how we make cider

At Thatchers Cider we have pioneered the redevelopment of traditional techniques with state-of-the-art technology. We have played an instrumental role in extending the range of ciders which are readily available. Our work on single variety ciders, which originally date back to around the 17th century, has revolutionised not only their production but also their reputation in the marketplace. Our entire product range is made from English apples, many of which we grow in our own orchards.

Our Orchards
We currently run around 180 acres of orchard growing a total of around 25 commercial varieties. Most of our varieties are traditional cider apples known as ‘bittersweet’ or ‘bittersharp’. These apples are traditionally chosen for cider-making for their fibrous nature which makes them easy to press. Bittersweet apples also have high levels of tannin which is essential for producing great tasting cider.

Harvesting and washing
In the autumn when the fruit is ripe, tractor mounted tree shakers are used to harvest the crop. The machine sends vibrations through the trunk of the tree which causes the fruit to drop and it’s then swept up by mechanical brushes. After harvesting the fruit is washed in large baths of water known as apple bays to remove any debris. The water is then used to move the apples, via a series of channels, onto the apple table where the fruit undergoes a final quality check before milling.

Milling & Pressing
Unlike grapes where only the skins need to be burst, apples need to be completely crushed to properly extract the juice. Traditionally this was done using a large stone wheel which was wheeled around by a horse. We now use an automated wheel with graters fixed to its surface which rotates to crush and grind the fruit.

After pulping, a horizontal piston press, with a closed steel cylinder, is filled with the pulp and gradually compressed. The fluid is then drained through flexible nylon channels within the cylinder.

Once pressed, the various elements within the juice are tested. The proportion of sugar is tested by measuring the juices ‘specific gravity’. The typical density of juice is 1.050 SG compared to 1.0 SG for water - the higher the specific gravity, the higher the sugar levels and therefore the greater potential alcohol. The natural acids in the fruit are also checked – if they are too low, the juice can spoil more easily and if it is too high the resulting cider will taste too sharp.

Fermentation
The juice is then transferred to large tanks to ferment. Fermentation is the process where the sugar in the juice is turned to alcohol with the help of yeast. This process can take between 6-20 days.

Blending
After fermentation, different levels of tannin and sugar across different batches are balanced by blending the ciders. Then the cider is often filtered to remove all excess yeast.

Bottling
The cider is then pumped into steel kegs and casks ready to be shipped out to wholesalers and pubs. Or, it is pumped into sterile glass or PET bottles or into aluminium cans. These are then placed directly onto pallets for delivery to shops, pubs, supermarkets and restaurants nationwide.