration, and enthusiasm are what drive us to continue innovating and delivering solutions that exceed expectations for the winery industry.

Thank you for being part of this journey of success with us—we look forward to building even stronger partnerships!

Visit CLEVERTECH at Booth #220 during the 2024 WIN Expo for a chance to take home a luxurious Copper Cane Wine Box—featuring a selection of exceptional wines! 

Join us at booth #220 to meet our team, watch a video showcasing our capabilities, and discuss how we can partner to enhance your packaging line while enjoying a complimentary glass of wine from Copper Cane Wine & Provisions.

Register for FREE when using our promo code CLE22 https://lnkd.in/dwwp7E_h 

Don’t miss this chance to win a taste of luxury and explore cutting-edge  front and end-of-line solutions. We’ll see you there!

CLEVERTECH is the presenting sponsor of the 2024 North Coast Wine Industry Expo - WINExpo, we proudly invite wine and spirits professionals to join us in Booth #220 on December 5^th, at the Sonoma County Fairgrounds, in Santa Rosa, CA.

Clevertech: Shaping the Future of Wine & Spirits Packaging
As a trusted partner in fully integrated front and end-of-line packaging solutions, CLEVERTECH brings decades of expertise to the wine industry. Our solutions cater to the unique requirements of wine production and packaging, from depalletizing to case packing to palletizing and much more. With innovations in customization, efficiency, and integration, we’re here to support wine producers in achieving operational excellence and optimizing their packaging lines to maintain quality.

What to Expect from Clevertech at WIN Expo 2024

Visitors to our booth will learn how CLEVERTECH's technology can streamline the wine packaging process and achieve their capex goals with cutting-edge front and end-of-line solutions to boost efficiency. Our team will demonstrate personalized solutions for:

• Depalletizing and Palletizing: Improve labor cost and achieve ROI faster.
• Case Packing: Ensure secure and visually appealing packaging.
• Complete Packaging Automation Lines: Get a full-spectrum view of how our solutions can transform your entire packaging line.

Join CLEVERTECH in booth #220 to meet our team, watch a video showcasing our capabilities, and discuss how we can partner to enhance your packaging line while enjoying a complimentary glass of wine from Copper Cane Wine & Provisions.

Whether you’re looking to optimize efficiency or automate your production line, CLEVERTECH has solutions that can transform your winery’s operations.

Clevertech's Booth at the 2024 Pack Expo Event!

With decades of automation expertise, Clevertech delivers fully integrated, customizable solutions to streamline production and enhance efficiency for wineries across North America.

The family-owned business is one of the hallmarks of the wine industry. These are the oldest type of commercial organization. Studies have found that they are more likely to thrive, in part because they approach business from a legacy perspective. One of the reasons for this success is the inherent multi-generational focus.

“The family legacy matters,” says Beth Zarnick-Duffy, who has worked with many family-owned wineries in her 30-year career and is now a sales manager for Clevertech North America (NA). “It's more personal, more about relationship building.”

“I agree. It’s a big plus,” says Giorgio Zanardi, Clevertech NA’s General Manager. “Our parent company, Clevertech SPA, is a family-owned company. That means when we do business with our customers, it's not just about business and profits. It's about building a partnership with them that lasts years. Our clients have a direct relationship with us here in North America, but, of course, the owner of Clevertech SPA in Italy is also involved. I can tell you he has direct conversations with our customers.“

Holistic and fully integrated solutions

Since its founding in 1987, the Italian company has become a leader in the automation sector, designing and manufacturing depalletizers, palletizers, case packers, partition inserters, carton erectors, and fully integrated handling systems for a wide variety of industries, including home care, personal care, petfood, container manufactures, beverage, and in the last 2-3 years, wine and spirits. It provides its holistic and fully integrated engineering solutions to the world’s largest producers of consumer goods, including Procter & Gamble, Henkel, Clorox, Smucker's, Folgers, and Kroger.

