Top Line

Water is one of the most critical—and increasingly scrutinized—resources in modern winemaking.

From cleaning tanks and floors to maintaining oak barrels, cellar operations can consume thousands of gallons daily. With rising sustainability expectations and operational costs, reducing water use is not just good for the environment, it is good for business.

• Water conservation is becoming an issue in modern winemaking.
• In the past, much of the conversation centered around vineyard irrigation.
• Today, one of the most overlooked areas of water consumption occurs in the cleaning and maintenance of barrels.
• Small efficiency improvements per barrel can translate into thousands of gallons saved per year in your operation.

The Challenge

• Traditional oak barrels, while prized for the unique flavor addition and maturation with O2, also come with a significant sustainability issue: water usage.
• Cleaning and sanitizing an oak barrel typically require several high-impact water events. These generally include: a lees dump and hot-water rinses, followed by a sanitation phase using steam, ozone, or a citric acid neutralization conditioning rinse.
• Traditional multi-step oak barrel cleaning cycles remain highly water-intensive and can consume between 20 and 60 gallons of water per barrel.
• In cases of heavy tartrate buildup or microbial contamination, “deep cleaning” protocols may require a full-volume soak of 60 gallons or more. Multiply that across hundreds of barrels.

The Solution: Three Practical Ways Cut Water Usage

1. Rethink Oak Barrel Cleaning Practices

Oak barrels are essential for many premium wines, but they are also one of the biggest water consumers in the cellar. This process can use dozens of gallons per barrel, especially when dealing with heavy tartrate buildup or microbial concerns.

Traditional cleaning methods involve:

• High-pressure rinsing
• Repeated flushing cycles
• Chemical washes followed by extensive rinsing

How To Reduce Water Use

• Use targeted cleaning tools instead of open spray methods
• Adopt foam or gel-based cleaners that cling to surfaces and require less rinsing
• Implement dry pre-cleaning steps (scraping, brushing) before introducing water
• Standardize cleaning protocols to avoid overuse “just to be safe”

2. Upgrade Cleaning Systems and Processes

A large portion of cellar water use comes from inefficient cleaning methods. Work to change your methods and track your water usage per task (barrel cleaning, tank cleaning, floor washdowns).

Processes That Reduce Water Use

• Use high-efficiency spray nozzles that reduce flow and maintain pressure
• Consider automated cleaning systems (CIP) for tanks and lines
• Invest in trigger-controlled hoses instead of free-flowing water.
• Digitally track your area-zone cleaning schedules to prevent repeated washdowns.
• Shut off hoses between uses.

3. Utilize Alternative Vessels Such as Flextanks

Alternative vessels such as O2-permeable Flextanks are gaining fast traction with wineries as the best fermentation and storage substitute for oak barrels.

Unlike oak barrels, Flextanks:

• Have smooth, non-porous interiors.
• Eliminate deep absorption issues that demand frequent, intensive washing.
• Have reduced need for chemicals.
• Require minimal scrubbing or pressure washing, and have faster rinse cycles.
• Require significantly less cleaning time and water.

How Flextanks Reduce Water Use

• Typical cleaning of a Flextank can be completed with a quick rinse with a light cleaning solution if needed.
• This can reduce water usage by 70–90% per vessel, depending on the winery’s previous barrel protocols.
• Many wineries are adopting a hybrid approach, using oak for specific programs while shifting a portion of their production to Flextanks.
• This not only reduces water use but also lowers labor and maintenance costs.

The Bottom Line

Reducing water use in the cellar does not require sacrificing cleanliness or wine quality. Wineries can significantly reduce water consumption while improving efficiency and sustainability by:

• Improving how oak barrels are cleaned
• Upgrading cleaning tools and processes
• Integrating alternative O2-permeable vessels such as Flextanks where appropriate

In an industry rooted in agriculture and environmental stewardship, and with situational downturns in snowpack and water runoff, smarter water use is not just a trend, it is the future.

For wineries looking to reduce water consumption, improve operational efficiency, and prepare for future sustainability demands, reevaluating cellar practices is critical. Barrel cleaning represents a significant opportunity for improvement.

