The Challenge
As the craft beverage market evolved, Ore Dock Brewing Co., a Michigan-based brewery, sought to expand beyond beer to meet growing demand for gluten-free and non-beer beverage options. They decided to launch Breakwater Hard Seltzer, a high-carbonation seltzer line that would appeal to a broader customer base.
The challenge was to create a standout seltzer with a unique mouthfeel and enhanced flavor, all while maintaining operational efficiency and avoiding costly upgrades to their existing canning system. Many in the industry believe counter pressure fillers are required for high carbonation beverages, which can add significant complexity and costs. Ore Dock needed a solution that would let them achieve their creative vision without limiting the versatility of their operations.
The Solution
Ore Dock Brewing Co. had their Cask system in place for their beer production. Cask’s atmospheric filling technology, known for its ability to handle carbonation levels exceeding 2.8 vol CO2, allowed them to seamlessly expand into high-carbonation products like Hard Seltzer without requiring additional equipment.
The versatility of Cask’s equipment enabled Ore Dock to:
- Experiment with carbonation levels: Breakwater Hard Seltzer achieved an average of 3.3 vol CO2, significantly higher than most commercial seltzers.
- Package a broad range of beverages: From craft beer to high-carbonation seltzers, their Cask system supported Ore Dock’s commitment to product innovation.
- Optimize operations: The system ensured smooth running and minimal waste, even with the elevated carbonation levels required for Breakwater.
The Results
The launch of Breakwater Hard Seltzer enabled Ore Dock to diversify their product line and reach new customers, particularly Lake Superior visitors looking for refreshing, gluten-free options during the summer. The success of Breakwater validated their decision to innovate within their existing system.
"Our packaging operators love the days we package seltzer. It is straightforward, there’s no waste, and it’s smooth running. The Cask system controls carbonation very well and lets us experiment with our parameters to achieve the mouthfeel we are looking for."
Cask's filling technology gave Ore Dock the confidence to explore new beverage categories without limiting their creativity or efficiency, allowing them to maximize the versatility of their equipment.
Cask Filling Technology
Cask’s atmospheric filler is uniquely capable of handling high carbonation beverages without requiring counter pressure systems. This versatility allows breweries to:
- Expand product lines: From beer to seltzers, ready-to-drink cocktails and beyond, Cask systems adapt to a range of beverage types.
- Minimize product loss: Cask systems can handle high carbonation while still maintaining <1% product loss; versus counter pressure fillers that often see 8%+ product loss on higher carbonated beverages.
- Achieve product innovation: Experiment with carbonation and flavor profiles to create standout beverages without having to limit your beverage to the constraints of your packaging equipment.
For breweries like Ore Dock, Cask’s equipment empowers creativity without adding complexity or cost, making it the ideal solution for dynamic craft producers.
🔗 Read the Full Data Lab on High Carbonation
