alcohol-copacking

How to Manufacture a high ABV beverage

Mon, 23 Feb 2026 23:11:27 GMT

How to Manufacturing a High ABV Beverage

From Moderation to Maximum Strength — The Market Is Expanding

While headlines often focus on moderation trends, another shift is happening at the same time: consumers who do drink are increasingly reaching for higher ABV beverages.

High ABV beverages and high-alcohol RTDs continue to gain traction as consumers seek:

✔️ Higher strength
✔️ Premium positioning
✔️ Bold, differentiated experiences

From elevated RTDs to ultra-strong specialty releases, the category is far broader than many brands realize. For companies exploring high alcohol beverage manufacturing, understanding the different segments is key to positioning — and profitability.

What Are High ABV Beverages?

“High ABV” (alcohol by volume) generally refers to beverages above traditional beer strength (4–6% ABV). Depending on the category, this can range from 7% to well over 40% ABV.

Here’s a breakdown of the major high alcohol segments and what they mean for manufacturers.

1. Spirits (40%–95% ABV)

Spirits are the foundation of high alcohol beverages.

Typical ABV Range:

Vodka, Gin, Whiskey, Rum: 40–50% ABV
Overproof and specialty spirits: 60–75%+ ABV
Neutral grain spirits (e.g., Everclear): up to 95% ABV

These products are staples in cocktail culture and remain one of the most profitable segments in alcohol. Ultra-high-proof spirits are often used for:

Infusions
Flavor extraction
Limited-edition releases
Cocktail concentrates

Manufacturing Considerations:

Federal TTB permitting
Flammable material handling and storage
Precise dilution and proofing
Glass packaging or high-integrity closures
Tax classification impacts

For brands entering this space, compliance and facility capability are critical.

2. Fortified Wines & Liqueurs (16%–24% ABV)

Fortified beverages sit between wine and spirits.

Examples include:

Port
Sherry
Madeira
Vermouth
Cream and herbal liqueurs

These products are used as:

Dessert beverages
Cocktail modifiers
Digestifs
Premium sipping options

The appeal lies in flavor complexity and elevated alcohol without reaching full spirit strength.

Manufacturing Considerations:

Blending base wine with neutral spirits
Stability at higher alcohol levels
Sweetener balance
Shelf-life validation
Regulatory classification (wine vs. specialty product)

Fortified beverages offer strong margins with lower alcohol tax rates compared to distilled spirits in some classifications.

3. High-Octane Beers & Malt Beverages (7%–15%+ ABV)

This category has expanded rapidly in recent years.

Examples include:

Imperial IPAs (7–9%+ ABV)
White Claw Surge (8% ABV)
Voodoo Ranger Imperial variants
Specialty barrel-aged beers (10–15%+)
Avery Rumpkin (18.5% ABV)

These beverages deliver higher impact in single-serve cans or bottles and are often positioned as:

Premium craft offerings
Limited releases
Seasonal drops

Manufacturing Considerations:

Fermentation control to reach higher ABV
Yeast strain optimization
Sugar management
Can pressure and stability
Malt beverage regulatory compliance

High-ABV malt beverages are particularly attractive because they may qualify for beer distribution channels while offering elevated price points.

4. Extreme Beers (20%–75% ABV)

At the far end of the spectrum are ultra-strong specialty releases.

Examples:

Freeze-distilled beers
Specialty products like Beithir Fire (75% ABV)
Experimental high-proof craft releases

These products are rare and often:

Sipped like spirits
Packaged in small formats
Released in limited quantities
Used for brand-building and press attention

While not mass-volume products, they can generate substantial publicity and premium margins.

Why High Alcohol Beverage Manufacturing Requires Expertise

Each high ABV category comes with different production challenges.

When manufacturing higher alcoholic beverages at scale, brands must consider:

Accurate alcohol blending and proof verification
TTB and state-by-state compliance
Ingredient sourcing at scale
Stability at elevated alcohol levels
Flammability and safety protocols
Packaging compatibility

Higher ABV beverages amplify risk if not formulated and tested properly. Minor inconsistencies in alcohol measurement can lead to compliance issues, labeling problems, or costly recalls.

Profit Strategies in the High ABV Segment

For alcoholic beverage companies, higher ABV products can support profitability in several ways:

1. Premium Pricing

Higher alcohol often supports higher perceived value, especially in specialty, barrel-aged, or limited-run releases.

2. Smaller Format, Higher Margin

Higher strength allows for smaller packaging formats while maintaining strong price points and margins.

3. Brand Differentiation

In crowded RTD and beer markets, elevated ABV offerings stand out and attract experienced consumers.

4. Line Extensions

Introducing a “Reserve,” “Imperial,” or “Surge” version of an existing product can increase average revenue per customer.

5. Strategic Tax & Base Selection

Choosing between malt-based, wine-based, or spirit-based formulations impacts regulatory classification, distribution pathways, and profitability.

Partnering for Scalable High Alcohol Beverage Manufacturing

From fortified wine-style beverages to high-octane RTDs and specialty spirits, high ABV innovation requires both technical and regulatory expertise.

At Big Brands, we support brands entering the higher alcoholic beverage space with:

Formulation guidance
Alcohol blending and verification
Compliance navigation
Scalable production systems
Strategic manufacturing planning

If you’re developing a product in the 7%–75%+ ABV range, the right production partner can make the difference between a niche experiment and a scalable, profitable product line.

High alcohol beverage manufacturing is complex — but with the right strategy, it’s also an opportunity.

Ready to explore your next high ABV innovation? Let’s build it the right way.

Emulsified Beverage Formulation of Cream Spirits and Creamy Liqueurs

Mon, 24 Mar 2025 19:35:20 GMT

Emulsified Beverage Formulation of Cream Spirits and Creamy Liqueurs

Big Brands brings decades of experience in the co-packing of alcoholic beverages. One of the categories that we offer our co-packing services for are emulsified beverages. The emulsion process introduces an item such as cream, chocolate or coffee to the recipe for your alcoholic beverage. This is commonly referred to as cream based spirits or creamy alcoholic liqueurs. If you are looking for an emulsion beverage co-packing partner for your cream based spirit or creamy liqueur, we are the only call you need to make!

What are Emulsified Alcoholic Beverages?

The emulsion process to create an emulsified alcoholic beverage includes adding an ingredient such as cream, chocolate or coffee to the beverage formulation. A good example of this process would be Irish Cream or Egg Nog. Other examples would be Coconut Cream Liqueur and Chocolate Based Liqueurs. Our formulation team is well versed in the creation of alcoholic beverages that are Emulsified or Creamy.

What Spirits Can Be Emulsified?

More than you think! The common spirits that are used in alcoholic beverage emulsion include gin, rum, whiskey, bourbon, wines, tequila and more! If you have an idea about the alcoholic beverage that you would like to create, our team will work with you to turn your concept into reality!

Are Emulsified Alcoholic Beverages Shelf Stable?

The beverages made by Big Brands formulation or co-packing team are completely shelf stable. Our emulsion technology does not use pasteurization, so refrigeration is not required.

I Already Have an Emulsion Alcoholic Formulation

Fantastic! Big Brands offers both a turnkey solution for emulsified beverages that includes formulation and co-packing. We also offer these services independently. If you already have your alcoholic beverage formulation, our co-packing team will use your formula for the production and filling of bottles.

Looking for some fun creamy cocktails? We've put together a few unique ones:

Torito de Cacahuate

Torito is the unofficial state cocktail of Veracruz, Mexico. It’s a rich, creamy drink that comes in multiple flavors, but peanut (cacahuate) is by far the most popular. Legend has it that sugar cane workers of Veracruz made the recipe with roughly-distilled aguardiente and said the drink made them feel “like bulls” – hence the name, meaning “little bull” in Spanish. We can formulate your creamy cocktail with peanut flavors so the product is nut free.

Peace Pachacti

Peachy Pachacuti was the losing entry in a Peruvian cocktail competition, after its creator, legendary mixologist Thomas Waugh. Made properly, it’s a fluffy peach dream, lush with the ripe taste of summer. Waugh’s recipe calls for Greek yogurt, but really any plain yogurt will do or our beverage formulation team can work with a similar creamy substance for the bit of creamy tang.

Peppermint Paddy

Minty chocolate was the theme for this winter themed cocktail, a perfect chocolate dinner mint with depth and complexity from creamy coffee liqueur and mint flavors.

And, some more popular manufactured creamy cocktails:

Creamy Chocolate Martini
Pina Colada
50/50 Orange and Vanilla
Irish Cream
Egg Nog

Canned Alcoholic Beverage Formulation

Mon, 24 Mar 2025 03:17:43 GMT

Canned Alcoholic Beverage Formulation

The world of canned alcohol is bursting with creativity, offering something for everyone—whether you’re wanting to co-pack a fruity hard seltzer, a crisp gin canned cocktail, or a spicy, herb-infused canned margarita. From the base alcohol to the spices, fruits, and botanicals, the ingredients used in copacking canned alcoholic drinks can completely transform your drinking experience. With an ever-growing variety of flavors, there’s no shortage of options to explore, making canned alcohol a fun and diverse category for both casual drinkers and connoisseurs alike.