Flextank Is Ready to Help You Grow

Looking to reduce water consumption, improve production and revenue? Let us talk. We are ready to help you scale with ease.

• Call: +1-360-450-2694
• Email: flexsales@flextank.com
• Visit: www.Flextank.com

Winery Resource Page Gives Wineries new ways to reduce operational expenses,  increase award possibilities, revenue, efficiency and productivity

Vancouver, WA – July 8, 2025 – Flextank, the leader in advanced oxygen-permeable polyethylene tanks for wine, cider, spirits and craft beverage fermentation and storage, today announced the company has developed a new Winery Resource Page that provides wineries with information, tips, and methods to help them increase production and reduce costs. 

The new Winery Resource Page provides online tools, expert guidance, and winery production  and project consultation tips that are designed to help winery operators reduce their OpEx overhead and increase their productivity, sustainability, and margins.

The information guides winemakers through common challenges and requirements they face such as: How to increase production space, sustainability, efficiency, cuvee turnaround, cleaning, portability and productivity. These tools will help winery CFOs and winemakers: 

• Estimate in real-time a Winery’s projected production, OpEx costs and potential revenue.  

• Assess wine production vessel requirements by gallons or liters.  

• Reduce overhead and OpEx costs, and expand capacity and production efficiency.  

• Create new, sustainable long-term production and storage solutions.  

The Winery Resource Page allows the winemaker or vineyard operator to send Operational Expense calculations to their email address, or contact Flextank directly for additional free consultation. The Winery Resource Page is available HERE.

“Wineries and vineyard operators are under margin pressure now, and have asked us for insight on how to help them reduce their expense line and bring-to-market more sustainable, market driven beverages more quickly,” said Flextank CEO, Jon Smalley. “For 25 years, Flextank has helped wineries reduce costs, create award-winning beverages, and increase revenue.”

The Winery Resource Page also includes new information on how Vortex (egg-shaped) Apollo Vessels are the best shape for producing complex wines more quickly and efficiently. Apollo Vortex Vessels speed natural fermentation and increase beverage production turnaround. Apollo Vessels use the naturally occurring CO2 and heat evolution to simulate upward movement. At the top, the fermenting wine hits the cooler outside of the vessel and is drawn down the outer sides. This creates a vortex of healthy, performing yeast.

“Many wineries are struggling with increasing costs and shifts in customer demand. The new  Winery Resource Page information and calculators are designed to help winery operators  become more efficient, productive and revenue generating,” added Mr. Smalley. “We’ve  created ideas to help winemakers reduce barrel and labor costs, and increase capacity.”

About Flextank  

Flextank advanced oxygen-permeable polyethylene tanks and hoppers are the leading wine,  cider, spirits and craft beverage fermentation and storage solutions available worldwide. Flextanks are made in the USA and have a lifetime guarantee. Flextanks help beverage makers  have affordable, efficient operations. More than 5000 craft beverage production operations  worldwide rely on Flextank for controllable, sustainable production. To learn more about  Flextank and its products, visit: www.flextank.com. Phone +1-360-450-2694.

Flextank Provides Winery Conference Attendees with Methods to Cut Costs and Increase Margins and Revenue

April 1, 2025 - Flextank, the leader in advanced oxygen-permeable polyethylene tanks for wine, cider, spirits, and craft beverage fermentation and storage, successfully presented innovative ways for wineries to reduce operational expenses (OpEx), expand production, increase efficiency, and improve revenue and margins at the WiVi Central Coast Conference & Tradeshow, held on March 13 in Paso Robles. At Booth #227, Flextank’s team of winemaking experts engaged with winery professionals, demonstrating how Flextank solutions can help lower costs and enhance productivity. 

“For more than two decades, blind taste trials have confirmed that there is no difference in the quality or oak profile of wines produced in a Flextank compared to a traditional oak barrel,” said Flextank CEO, Jonathan Smalley. “Winemakers using Flextanks enjoy the benefit of producing award-winning wines at a fraction of the cost of using traditional oak barrels. With today’s economic pressures on the wine industry, it’s time to rediscover a proven, more sustainable technology that creates quality wines.”

