How to premix a Hard Orange RTD like a Pro!

How to premix a Hard Orange RTD like a Pro!

Dermott Dowling

The Hard Orange RTD is a massive growth segment in the "Hard Sodas" category in the Australian market right now, driven by the desire for nostalgia and refreshing, fruit-forward drinks. Brands like Hard Rated Orange and Beenleigh Hard Orange Crush have set the standard for a zesty, balanced, and highly 'crushable' beverage.  If you are a craft brewer or distiller who is looking to replicate or compete with these market leaders, success is all in the formulation. Here is a professional guide to compounding a Hard Orange RTD that hits the key commercial targets: 4.5% ABV and a perfectly balanced 10 Brix sweetness.

The Target Profile: 4.5% ABV Zesty Orange 🍊

Metric Target Value Commercial Rationale
Alcohol Volume (ABV) 4.5% The established standard for mainstream, sessionable RTDs.
Sweetness (Brix) approx 10.1 Lands in the sweet spot (8-11 Brix) to ensure a satisfying, soft-drink-like mouthfeel while balancing the acidity.
Acidity (pH) < 3.8 Crucial for zesty flavour and product stability/preservation.
Juice Level approx 5.0% (Reconstituted) Provides authentic colour and flavour complexity without making the product overly pulpy or cloudy.

The Pro Formula (1,000 L (10hL) Batch)

Ingredient 1000 L Quantity Unit Purpose
Carbonated Water 846.28 Litres The primary base and top-up volume.
Neutral Spirit (95%) 47.378 Litres The exact volume required to hit 4.5% ABV
Manufacturing White Sugar 94.248 Kg Provides the bulk of the Brix sweetness.
Orange Concentrate/Juice (65 Brix) 8.85 Litres Provides natural colour, fruit acid, and a 5% equivalent juice level.
Orange Vlavour 2.50 Kg Provides the intense, high-impact orange aroma and top-note zesty flavour.
Citric Acid 0.50 Kg The primary food acid for tartness and pH correction.
Sodium Citrate 0.10 Kg Acts as a buffering agent, smoothing the acid profile and stabilising the pH.
Sodium Benzoate (Optional Preservative) 0.20 Kg For mould and yeast control (at 200 ppm dose rate).


Step-by-Step Premixing Method

A commercial premix requires careful preparation and mixing of the ingredients to ensure consistency and stability.

Step 1: Prepare the Syrup Base (The "Cold Throw" Method)

  1. Dissolve Solids: In a small mixing tank, combine the Orange Concentrate/Juice (65 Brix), Orange Vlavour, and a portion of the total Carbonated Water.

  2. Add Sweetener & Acids: Gradually add the Manufacturing White Sugar and mix until fully dissolved. Then, introduce the Citric Acid and Sodium Citrate buffer. It is crucial for the pH to be low (below 4.0) for preservative effectiveness.

  3. Preservation: If using a preservative (like Sodium Benzoate), dissolve it separately in warm water and add it to the mix, ensuring the temperature is below 60C degrees celsius to maintain efficacy.

Step 2: Incorporate the Alcohol

  1. Add Spirit: Introduce the precise volume of 47.378 Litres of 95% ABV Neutral Spirit into the syrup base. This is the ABV control step.  Take measurements with your alcometer.

  2. Mix Thoroughly: Mix the syrup/spirit blend until homogenous.

Step 3: Carbonation and Final Volume

  1. Transfer to Final Tank: Transfer the entire syrup/spirit blend into the main holding tank.

  2. Top-Up: Add the remaining volume of Carbonated Water (approximately 846.28 Litres until the final batch size of 1,000 Litres is reached.

  3. Chill: The product must be well-chilled before packaging to ensure optimal carbonation retention.

Pro Quality Control Checks:

For a professional-grade product, you must verify the following metrics before packaging:

Metric Tool Check Value
ABV Densitometer/Alcolyzer 4.5% (+/- 0.1%)
Brix Refractometer 10.1 Brix (+/-0.5 Brix)
pH pH Meter < 3.8 pH
Carbonation Zahm & Nagel or equivalent 2.5 – 3.5 volumes CO2

 

We cannot stress highly enough the importance of doing small scale bench or lab trials before you dial up to your full batch production.  You can do a division to 10L and then even split your base out to 10 x 1L before flavour dosing, pH balancing and preservative to make sure your happy with the taste of the beverage.

BeerCo.com.au would like to reiterate that we are not product development specialists or new beverage designers and also recommend if your new to premix premium package spirits that you consider engaging with an industry professional to formulate your RTDs so they hit the high mark when they hit the market.  You only get one chance to make a first impression as they say!

If you need help with anything or wish to discuss the wide array of adjuncts and aids and fermentables for your next Hard Lemonade please do not hesitate to reach out to us at Service@BeerCo.com.au or call us on +61 490 501 392 and have a great Brewing and Distilling and Selling week!