In order to provide winemakers with the finest cork closures in the world, Ganau’s manufacturing allows for precision control over each step of production. From maintaining cork forests to deep-cleaning processes, Ganau has revolutionized the way raw cork is processed to produce corks that exceed the highest industry standards.
From Forest to Delivery, Learn More about Ganau’s Production Process
As a 100% natural, sustainable and recyclable material, Ganau’s commitment to cork begins with a dedication to nurturing company-owned forests and supporting selected Mediterranean growers.
Ganau’s sustainable practices rely on decades of knowledge and a skilled team, in order to guarantee the cork oaks are never harmed during the extraction process.
As a renewable resource, Ganau understands the amazing benefits of cork and is dedicated to long-term sustainable practices.
Once the raw cork has been harvested, the planks are selected for thickness and quality, thus discarding those with any critical defects. The chosen planks are stored at Ganau facilities in Sardinia, Italy and Montijo, Portugal, where the utilization of plastic pallets and sloped concrete floors serve to improve air circulation and drainage, eliminating the possibility of contamination. The raw planks are left to cure for a minimum of eight months in order to stabilize before being processed into corks.
REVO-BOIL utilizes superheated water and steam to deeply penetrate cork planks, effectively reducing TCA levels. Operating at temperatures of up to 120°C, REVO-BOIL consistently achieves maximum purification while minimizing water usage and preventing cross contamination between
batches. The proprietary Ganau Revolution purification process represents the latest stage in the development of traditional boiling methods and is unrivaled in taint reduction.
Cork planks are hand-cut into strips within 24 hours of completing the Ganau Revolution cleaning process, preventing an unnecessary waiting period at high moisture levels which can lead to mold growth and possible contamination. After passing visual inspection, the strips are hand-cut by skilled employees, first into squares and then into cylindrical natural corks. The excess material created during the production of natural corks and discs is subsequently broken down into granules to be later molded into agglomerated corks.
Following the cutting stage, the raw corks and discs are submitted to Ganau’s second cleaning process. Centered on a custom-manufactured system, TECH-FLOW is a disinfection process that effectively removes TCA and other unwanted off flavor molecules from cork using controlled steam and heat flow.
QUANTUM is a chemical-free technology that operates on the principle of thermal desorption. By employing high temperatures of up to 180°C alongside a steam counterflow mechanism, QUANTUM effectively eradicates TCA and other sensory deviation molecules from cork granules – all while preserving cork’s natural properties.
Each cleaning cycle is tested for TCA (through our GCMS’s) before proceeding to the next stage of molding.
Finished cork products are rinsed of any production residue, using water for a natural finish or hydrogen peroxide for a white finish, before being rapidly dried by specialized machines to immediately remove any excess moisture. Corks are sorted first electronically and then by employees, simultaneously dividing the finished corks into different visual classes and eliminating any corks with flaws or critical defects.
Whether order quantities are in the millions or few thousands, Ganau offers cork branding to all of its clients. Ganau can assist in designing artwork, as well as work with clients to execute laser, fire and ink branding that meets their requirements. Fire branding is the preferred method of prestigious winemakers, since the final brand consists of a neutral imprint, whereas ink branding may benefit clients that require complex artwork or a more economical alternative to fire branding. Laser branding is the newer and more precise technology available for both side and cork ends.
In the final step of the production process, all cork products are lubricated using Ganau’s exclusive system, which achieves perfectly even and consistent lubrication for excellent bottling performance, optimal seal and easy extraction. Once lubricated, corks are moisturized, packaged and sealed to ensure maximum quality upon delivery.