During the event, Flextank provided free online tools, expert guidance, and consultation tips to help winery operators reduce OpEx overhead and increase productivity, sustainability, and margins. These tools assist winery CFOs and winemakers in:

• Estimating real-time winery production, OpEx costs, and potential revenue.

• Assessing Flextank and barrel requirements by gallons or liters.

• Reducing overhead and OpEx costs while expanding capacity and production efficiency.

• Developing custom, durable long-term production and storage solutions.

Winery professionals were able to access the Real-Time Flextank Revenue + Operational Expense Calculator at the WiVi Booth #227, as well as online. Users could send their results directly to their email via the interactive calculator. Additionally, attendees obtained free downloadable checklists and content designed to help their wineries increase productivity and revenue.

About WiVi Central Coast Conference & Tradeshow

The conference and tradeshow featured sessions by top industry leaders on regional viticulture, enology, and DTC topics, providing attendees with insights into new trends and technology. For more information, visit: https://wivicentralcoast.com/.

About Flextank

Flextank’s advanced oxygen-permeable polyethylene tanks and hoppers are the leading wine, cider, spirits, and craft beverage fermentation and storage solutions available worldwide. Flextanks help beverage makers achieve affordable, efficient production. More than 5,000 wineries, cideries, and craft beverage production operations worldwide rely on Flextank for efficient, controllable, sustainable production. Flextanks are cost-effective, sustainable, efficient, controllable, and award-winning. Flextank is based in Vancouver, Washington, with product dealers around the world. To learn more about Flextank and its products, visit: https://flextank.com/.

Modern winemaking demands storage solutions that blend innovation with practical results. Both Flextanks and concrete eggs offer excellent fermentation dynamics and temperature control, yet Flextanks provide clear advantages in cost, flexibility, and maintenance. Here’s a closer look at why Flextanks are the smarter choice.

Cost Efficiency

When storing 450 gallons, Flextanks come in at around $1870, whereas concrete eggs typically exceed $10,000. This significant difference makes Flextanks the clear choice for winemakers looking to maximize efficiency without sacrificing quality. By opting for a Flextank, you can free up resources for other critical areas of your winery.

Fermentation and Temperature Control

Both options support robust yeast circulation and natural internal convection, ensuring a consistent fermentation. However, Flextanks provide the same benefits without the hefty price tag or the permanence of concrete eggs. Additionally, their seamless construction makes precise temperature control more predictable and manageable.

Mobility and Wine Transfer

A major advantage of Flextanks is their inherent mobility:

• Ease of Movement: Flextanks can be easily relocated, offering flexibility in layout and operations.
• Simplified Wine Transfers: Their design simplifies the process of moving wine, reducing the risk of contamination and minimizing oxygen exposure during transfers.

In contrast, the fixed nature of concrete eggs may restrict operational flexibility, particularly in dynamic production environments.

Cleaning and Sanitation

Maintaining high sanitation standards is crucial:

• Flextanks: Their smooth, non-porous surfaces allow for straightforward cleaning without the need for extensive pretreatment, effectively reducing the risk of residual buildup.
• Concrete Eggs: May require more rigorous cleaning procedures to avoid potential cleaning impediments.

Micro-Oxygenation Benefits

Flextanks offer a controlled level of micro-oxygenation, similar to what you’d find in traditional wooden barrels. This subtle oxygen exposure can help enhance the complexity of the wine, providing a modern solution that still honors time-tested winemaking practices.

Conclusion

Flextank Helps La Mesa Vineyards Deliver Award-Winning Wines

Sweep Gold Medals At Three Prestigious California Wine Competitions 

La Mesa Vineyards uses Flextank vessels to capture gold medals 
and create top small-batch artisan-style wines of exceptional quality.

Vancouver, Wash. – August 06, 2024 – Flextank, the leader in advanced oxygen-permeable polyethylene tanks for wine, cider, spirits and craft beverage fermentation and storage, today announced one of the company’s premier Flextank customers, La Mesa Vineyards, recently swept prestigious industry wine awards in three separate competitions.