Clevertech has brought its experience with developing highly customized solutions for these companies to the wine industry, along with our robotic and traditional pals and depals at high or low level. These engineering solutions are fully integrated so that every piece of technology has standardized mechanical and electrical design and components. The machines also share a software language, Pack ML, with a library of programming code modules that are reused across the machines, making it faster to program and increasing reliability.

“This full integration is our signature,” says Zanardi, who has over 18 years of experience in the industrial packaging equipment business. “We are the only company capable of delivering a fully integrated system to the wine market.”

Having the same design throughout translates to a higher line and operator efficiency. Operator training on one machine in the line means immediate familiarity with all modules. As they move from screen to screen, they see the same schematics, format and alarms. This level of standardization minimizes downtime and boosts efficiency. Clevertech's gold-standard approach to full line integration distinguishes it from companies that merely integrate machines without this level of consistency.

These fully integrated systems align with the design guidelines of TPM (Total Productive Maintenance), a holistic approach to maintenance that gives the operator a full view of each machine and its components. They can stand outside the machine safety area and visually detect and troubleshoot any problems that arise much more quickly, thus reducing downtime and recovery time.

Design and Testing

Clevertech’s unique modular design allows it to configure each line to match the customer’s space and functionality requirements. This customization through standardization allows Clevertech to tailor the machines and layout without requiring a complete redesign. It makes options like a compact system that can depalletize empty glass and palletize cases from two different lines.

Zanardi points out, “We’re bringing advantages we’ve learned in other markets to the wine industry.” He offers the example of being the first to bring a particular type of VAT/ FAT (Factory Acceptance Testing) from the food industry to the wine industry. Clevertech’s different approach to FAT ensures that everything Clevertech sells is thoroughly tested and fully assembled at its facility and invites the customer to see all their equipment from the line fully assembled and running that the same production speed it would be in their facility, prior to preparation for delivery. That means a vertical start up on site; reassembly, commissioning and startup at the customer site is much faster, which saves the winery time and money. Another innovation is doing a complete simulation of a one-of-a-kind project or a new application that is in the conceptual stage to ensure a new idea will work—even before it is sold. Proof in the concept!

Clevertech’s North American headquarters are in a 29,000 sq ft facility in Fort Myers, Florida, where it hosts an aftermarket team, a team of 50 engineers and technicians, a warehouse of spare parts and 24/7 support that is backed by Clevertech's eight worldwide subsidiaries. The Florida team regularly travels to customers on preventative maintenance schedules or to do periodic audits.

“It’s really critical that our customers know Clevertech North America is their first point of response,” says Zarnick-Duffy, “and if they call us, someone will pick up the phone any time of the day or night, listen to the problem and walk them through how to get their system up and running. If it can’t be done remotely, we’ll send someone to fix it.”

To learn more about Clevertech's automation & equipment solutions, visit their website or contact Beth directly at or b.zarnick@clevertech-group.com

WIN Webinar: Unlocking the Power of Automation: Streamline Your Winery’s Post-Production Process

Explore the benefits of automation in winery operations, from evaluating equipment needs to solving labor challenges and boosting efficiency, with insights from industry experts.

How can a winery determine what equipment is the right solution for its specific operational needs? What are the steps involved in integrating automation technologies into post-production process? How can automation help with labor challenges and improve overall efficiency while staying competitive in the market?

Join us on October 3rd at 11:00am for an in-depth webinar that guides wineries through the complete process of evaluating post-production equipment, from initial assessment to implementation of solutions to solve challenges of increasing efficiency. We’ll explore how to determine if your winery can benefit from automation equipment and the key steps involved in integrating these technologies. Discover how automation can address labor challenges, improve efficiency, and help your winery evolve its operational processes. 

We’ll showcase winery clients utilizing various equipment solutions, allowing you to see firsthand how these customizable systems work in real time to enhance productivity and efficiency. Learn from industry experts about the latest innovations in winery automation and how they can help your business stay competitive and sustainable in today’s market.

Speakers: