A MULTI-DISCIPLINE CRAFT COMBINING DISTILLATION CREATIVITY, PRODUCTION TECHNOLOGY & LEGAL COMPLIANCE ARTISAN-CRAFT DISTILLING
A MULTI-DISCIPLINE CRAFT COMBINING DISTILLATION CREATIVITY, PRODUCTION
TECHNOLOGY & LEGAL COMPLIANCE
ARTISAN-CRAFT DISTILLING
WELCOME TO A NEW INDUSTRY
1 July 2008 “Craft Distillery Bill” signed into law 20,000 proof-gallon production ceiling, now
60,000 proof gallons 25,236 cases @ 50% ABV 30,783 cases @ 40% ABV 50% Washingtonian raw product On-site sampling; half-ounce samples, 2
ounces per person maximum Sales; 2 litres per person per day
THE HISTORY OF DISTILLING
Babylonia, 2nd Millennium BC Egypt, 3rd Century AD Persia, 8th and 9th Centuries Holy Roman Empire, 12th Century Ireland, 14th Century Scotland, 15th Century Americas, 17th Century Laird’s, oldest American distillery, “still” in
business
DISTILLATION = SCIENCE
Fractionating action as heat liberates alcohol from aqueous solution
Change in physical state and back again many times at the molecular level
As nature’s most efficient organic solvent, beverage alcohol derives all of its color and much of its flavor and aroma from a barrel
DISTILLATION = ART
Individualized choices of grains, fruits, yeasts and nutrients; i.e. limitless variables
Subjective determination of fractions or “cuts”
Sensorial determination of maturation
Creative design of brands and labels
DISTILLATION = HRP* = DAMN!(* HEAVILY REGULATED
PRIVILEGE) Not legal without proper Federal, State, County,
City permits and licenses No level of amateur distilling permitted Revenue-earning potential for all governmental
agencies Health and safety hazards galore Burns, impaired vision and death are the most
frequent result of careless distilling Stiff penalties and/or incarceration No chance for commercial license
1:00 PM TO 5:00 PM
Distillation Engineering
METHODS OF HEATING
Open flame (gas, coal, wood, pellets)
External steam heating
Internal steam heating
Internal electric heating
REFLUX AND CONDENSATION
Reflux is a physical change in state of any matter; solid to liquid to vapor to …....….?
Reflux at the molecular level is essential to distillation of alcohol; liquid / vapor / liquid
Successive multiples of reflux strengthen and purify beverage alcohol
Condensation happens as vapor returns to liquid state due to cooling
Reflux and condensation are essential to the distillation of beverage alcohol
THE POT STILL A = Pot, or Kettle
B = Radius
C = Column
D = Gooseneck
E = Lye Pipe, or Lyne Arm
F = ?
THE CHARENTAIS STILL
THE CHARENTAIS STILL
THE COLUMN STILL(COFFEY, CONTINUOUS, PATENT)
THE FIGGINS POT~COLUMN HYBRID STILL
COPPER AND STAINLESS STEEL;COMPARED AND CONTRASTED
High heat conductivity High malleability High chemical
reactivity Difficult to weld Discolors when heated Aesthetically pleasing Requires cleaning often Costly
Low heat conductivity High tensile strength Low chemical reactivity Easy to weld Stays brilliant when
heated Sanitary Requires little care Inexpensive
COPPER STAINLESS STEEL
9:00 AM TO 12:00 PM
FERMENTATION FUNDAMENTALS
GRAIN FERMENTATION
Requires gelatinization of proteins to liberate starches into mash water (cooking, mashing)
Requires at least 5% by weight additionally of malted grain, chiefly barley
Liquid preparation of gluco-amylase enzymes used in place of malted barley by some producers
Mixture of grains (mash-bill) in any proportion, or single grain
Result of any grain fermentation is beer
MALT FERMENTATION
Requires germination and kilning
No cooking required
Abundance of enzymes
Higher potential gravity than grain
More expensive than grain
Result of any malt fermentation is beer
TUBER FERMENTATION
Potatoes or sugar beets
Requires cooking and mashing to release starches
Requires enzymatic conversion of starch
High-yielding
Neutral, and thus perfect for vodka
FRUIT FERMENTATION
Mono-saccharide (glucose, fructose)
Requires nutrient additions to prevent H2S formation
High levels of acids and phenols
High potential alcohol, especially from grapes or fruit concentrates
Result of any fruit fermentation is wine
SUGAR, MOLASSES, HONEY, SORGHUM AND AGAVE SYRUP FERMENTATION
Requires dilution with water Requires a buffering agent to ~ 3.6 to 4.0 pH Requires cellulose and nutrients Extreme control over strength Can result in excellent yields Low SO2 production Result of a honey fermentation is mead
YEAST, NUTRITION & OXYGEN SUPPLY