The Amador County, Calif.-based La Mesa Vineyards received several Gold, Double Gold and Best-in-Class awards at the respected 2024 Peninsula Underground "Under the Radar" California wine competition, 2024 Orange County Fair Commercial Wine competition, and at the 2024 California State Fair competition.

Competition is Fierce. Flextank Helps Deliver Award-Winning Results.

With nearly 5,000 wineries in California, the competition for consumer preferences and loyalty is fierce. Winemakers must rely on steady, solid methods and vessels in their creation of an awarded, and highly demanded beverage from the simplicity of a small fruit.

For La Mesa Vineyards, the Flextank advanced oxygen-permeable polyethylene tanks were an essential element in the creation of their award-winning wines in all processes: from crush to fermentation to bottling.

In the 2024 Peninsula Underground "Under the Radar" California wine competition, La Mesa’s award-winning wines included: La Mesa 2023 Muscat Canelli: Double Gold, Best Muscat; La Mesa 2023 Chardonnay: Double Gold, Best Chardonnay; La Mesa 2022 Soleil: Gold, Best Value; and La Mesa 2022 Zinfandel: Gold, Best Zinfandel.

La Mesa Vineyards also won two major awards at the 2024 Orange County Fair Commercial Wine Competition. At 96 points, the La Mesa 2023 Chardonnay received the highest score among all 2,500 wines entered in the competition, receiving both a Double Gold and a Best of Class award.

Also, La Mesa Vineyards was decorated with two major awards at the 2024 California State Fair: The La Mesa 2020 Primitivo received Double Gold, with 99 points, "Best of California"; and the La Mesa 2020 Barbera received Gold, with 95 points.

Previously, La Mesa Vineyards won Gold Medals at the largest competition in North America, the 2024 San Francisco Chronicle Wine Competition. La Mesa took the Double Gold with the 2020 Tierra GSM, and Gold on its 2020 Primitivo, and 2021 Syrah and Mourvedre wines.

"As a relatively new winery to Amador County, we're entering our wines in the big California wine competitions for the very first time,” said La Mesa Vineyards owner-winemaker, Côme Laguë. “All the early work we have done to research clones, innovations in winemaking techniques, and using our Flextank technology are paying off. We've benefited from encouragement from our family and friends during years marked by drought, wildfires, frost events, lockdowns and generally tough business conditions. So, it's gratifying to emerge from all that, placing among the very best in the state by an expert panel of judges."

Flextank Helps Wineries Increase Efficiency, Production and Revenue   

Flextank vessels are individually designed to have an adjustable oxygen-permeable surface area-to-volume ratio and related wall thickness and configuration. These superior qualities make Flextanks ideal for craft beverage production – from stem to glass.

Flextanks are also engineered to provide higher production capability in less space and produce efficient, controllable, stackable, sustainable production. This production efficiency helps craft beverage makers boost the capacity of their barrel rooms, reduce bottle costs and increase revenue.

“Many craft beverage makers are in a tight bind now. They need to both reduce overhead costs and increase production,” said Jon Smalley, Flextank CEO. “Flextank helps craft wineries assess and thereby reduce their current expenses, increase their ROI, better utilize their space, increase labor efficiency, expand operations, and increase margins.”                                                                  

Wineries, Cideries and Craft Beverage Makers Can Calculate Benefits

Flextank also provides Craft Beverage Makers a convenient way to assess production costs, estimate efficiency, map out how to expand capacity, improve output and revenue, and send the results directly to their email – via a free Production and Operational Expense (OpEx) Calculator. The Real-time Revenue and Operational Expense Calculator is available HERE (https://flextank.com/send-my-barrel-calculation-results/).

About La Mesa Vineyards

La Mesa Vineyards was founded in 2011, in the higher altitude and granitic red soil of Amador County’s Shenandoah Valley. The winery focuses on creating small-batch artisan style wines of exceptional quality. For more information, visit the La Mesa Vineyards website at https://lamesavineyards.com/.

About Flextank 

Flextank advanced oxygen-permeable polyethylene tanks and hoppers are the leading wine, cider, spirits and craft beverage fermentation and storage solutions available worldwide. Flextanks help beverage makers have affordable, efficient production. More than 4000 craft beverage production operations worldwide rely on Flextank for efficient, controllable, sustainable production. To learn more about Flextank and its products, visit: www.flextank.com. Phone +1-360-450-2694.

“Winemakers . . . are often pressured to do things like reduce staff costs, or costs generally . . . Wine is a social beverage – its production should be social too.” – Oliver Styles, winemaker at Winemaker Halcyon Wines- Hawke’s Bay NZ

“There is also the battle to reduce costs yet increase quality. We need to be profitable to be successful but defend what we need to successfully create wines of quality and distinction.” – Mark Beaman, Winemaker, Kenwood Vineyards

“Sustainability is becoming key. Organics. biodynamics, natural winemaking, to paperless systems. Everything we can do to reduce waste and give back and nurture the land and sky the better.” – Paul Dawick, Head Winemaker at Mills Reef,

“. . . we need to see a new wave of winemakers who are focused on innovation, sustainability, and inclusion.” – Lauren Barrett, Principal Consultant, By and By Solutions LLC

“. . . many grape growers are demanding better terms and that wineries provide picking bins, and arrange and pay for trucking among other things.” – Aaron Lieberman, Winemaker at Iris Vineyards

These, and other notable winemakers and industry consultants, chimed in to answer the question, “What are the current challenges winemakers are facing?” In Sommelier Business this week.

A top theme that these wine experts shared was that there need to be improvements in productivity and sustainability for wineries to remain competitive in today’s changing market.

Craft beverage makers need a solution to this challenge. And it’s right here.

Winemakers in the Know – Know Flextank.

Wineries, cideries, spirits, mead and craft beverage makers worldwide rely on Flextank for efficient, controllable, sustainable production. Flextanks are:

• Cost effective – Reduce barrel costs, labor, space and time. Deliver higher revenue.
• Efficient – Easier to move, store, stack and clean. Provide increased productivity.
• Controllable – Breathe like a barrel.
• Award-Winning – Hundreds of craft beverage makers have won industry awards using Flextank.
• Proven – After more than 25 years, 95% of all Flextanks are still in use by thousands of operations.
• Sustainable – Include a lifetime guarantee. Eliminate extensive cleaning, water and chemical use.

 It’s easy to transport empty or full Flextanks to different locations within the operation, including fermentation, blending, fining, maturation, production and cleaning stations.

Affordable. Efficient. Production.

Flextanks, made from polyethylene, are flexible and versatile vessels. Flextanks are recognized industry-wide for their sustainability, all-stage production and aging flexibility, cost-effectiveness, and ease of handling. For every stage of the winemaking process – from harvest to bottling.

The Flextank vessels are engineered to provide higher production capability in less space. This production efficiency helps winemakers, cidermakers and craft beverage makers boost the capacity of their barrel rooms, reduce bottle costs and increase revenue.

Flextanks are manufactured with the highest quality FDA and European Food Safety Authority-approved, North American resins.

Make it Happen. Now. We Can Help.

Let us help you – schedule your free call. 1:1 consulting session now.

Request Your Consultation.

Submit the consultation request form with your availability. We will contact you with a time that works.

Click Here

1. Prepare a List of Challenges.

Come prepared to discuss areas where you could use our help, and your project timeline (even if it’s ASAP).

2. Speak to our Experts.

During your consultation, one of our experts will discuss your workplace challenges and high-level ideas and solutions.

3. Create a Plan

We understand that no two worksites are the same. Our consultants will review your challenges, then develop strategies to help you reduce costs, maximize efficiency, and increase revenue.

4. Put it to Work

Your advisor will follow up to ensure you have all the information, planning and resources needed to complete your project.

Flextank can help wineries and craft beverage makers. It’s easy. Give us a call at + 1-360-450-2694

Or simply fill out the form HERE. We’ll help you make it happen.