1. Fruits and Berries: A Flavorful Foundation

One of the most popular flavor categories when formulating a canned alcoholic drinks is fruit flavor. The combination of alcohol with fresh, zesty, and sweet fruits provides a refreshing and often light taste, making these drinks perfect for summer or casual gatherings. Common fruit flavors include:

Citrus : Lemon, lime, orange, and grapefruit are staple citrus fruits used to bring tangy, tart notes to canned beverages. They are commonly used in hard seltzers and canned cocktails for a crisp, invigorating flavor.
Berries : Strawberries, raspberries, blackberries, and blueberries offer fruity, sweet, and sometimes tangy profiles. These flavors are popular in hard seltzers and flavored malt beverages, often giving a more mellow, juicy taste compared to citrus.
Tropical Fruits : Mango, pineapple, passion fruit, and coconut evoke tropical vibes and are frequently used in canned cocktails and hard seltzers. These flavors provide a sweet, exotic twist, often with a creamy undertone when paired with coconut or coconut water.
Stone Fruits : Peaches, cherries, and apricots are a sweet addition to canned alcoholic beverages, providing a fuller-bodied, soft sweetness. These fruits pair well with vodka or whiskey-based canned cocktails.

2. Herbs and Botanicals: Layering Complexity

Herbs and botanicals add depth and complexity when co packing canned alcoholic beverages. Many modern drinks, especially canned cocktails and hard seltzers, use these ingredients to provide a more sophisticated and often refreshing twist. Some common botanicals and herbs used include:

Mint : A cooling, aromatic herb often used in cocktails like mojitos or used in refreshing hard seltzers and other canned beverages for an invigorating touch.
Basil and Thyme : These herbs bring a savory, aromatic quality that complements sweet fruit flavors. They’re often used in craft canned cocktails for a more gourmet experience.
Lavender : With its floral and slightly herbal profile, lavender is increasingly used in canned cocktails and hard seltzers to add a subtle floral note.
Cucumber : While technically a fruit, cucumber is often treated as an herb for its light, refreshing, and slightly savory profile. Cucumber-infused canned drinks can be quite refreshing, offering a spa-like quality to the drinking experience.

3. Spices: A Dash of Warmth and Heat

Spices provide a warming element to many co packed canned alcoholic drinks, especially in the colder months or when aiming for a more complex, layered flavor profile. Common spices used include:

Ginger : A go-to ingredient in many ginger beers and spiked sodas, ginger offers a zesty, mildly spicy kick that balances sweetness with a sharp tang. It's a favorite pairing in canned cocktails like Moscow Mules or spiced hard ciders.
Cinnamon : Often used in seasonal beverages (think autumn or winter), cinnamon gives a warm, sweet-spicy flavor that pairs well with rum, whiskey, or cider-based canned drinks.
Cloves and Nutmeg : These warm spices are often used in mulled or spiced drinks, giving them a festive and comforting aroma and flavor.
Chili Peppers : For those who like their drinks with a spicy kick, chili peppers or jalapeño infusions add a level of heat that can balance sweet fruits or give an exciting twist to canned margaritas, Micheladas, or spicy hard seltzers.

4. Citrus Zest and Peels: Bright and Bold

Citrus zest and peels are commonly used the to add an extra layer of brightness. The oils found in the peel provide an aromatic, zesty component that can intensify the fruit flavors in the drink. Popular options include:

Lemon zest : Often used in cocktails and hard seltzers to enhance the lemon flavor and provide an aromatic sharpness.
Orange peel : Used for its fragrant, slightly bitter taste, orange peel adds depth to drinks, especially when paired with gin or tequila-based canned cocktails.
Grapefruit zest : The aromatic and slightly bitter flavor of grapefruit zest adds complexity to hard seltzers and canned cocktails, providing a tangy and refreshing edge.

5. Sweeteners: Enhancing the Flavor Profile

Most canned alcohol beverages balance sweetness with the bitterness of alcohol, often using different types of sweeteners to create that perfect harmony. Common sweeteners include:

Sugar and High-Fructose Corn Syrup (HFCS) : Both traditional sweeteners used to provide the primary sweetness in many beverages, including malt-based drinks and hard sodas. These sugars are inexpensive and effective in boosting flavor.
Stevia and Monk Fruit : These sugar substitutes are gaining popularity in the world of canned alcohol, especially among health-conscious consumers. They provide sweetness without the calories, though their flavor can sometimes differ from regular sugar.
Honey and Agave : These natural sweeteners add a distinct flavor profile to the beverage. Honey can provide a rich, floral sweetness, while agave offers a mild, neutral sweetness with earthy undertones, often used in tequila-based canned drinks.

6. Alcohol Base: What Defines the Drink

The base alcohol used in formulating canned beverages also contributes significantly to their flavor. Some of the most common types of alcohol found in canned drinks include:

Beer and Malt : Flavored malt beverages, such as hard seltzers, malt-based beers, and spiked sodas, are made from fermented grains, often barley, and come in a range of flavors from light to rich. They often serve as a neutral base that lets fruit and spice flavors shine.
Vodka : Known for its neutral taste, vodka is commonly used in canned cocktails, allowing the added flavors (like fruit or herbs) to dominate. Vodka-based drinks are typically cleaner and crisper, with a smoother finish.
Tequila : Tequila-based canned drinks, such as margaritas, are a fan favorite. Tequila’s herbal, earthy taste pairs perfectly with citrus and tropical flavors, providing a strong base that complements sweet and spicy notes.
Rum : Often found in tropical-flavored canned cocktails, rum’s sweetness and molasses-like depth provide the perfect base for flavors like coconut, pineapple, and lime.
Whiskey : Whiskey, with its smoky, oaky flavor, is commonly used in canned old fashioneds, whiskey lemonades, and other classic cocktails. The richness of whiskey works well with bold flavors like ginger or cinnamon.

7. Carbonation and Water

For many canned alcoholic drinks, especially hard seltzers and spritzers, the level of carbonation plays a big role in the drinking experience. The effervescence provides a refreshing, light mouthfeel and accentuates the flavors. In addition, some canned drinks use sparkling water or mineral water to add complexity to the flavor profile, while also keeping the drink light and crisp.

8. Natural and Artificial Flavors: Enhancing Taste

To create bold and consistent flavor profiles, many canned alcohol brands use natural and artificial flavorings. Natural flavors, derived from fruit or herbs, provide an authentic taste, while artificial flavors offer consistency and cost-effectiveness.

Natural flavors are often used to mimic fresh fruits, herbs, or spices in a beverage.
Artificial flavors may be added to enhance specific notes, especially in mass-market canned alcohol drinks, though some consumers prefer drinks with natural ingredients due to concerns over chemicals or synthetic additives.

Manufacturing a Sugar Brew

Sun, 09 Feb 2025 01:24:32 GMT

Manufacturing a Sugar Brew

We take a deeper look into what a sugar brew is, copacking a sugar brew, the benefits of manufacturing a sugar brew and the disadvantages of manufacturing a sugar brew.

What is a Sugar Brew?

A sugar brew refers to a beverage that is fermented primarily with sugars (often simple sugars like glucose or sucrose) rather than malted barley or other grains. These sugars are usually derived from cane sugar, corn syrup, or sometimes even fruit sugars. In many cases, sugar brews are used in the production of beverages like hard seltzers, some fruit wines, and even certain beers that are brewed with added sugar instead of malt.

How It’s Made:

Fermentation of Sugar: Sugar is dissolved in water, and yeast is added to ferment the sugars into alcohol.
Additional Flavoring: Often, sugar brews are flavored with fruits, spices, or other additives to enhance the taste.
Quick Production: Because the base sugar is easy to ferment, these drinks tend to be quicker to produce than traditional malt-based beverages.

Manufacturing process of a Sugar Brew

Create the concept of your sugar brew beverage
Start the sugar brew alcoholic formulation process
Decide on the packaging option for your sugar brew beverage
Finalize the alcoholic formation of your sugar brew and packaging
Manufacture your sugar brew beverage

Advantages of Sugar Brews:

Lower Production Costs: Since sugar is usually cheaper than malted barley, sugar-based brews can be more cost-effective to produce.
Light, Crisp Flavor: Sugar brews often result in a cleaner, lighter taste compared to the heavier, more complex flavors of malted beverages. This makes them popular in beverages like hard seltzers.
Gluten-Free Options: Many sugar brews, especially those made from corn or cane sugar, are naturally gluten-free, making them a great choice for those with gluten sensitivities or celiac disease.
Faster Brewing Process: The fermentation of simple sugars typically happens quicker than the malt brewing process, allowing for faster production.

Disadvantages of Sugar Brews:

Lack of Complexity: Because sugar is the primary fermentable ingredient, sugar brews often lack the depth and richness found in malt beverages, which benefit from the flavors of barley or other grains.
Excessive Sweetness: Without the right balance of ingredients, sugar brews can sometimes come off as overly sweet or artificial, especially if fruit flavors or additives are involved.
Potential for Lower Alcohol Content: Some sugar brews, particularly those designed to be lighter in flavor, can have a lower alcohol content compared to more traditional malt-based drinks.

Big Brands flavors, formulate all the beverages services needed to complete any beverage product. We take care of it all for you. Let us help you create your new beverage, contact us today.