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Handling pressurised bottles safely

How do I know if a cider bottle is dangerously over-carbonated, and what should I do about it?

In short

A bottle that is refermenting beyond what its glass was designed for can fail, and glass failing under pressure produces fragments travelling fast enough to cause serious injury, particularly to the eyes.

The warning signs are recognisable: a crown cap that has lifted or domed, weeping or crusting around the closure, a cork pushing out of the neck, a bottle that gushes violently when opened cold and settled, and a previously still cider that has become cloudy and hard.

The response to a suspect batch is to move it cold, keep it away from people, protect yourself and open the bottles deliberately over a sink — not to leave it and hope.

Why this is a real hazard

Carbonation stores energy. A bottle at three or four atmospheres of internal pressure holds a quantity of compressed gas that, if the container fails, is released in an instant and accelerates the fragments outwards. A purpose-made sparkling bottle is thick, heavy and punted precisely to contain this; a lightweight still-cider bottle, a reused screw-top bottle or a preserving jar is not.

The pressure in a bottle is set by how much fermentable sugar was available to the yeast, and it can go far beyond what any bottle is rated for. A cider bottled before fermentation had genuinely finished, or a sweetened cider that was not stabilised, has a large sugar reserve and no upper limit on where the pressure goes.

Temperature adds to it in two ways. Warmth restarts dormant yeast, and warmth raises the pressure of the gas already present. A batch that was stable in a cold shed can become dangerous in a warm room.

Bottles usually fail when handled — picked up, knocked, or opened — which is precisely when a person is closest to them. The injury pattern is lacerations and eye injuries, and eye protection is not an over-reaction when dealing with a suspect batch.

The signs of a bottle that should not be opened casuallyA crown cap that is domed, lifted or rusting at the crimp; cider weeping or a sticky crust around the closure; a cork pushing out of the neck; a bottle that is noticeably harder or colder to the touch than its neighbours; a still cider that has become cloudy and fizzy; a plastic bottle from the same batch that has gone rigid. Any of these means treat the whole batch as suspect, not just that bottle.

How bottles become over-carbonated

Causes, and what makes each one worse
CauseWhat happensAggravating factor
Bottled before fermentation finishedRemaining sugar ferments in the bottle with no reliefWarm storage; a cider that appeared stable because it was cold
Too much priming sugarPressure overshoots the intended levelUneven mixing, so some bottles are far worse than others
Sweetened without stabilisingAdded sugar plus viable yeastAny warmth at all
Sugar-tolerant spoilage yeastFerments sugars a normal strain leaves aloneLong storage; contamination at bottling
Malolactic fermentation in bottleCarbon dioxide produced from malic acid after bottlingWarm storage of a cider with high malic acid and live bacteria
Unsuitable bottlesOrdinary pressure exceeds what the glass can holdReused thin-walled or damaged bottles

What to do with a suspect batch

Preventing it

Bottle only when fermentation is genuinely complete, confirmed by stable gravity readings taken several days apart at a temperature warm enough for yeast to be active. A gravity reading taken once tells you nothing about whether fermentation has stopped or merely paused.

Prime by calculation rather than by habit, mix the priming solution thoroughly through the whole batch rather than dosing bottle by bottle, and fill a plastic test bottle from every batch so the pressure can be monitored without opening glass.

Use bottles rated for pressure where any carbonation is intended. Champagne-style bottles and heavy crown-cap bottles are designed for it; still-wine bottles, screw-top bottles and reused thin glass are not, and no amount of care compensates for the wrong container.

Where a cider is to be sweetened and not conditioned, it must be stabilised — by filtration, by pasteurisation, or by an appropriate combination of sorbate and sulphite — before the sugar goes anywhere near the bottle.

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