• Cost effective– Reduced barrel costs, labor, space and time. Higher revenue.
• Sustainable– Lifetime guarantee. Eliminate extensive cleaning, water and chemical use.
• Efficient– Easier to move, store, stack and clean. Increased productivity.
• Controllable– Breathe like a barrel.
• Award-Winning– Hundreds of craft beverage makers have won industry awards using Flextank.
• Proven– Over 25 years, 95% of all Flextanks are still in use by thousands of operations.

https://flextank.com/2024/03/28/fix-the-current-challenges-winemakers-are-facing/

New Flextank Production OpEx Calculator Provides Projected Efficiency, Space, Cost Savings, and Ways to Improve Productivity, Expand Production, Storage, Sustainability and Margins. 

Vancouver, Wash. – March 12, 2024 – Flextank, the leader in advanced oxygen-permeable polyethylene tanks for wine, cider, spirits and craft beverage fermentation and storage, today announced availability of a free Production and Operational Expense (OpEx) Calculator for beverage makers.

The new Flextank Production and OpEx Calculator helps Wineries, Cideries. Spirits and Craft Beverage Makers assess their projected production and OpEx costs, estimate production efficiency, map out how to expand capacity, and improve output and revenue growth.

The new Flextank Calculator helps Craft Beverage Makers:

• Estimate in real-time projected production, OpEx costs and potential revenue.
• Map out how to reduce overhead and OpEx costs, and expand capacity and production efficiency.
• Assess oak barrel requirements by gallons or liters.
• Develop custom, durable long-term production and storage solutions.
• Obtain free downloadable results that will help owners, operations managers and CFOs map out their 2024 marketing and production strategy.

“Many Cideries, Wineries and Craft Beverage Makers are in a tight bind now. They need to both reduce overhead OpEx costs and increase production,” said Jon Smalley, Flextank CEO. “Craft Beverage producers have to find new ways to increase their ROI, better utilize their space, increase labor efficiency and overall revenue. This new Calculator helps these beverage producers assess and thereby reduce their current expenses and plan how they can scale and expand their operation, and increase margins.”

Flextank Calculator Availability

The new calculator is available now. Beverage production, operational and financial planners can access the Real-time Flextank Revenue + OpEx Calculator HERE (https://flextank.com/send-my-barrel-calculation-results/)  and send the results directly to their email.

Flextank consultants can also provide Craft Beverage Makers with expert guidance, as well as production and project consultation that is oriented to help operators increase their: productivity, sustainability, efficiency, revenue, and margins.

About Flextank 

Flextank advanced oxygen-permeable polyethylene tanks and hoppers are the leading wine, cider, spirits and craft beverage fermentation and storage solutions available worldwide. Flextanks help beverage makers have affordable, efficient production. More than 4000 Cideries and craft beverage production operations worldwide rely on Flextank for efficient, controllable, sustainable production.

SmaK Plastics is the parent company of well-known industry brands such as  Flextank. SmaK Plastics is based in Vancouver, Washington with product dealers around the world. To learn more about SmaK Plastics and its brands, visit: www.smakplastics.com.

Flextank has partnered with one of the leading cooperage companies in the world to provide a proprietary staves system under the brand name FlexStaves that are designed to work in conjunction with our tanks.  Available to winemakers is a portfolio of different staves bundles types that are used to make a wide range red and white wines.

Each pack of FlexStaves is one barrel equivalent and serves to mirror aging in traditional oak barrels. So instead of putting wine into oak, winemakers can achieve greater control but putting the desired amount of oak into the wine. This system extends new barrel oak by exposing the maximum amount of wine to the maximum surface of the oak. And unlike barrels, once a desired profile is achieved, the oak to be easily removed.

Head to Flextank.com to try out our FlexStave calculator and all of the flavor profiles we offer!

Come See Us for Free Next Thursday at WinExpo in Booth #143 for:

• How to Save a Struggling Business
• THE Original Barrel Replacement Tanks Made in the USA
• Ways Poly Tanks are Better Than Oak Barrels
• Meet Flextank President Jon Smalley

I Want a Free WinExpo Floor Pass ($20-30 Value)