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Bottles and pressure: what glass will and will not hold

Which bottles are safe for sparkling cider?

In short

A bottle intended for sparkling wine is a different object from a still-wine bottle. It is heavier, thicker, has a deep punt to distribute stress, a reinforced neck and finish designed for a crown cap or a mushroom cork, and it is manufactured and tested against a design pressure.

Manufacturers state a working pressure and a higher test pressure for these bottles; the figures commonly quoted for sparkling-wine glass are around six bar of working pressure. A still-wine bottle carries no such rating and no such testing.

Because pressure in a bottle-conditioned cider is produced by fermentation and continues while sugar remains, a bottle is not a container that holds a known pressure — it is a container that holds whatever pressure the yeast eventually generates.

Why sparkling bottles are shaped the way they are

The punt — the deep dome pushed up into the base — is structural. A flat glass base under internal pressure is a plate in bending and concentrates stress at the edge; a domed one carries the load in compression, which glass is far better at. The heavy shoulder and the thick, reinforced neck do the same job at the other end, and the pronounced ring at the mouth exists so that a wire cage has something to hook under and so that a crown cap has a proper sealing surface.

Weight is the visible consequence: an empty sparkling-wine bottle is noticeably heavier than a still-wine bottle of the same volume. That difference is glass thickness, and glass thickness is what holds the pressure.

Bottles used for beer sit between the two. A returnable beer bottle is designed for the carbonation levels of beer and is substantially stronger than a still-wine bottle, while a lightweight one-trip beer bottle is designed to be used once and to be filled with a product at a known, controlled carbonation. Neither is designed for the pressures a champagne-method cider reaches.

What actually fails, and how

Glass does not fail at a single pressure. It fails from a flaw — a scratch, a chip at the rim, a bruise from a bottle knocking another on a line or in a crate — and the pressure at which a flawed bottle fails is much lower and much less predictable than the pressure a sound one will take. This is why reusing bottles requires inspection, and why bottles that have been scuffed around the body by years of handling are retired in commercial reuse systems.

Failure is also temperature-dependent, because pressure in a sealed bottle rises with temperature and because a warm bottle-conditioned cider ferments faster. A case of bottles that has been stable in a cold cellar can become dangerous in a warm room or a car in summer.

When a pressurised bottle fails it does not crack quietly. It fragments, and the fragments travel. Injuries from exploding bottles in home brewing and cider making are documented and include serious eye and hand injuries.

The rules that follow

Bottle safetyNever put a carbonating or carbonated cider into a still-wine bottle, a screw-cap wine bottle, a jar, or any bottle whose original contents were not carbonated. Use bottles made for sparkling wine or for beer, matched to the carbonation intended, and use the closure the finish is designed for. Inspect every bottle for chips at the rim and scratches on the body, and reject any that are damaged. Store bottle-conditioned cider cool, in a crate or a closed box, out of living space. Wear eye protection when handling suspect bottles, and if a batch is over-carbonated, chill it thoroughly before doing anything at all with it.

Bottle types in use

Bottles and what they are made for
BottleDesigned forClosure it takesSuitable for carbonated cider?
Sparkling-wine (champagne) bottleTraditional-method sparkling wine; manufactured and tested to a stated pressureCrown cap during conditioning; mushroom cork and muselet for finishYes, to the manufacturer’s rating
Returnable beer bottleBeer carbonation, repeated washing and reuseCrown capYes, at beer-range carbonation
Lightweight one-trip beer bottleA single fill at a controlled carbonationCrown capOnly at modest carbonation, and once
Swing-top bottleCarbonated soft drinks and beerIntegral ceramic or plastic stopper with a gasketYes at modest carbonation, if the gasket is sound
Still-wine bottleStill wine at atmospheric pressureStraight cork or screw capNo, under any circumstances
PET bottleCarbonated soft drinksScrew capYes within its own rating; it deforms visibly before failing, which is a useful warning, but it passes oxygen

A historical footnote

The connection between strong glass and sparkling drinks is not incidental. English glasshouses of the seventeenth century, fired with coal rather than wood, produced a darker, stronger bottle than was available elsewhere, and it was that bottle — together with cork — that made it possible to keep a fermenting drink under its own pressure. Worlidge’s account of cider in the 1670s describes bottling cider with some sugar remaining and stopping it tightly to produce a sparkling drink.

The practice therefore predates its association with Champagne, and it also predates any understanding of why bottles burst. Contemporary accounts of losses in the cellar are frank about the proportion of bottles that failed.

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