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If you are Kegging it than why do you need to pasteurize it? If you are worried about it fermenting further in the keg then let it ferment out before Kegging and then back sweeten with a non fermentable sugar. Or do you plan on storing the keg at room temperature for an extended period of time...

Well I never found an answer so ended up changing all the seals and pasteurising sooner with less pressure in the bottles. Seem to have done the trick. Not a 1 out of the batch popped.

Several weeks ago I picked 300+lb of free apples and thought I would make a couple different varieties of cider. I have done 20L dry at 7% (no added sugar), 20L sweet (adding brown sugar to bring the gravity up to 1.090) fermented to 1.045 then cold crashed. 20L I just canned as is for drinking...

If there were no preservatives in the cider than the only other explanation is that you somehow killed (or had dead) yeast. Did you add the dried yeast directly into the cider or dissolve it first in warm water to wake it up? Try that if you didn't do it the first time and don't use chlorinated...

When using the Grolsch bottles for this do you replace the seals each time? I tried without using new seals and they all started blowing out the side when I put them in the 160 water after about 3min? They weren't overlay carbonated, I popped one and it was perfect (before the hot water). Also...