What's it like working a winery bottling line? Earlier this month I took a day to find out, and worked a bottling line at Garretson Wine Company. Originally I had a whirlwind tour of the Central Coast planned... Matt and I would drive down to Paso Robles Thursday night, I would work the line Friday while he entertained himself, and then we would drive down to Solvang (which, until I was fifteen minutes north of Paso Robles, I thought was only another half hour south when in reality it is 90 minutes away) and spend Saturday and Sunday wine tasting and checking out the area. Well, unless I lost fingers in a horrible bottling accident or got buried under a ton of bottles a la I Love Lucy.
Then Matt got sick. He felt terrible and terrible about it, and we both knew it was better if he stayed home. I cancelled the second night's stay in Solvang, and decided to come home a day early since I was stranding him at home sick and with no car. I got my six pack of Diet Coke in bottles (because I get kind of frantic if I travel without it, having been stranded in a motel with only Diet Pepsi machines one too many times before) and I was ready to go.
Anyway, I got down to Paso Robles after being stuck in traffic on 101 for a million hours (really, it took me 3 1/2 hours when it should have been around 2 1/2). I got in fairly late, and spent a miserable night worrying about the next day and watching terrible movies on TV. What would I have to do? What if I messed everything up? I couldn't get to sleep and took some mostly-useless-to-me-but-I-was-desperate melatonin at 12.30 AM and then ended up waking up all night anyway. I gave up on sleep a little before 6 , figuring I had to be up by 6.30 anyway, to get to the winery by 7.30. Needless to say, I got there in plenty of time.
The winery is in a industrial complex off Route 46 to the east of Paso Robles, and, as would make sense, has a tasting room in the front. Behind that is the huge warehouse and office area of the winery. The bottling truck (who knew there was such a thing) was parked around the side. It looked kind of like a taco truck (I have included some crappy pictures from my cell phone so you can get the idea), except there was a conveyor belt that made an upside down U in it, if you were looking in from the back. Later I learned that bottles came in on the bottom right side of the U, were fed from the belt into a single line, and were then filled with argon, filled with wine, capped or corked at the back end where the bend in the U would be (we were using Stelvin screwcaps that day) and came around where they were put into boxes. The boxes were then slid down to be loaded on to the pallet, where they were then checked by Mat Garretson, sealed, rearranged slightly on the pallet, and packaged up with huge industrial saran wrap.

I felt out of place when I got there since everyone there seemed to know each other already, but I met a few folks (and dogs) and felt a little more at ease. It was a funny situation, since I never actually learned the names of some people I worked with all day. There were seven volunteers, two guys who worked the truck (they knew how to fix things on the line), and two people from the winery, plus Mat. Mat is awesome, and is not the kind of guy to stand around and direct people... I saw him do everything that day, from driving the forklift to packing boxes to climbing into a dumpster filled with cardboard to be recycled and jumping up and down like a gorilla to pack it down so we could put more in. Everyone milled around for a few minutes and chatted and set stuff up, and then it was time to get to work. I wasn't sure where to go, but got pointed at the head of the line, to get started bottling rose.
Three people worked the front of the line. One herded the bottles into the system via the conveyor (they often fell over or got stuck) and two handed bottles to that person by placing them on a stationary table at the head of the conveyor. Two people had to do that job since we were working with pallets of wine bottles (144 bottles a layer, six layers high) and one person had to get on a ladder for the upper layers and then crouch on the ground below the truck and hand them up when we got to the bottom layers. When one pallet was nearly empty, someone on a forklift would bring the next one over and then replace the old pallet with the new (all while people were grabbing bottles from the new pallet to keep the line going). I started out doing bottle-herding, and once I got the hang of sweeping bottles onto the conveyor, feeding them in and also making sure they didn't get snagged on the way into the line, things were fine. I only felt like Lucy once or twice.
I worked the front with two guys, Ed and another guy whose name I didn't get. They were both very cool and knew the ropes and even gave me tips on places to go down around Solvang (wineries and restaurants) when we were done for the day. I found it hard to talk since the machinery was really loud and they were often facing away from me, but we got to chat when something would break and we could stand in the sun and wait for it to get fixed. We also had music to listen to, which amused me to no end because we were listening to an eighties station. I had to suffer through Animotion and U2 but got to hear some Echo and the Bunnymen and even Public Image Limited's "This Is Not A Love Song" which I thought fantastically amusing at 9.30 in the morning, because I had had no sleep.
It was freezing all morning and things didn't get warm until maybe 2 in the afternoon. My feet were even cold, and they are usually too warm in the shoes I was wearing. Next time I am definitely bringing gloves.
I learned a few important things:

1. Wine bottles that have been out in 35 degree weather all night are really cold.
2. If you handle a couple hundred/thousand wine bottles, your hands turn black and shiny.
3. One tipped bottle will, in two seconds, equal three tipped bottles, which will, in two more seconds, tip about eight more bottles, if you let it happen, so be alert and move fast.
4. Time has not done that stupid Romeo Void song any favors.
Bottling is extremely boring but I was thrilled to not be sitting at a desk all day. You have long periods where you get into a rhythm and things flow smoothly and it is almost meditative, only to have one bottle tip and then it all goes south. We worked all morning on rose, and then in the afternoon did two bottlings of Syrah (one small, about 200 cases, and another larger, about 500 or 600 cases, I think). In the afternoon I moved all the way to the front of the line and worked on getting bottles off the pallet and to the person working the belt and found that balancing on a ladder trying to yank bottles off a pallet is pretty difficult. And your arms get tired! When we ran out of wine to bottle and they walked the line to get the last out, my arms were happy to be done. I ended up dead tired that night but the next day I felt fine (and after some Danish pancakes I had a lovely day of wine tasting, the highlighted with Beckmen and Sanford).
It was a good experience (and hard work) and I would definitely go back and do it again. The folks there also talked me into going to Hospice du Rhone after the bottling-- we lingered for a while afterwards and talked and tasted some wine and Mat's family showed up with Fireball (especially exciting because I love bulldogs) so I will be headed back down to the area in May. I mean, I figure after ZAP I should probably go to a tasting that isn't unpleasant, and everyone promised me that Hospice would be fine (tickets are limited too, which is a great thing).
Randomly, Mat Garretson makes the darkest rose I have ever seen. It smells like a rose (lots of cranberry), tastes like a rose, but it's darker than a lot of Pinot Noirs I've seen. It would be a great thing for stumping people at a blind tasting (not that blind tastings aren't baffling enough, really).
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