Choose appropriate yeast strain(s) Freeze-dried (dormant) or liquid (living)? Complex substrates require feeding B vitamins ~ Thiamine, Niacin, Pantothenic
Acid, Biotin most important Nitrogenous compounds needed for cell
mitosis Oxygen absolutely essential
1:00 PM TO 5:00 PM
DISTILLATION FUNDAMENTALS
VODKA Must be distilled at or above 95% ABV Must be “neutral” in flavor and aroma Can be made from any raw product provided
that the first conditions are met Usually made from a potato, corn, wheat
starch base, though rye and malted barley are more flavourful
Available in bulk at high strength (190° to 196° proof) as grain neutral spirits (GNS)
No maturation Diluted to beverage strength and filtered
through activated carbon, with coconut carbon being of a superior grade
GIN Made from vodka Re-distilled with botanicals suspended in
vapor or liquid; or Infused with botanicals Juniper berry is the chief botanical Proprietary mixes of botanicals No maturation, though some Dutch genever
is aged Diluted to beverage strength
RUM
Made from cane sugar or molasses No beet sugar allowed No honey allowed No agave syrup allowed Matured and non-matured styles Called cachaça in Brazil and made from cane
juice, not granulated or molasses
MESCAL / TEQUILA
Made from the syrup pressed from roasted agave
Use of Tequila name only if made in Mexican state of Jalisco
100% from agave; inferior grades are blended with grain neutral spirits
Matured and non-matured styles, e.g. Plata or Blanco, Reposado, Añejo
WHISKY / WHISKEY U.S.: “Distilled at no higher than 95% ABV
(Bourbon, 80% ABV) but stored in oak containers and bottled at no less than 40% ABV”
Grain, malt and grain-malt blends Bourbon at least 51% corn in mash-bill; aged for ≥ 2 years in new charred barrels Scotch is all-barley, grain or malted; aged for > 3
years in prior-use barrels Irish is all-barley and is aged for ≥ 3 years Canadian whisky, chiefly rye, is aged for ≥ 3 years
and must be at least 92% whisky
BRANDY AND EAUX-DE-VIE Made from any fruit-based wine Brandy is aged for a minimum of 2 years for
grape, except if a modifier is used Eau-de-vie not recognized by TTB All Cognac and Armagnac is brandy VS, VSOP and XO nomenclature Grappa is pomace brandy from the spent
skins of the winemaking process Pisco is young South American brandy
LIQUEURS, OR CORDIALS
Any spiritous mixture containing a combination of spirit blended with a sweetener, herbs, botanicals, spices or a dairy product
Generally fall between 17% and 38% ABV, though absinthe is much higher
6:00 PM ODDFELLOWS RESTAURANT
RAINIER ROOM, TRUITT BUILDING102 W MAIN ST
AUBURN, WA 98801
NO-HOSTSPIRITS TASTING
AND DINNER
9:00 AM TO 10:30 PM
GAUGING OF SPIRITS
WEIGHT, VOLUME AND TEMPERATURE
If weight, volume and temperature are known, proof can be extrapolated
TTB gauging manual is essential % ABV x 2 = ° proof Proof-Gallon = one U.S. gallon of spirits having a
strength of 100° proof (50% ABV)
HYDROMETRY
Uses the principal of specific gravity Adapted to liquids, a hydrometer floats
proportional to density of the liquid The alcohol hydrometer is usually calibrated
to a scale of % ABV and/or ° Proof Some hydrometers have an integrated
thermometer with correction gradations
DENSITOMETRY
Uses oscillation technology to determine specific gravity and hence, density of a given sample
GAS-CHROMATOGRAPHY
Uses fractional distillation to separate constituents of a liquid matrix and analyzes them for density and volume
Used to most accurately measure percent of alcohol in a given sample
Usually carried out by a commercial laboratory, but some larger distilleries own a GC unit
10:45 AM TO 12:00 PM
SPIRITS PACKAGING
BOTTLE, CLOSURE AND LABEL
Clear (flint) for spirits Brown or antique green for liqueurs Cork, Zork®, glass stopper or screw cap Bar top or screw top Tin, poly-laminate or PVC capsule, or wax
seal Hand-applied or machine-applied label Silk-screened label Cost varies; $15.00 to $30.00 per case
STANDARDS OF FILL
Federal requirements mandate that the actual fill cannot vary more than 0.5% of stated volume for spirits
Spirits can only be bottled in 1.75 L, 1.0 L, 750 mL, 375 mL, 200 mL, 100 mL and 50 mL volumes; no filling into 500 mL since 1986
Calibrate any filling device with an accurate graduated cylinder after stabilizing the bottling room at 60 °F / 15.6 °C.
BOTTLING, SEALING & LABELLING
Calibrate any filling device with an accurate graduated cylinder after stabilizing the bottling room at 60 °F.
Stopper or screw-cap closure Tin capsule; spun on PVC capsule, heat-shrunk on Beeswax or plasticized wax seal Paper tag as tamper-evident seal Closure and capsule all in one (Zork®)
1:00 PM TO 5:00 PM
BUSINESS OF DISTILLING 1
THE DISTILLERY BUSINESS PLAN
BUSINESS FINANCING
PRODUCT SALES AND MARKETING
9:00 AM TO 12:00 PM
LICENSING AND COMPLIANCE 1
PHYSICAL PLANT CONSIDERATIONS
Lockable doors Impenetrable windows Signage Means of gauging on premises Gauging manual on premises Physical barrier between production & tasting
area Tasting area not in bonded area
US TREASURY, ALCOHOL & TOBACCO TAX &TRADE BUREAU
1:00 PM TO 5:00 PM
LICENSING AND COMPLIANCE 2
STATE LIQUOR CONTROL BOARD
STATE DEPARTMENT OF REVENUE
COUNTY AND MUNICIPAL CODES
LICENSING AND BONDING SERVICES
LABEL APPROVAL
4:00 PM TO 5:00 PM
BUSINESS OF DISTILLING 2
“BRANDED HOUSE” VERSUS
“HOUSE OF BRANDS”
Company name same as brand name Company name not identical to brand(s) View each brand name as an asset Each brand requires identity creation The more assets owned by a distillery, the
greater its re-sale value Multiple products have multiple markets,
requiring specific brand dynamics
SPIRITS DISTRIBUTION Retail privileges ~ bottle sales and single-
serving sales WSLCB Distribution Center WSLCB Special Order catalog WSLCB General Listing Agents and Brokers Internet sales direct to consumer Class H licensees in WA WY and NH have lowest spirits tax in USA WA has highest spirits tax in USA NY, CO, DC – no agent required
6:00 PMODDFELLOWS RESTAURANT
RAINIER ROOM, TRUITT BUILDING102 W MAIN ST
AUBURN, WA 98801
NO-HOST DINNER
9:00 AM TO 12:00 PMSIDETRACK DISTILLERY
27010 78TH AVE SKENT, WA 98032
DISTILLATION IN PRACTICE 1
DISTILLATION APPARATUS EXPLAINED
Pot, or kettle Heat source Column Lyne arm, lye pipe, swan’s neck (col de
cygne) Thermometers Condenser (heat exchanger) Spirit manifold / carbon cup Heads removal port Spirit receiver / hydrometer well
HEATING AND COOLING ESSENTIALS
Electric sources of heat; all on at first, and adjustments as temperature rises
Tap water for cooling; low flow rate Re-circulated glycol or saline as a substitute cold inlet at top and valved warm oulet at
bottom (in-flow heat exchange) cold inlet at bottom and valved warm outlet at
top (cross-flow heat exchange)
HEALTH & SAFETY CONSIDERATIONS
Never fill below heating elements, and always a fair level above, factoring in loss
Never have any contact with foreshots Never touch hot kettle or column Handle hot liquid sensibly No smoking in distillery Never under-cool condenser
STILL CONSTRUCTION
All-copper construction Silicone or Teflon® gaskets 5500-watt heating elements Tri-Clover® flanges and clamps Tube-in-Shell (Liebig) condenser Worm-in-Tub condenser Copper spirit receiver / hydrometer well
CHARGING THE STILL
Fill from bottom Watch for level to rise Do not over-fill the kettle Do not under-fill the kettle
APPLYING HEAT
All four elements on at first Apply one at a time, using audible test to
check for faulty elements Use mechanic’s stethoscope in noisy plants Reduce to three elements as lye pipe
temperature rises to 172 °F / 77.8 °C. Reduce to two opposing elements as
substrate volume decreases or if spirit proof weakens
1:00 PM TO 3:00 PMSIDETRACK DISTILLERY
27010 78TH AVE SKENT, WA 98032
DISTILLATION IN PRACTICE 2
DISTILLATION DEMONSTRATION
HEADS, OR FORESHOTS
Rich in methyl alcohol (methanol) ~ CH3OH Rich in all low volatiles (ethyl acetate,
sulphur dioxide, acetone, acetaldehyde) Toxic, injurious and fatal if ingested Discard generous proportions, at least 100 ml
per 225 litres substrate; double in actual practice
Federal regulations require plan for disposal Bio-fuel plants require CH3OH
HEARTS, BODY OR MIDDLE CUT
Begin at 172 °F / 77.8 °C Rich in ethyl alcohol (ethanol), ~ C2H5OH Trace amounts of the good congeners (esters,
fusel oils, phenols) Always in a matrix with water Begins high in strength, ~ 80% ABV Constant flow rate Ends low in strength, ~ 40% ABV Average of 60% ABV need not be re-distilled
TAILS, OR FEINTS
Low in alcohol, high in water content Keep in still, cool spent wine or pot-ale, then
discard Deposit distilled tails into separate vessel
and record volume / proof Rich in di-methyl sulphide and fusel oils Re-distill tails with next batch, if collected at
all
GO FORTH WITH GREAT SPIRIT!