Author: birendra@midnightmachines.io

What Is a Hybrid Still?

Posted on by birendra@midnightmachines.io

There are a few competing definitions on what a true hybrid still is. Some people call a column on top of a kettle a hybrid still, while others would call a still that is capable of switching between running as a pot still and a column still as a hybrid still. Whatever your definition, knowing the difference between the types of stills and their strengths and weaknesses will help you run your equipment more efficiently and help you choose the right commercial distilling equipment for the flavor you’re looking for.

For many people, pot stills are the traditional style of still while column stills are more high tech and necessary for producing higher proof liquors. There are pros and cons for each of these types of stills, and knowing them will help in figuring out what distilling equipment should work best to produce the flavors you want in your final spirit. 

Pot Stills: Pros and Cons

Pot stills are very likely the original distillation technology. (The discussion on when freeze distillation started and when pot stills started is beyond the scope of this article.) In their simplest form, pot stills are made of a kettle that is heated to boil lower boiling materials out of a solution and then sending the vapor to a product condenser to turn it back into a liquid. 

It sounds uncomplicated, but there are a lot of nuances that can impact the final flavors. Things like the angle of the lyne arm, the height of the hat on the kettle, the overall area capable of creating passive reflux, and many other factors contribute to the character of the final product. 

Column Stills: Pros and Cons

Column stills work under the same basic principles. Each plate on a column still acts as a separation step similar in concept to how a kettle separates materials. The comparison isn’t one-to-one, meaning that running three plates in a column will likely not give you the exact same result as triple distilling on a pot still. 

It All Boils Down to Reflux

Part of why the two types of stills produce different characteristics is due to the amount of reflux possible in each system. In a pot still, the shape and surface area inside the still itself create a passive reflux. In a distillation column, the reflux can be controlled with a piece of equipment called a dephlegmator which cools vapor at the top of the column to control the volatility of the material heading to the product condenser. A pot still can also increase the amount of reflux achieved by using a dephlegmator.

As a rule of thumb, the closer to 100% reflux you run will allow the plates to create a more efficient separation and the higher the number of plates the cleaner the product will be. This is why it’s more efficient to make vodka on a column still than a pot still, because there’s less smearing that happens and you have a more defined separation between heads, hearts, and tails. More separation and a cleaner product can be wonderful, but the tradeoff happens because plate sections are a separation step, so it can only remove parts of the starting material. This means that compounds that have a higher boiling point that can add flavor are also removed. There are ways around this, such as using fewer plates or blending small amounts of the tails back into the final product.

So, now that we know about two common types of stills, what should we use as our criteria for a hybrid still? Does putting a column on top of a kettle make it a hybrid still, since you’re technically combining two types of stills? Or would a configuration that allows you to switch between running as a pot still or as a column still be closer? 

The Double Dragon kettles have two column openings and allow you the flexibility to run in multiple modes. By putting a whiskey hat on one side and a column on the other side, you can valve the system to allow you to choose the type of still you’re running. Part of the craft of craft distilling is adjusting and refining your recipes. The other part is how you run the distilling equipment to achieve the flavor profile that speaks to you and your audience. 

> Contact the knowledgeable team at StillDragon at 561-264-6490 for help choosing the right equipment for your craft distillery.

Still Parts: What Is a Lyne Arm?

Posted on by birendra@midnightmachines.io

The simple answer is that a lyne arm is a pot still part that connects the still head to the product condenser. There are many different ways to configure this connection, and each option has a different effect on the final flavor of the spirit produced.

Lyne Arm vs. Lye Pipe

Before we dive into the way that the lyne arm affects the spirit’s characteristics, it’s fairly interesting to note that the history of the name is fairly uncertain. “Lyne arm” seems to be the more accepted name (at least here in the States), but like many other things, there are different names for this part. Sometimes the part is called a “lye pipe”, which seems to be the Scottish slang for a pipe laid between the kettle and condenser. The term Lyne Arm originates from Ireland but no one knows the actual origin of the term. 

Lyne Arm Angles

Different lyne arm angles affect the reflux characteristics of the still. Reflux is the term for vapor that condenses on the inner surface of any still parts. A deflegmator is purposely built to actively control the reflux but many still parts contribute to the passive reflux. As a general rule, a lyne arm angle above 90 degrees allows less congeners and gives a lighter spirit by increasing the passive reflux and allowing any condensed material to flow back into the kettle. A lyne arm angle below 90 degrees gives a heavier flavor by allowing the material that condenses on the lyne arm to parr to the condenser. This allows more congeners to pass through. A straight lyne arm is considered a neutral position. This can allow for a more balanced spirit. The height of the head on a pot still also has a similar effect as an upward-angled lyne arm by increasing the passive reflux heading back to the kettle.

Lyne Arm Shapes

Those are the simplest options, but like everything else in the crafting of fine spirits, there is an almost endless amount of variations. Aside from the angle, adjusting the shape of the lyne arm or still head can also have an effect on the final product. A vertical “S” or “U” shape will help increase the passive reflux, and so will adding in an hourglass shape to the vapor path. Any increase of surface area will increase the opportunity for passive reflux to occur. 

Part of the craft of distilling is experimenting and finding out what still parts configuration gives you the results you’re looking for. There is no one-size-fits-all solution, and all of the still parts have to work together to produce a quality product. Everyone’s “best” will be different, and trying different configurations will help you find what works best for you. 

> Need help choosing still parts? Contact StillDragon today at 561-264-6490. We’re glad to help!

What’s the Best Alcohol Still on the Market?

Posted on by birendra@midnightmachines.io

This is a question we get a lot. While the knee-jerk reaction is to simply say it’s ours, there’s actually no simple answer to this question. Every spirit is different, and part of the craft of distilling is experimenting with different setups and technologies to find the best fit for the flavor profile you’re going for. To find the best alcohol still on the market, you’ll need to know the ins and outs of how different alcohol stills work and how they affect your final product.

Alcohol Stills: Pot vs. Column

Pot Stills

Pot stills are the oldest distilling technology and arguably the simplest form of setting up an alcohol still. Copper is traditionally used to make a pot still, but the discussion about how much copper you need in the vapor path is a blog topic in and of itself… so we’ll table that for now.

Traditional pot stills are heated directly from the bottom, and you boil the mash or wash to produce vapor that is piped over to your product condenser. Once you have a liquid, you can make your cuts to separate your hearts from the heads and tails to get the final product.

This seemingly simple variety of alcohol stills can actually be as complex as you want (or don’t want) it to be. The temperature in your still, the timing of your cuts, and the fermentation itself can all be varied to give a different flavor and feel to your final product.

This is by definition a batch process, so some variation will occur between runs since so many factors have an impact on these alcohol stills. While consistency can be a challenge, the ability to have heavier congeners and different flavors coming through in the final product may make this the best alcohol still on the market for you.

There are other ways to configure a pot still than just the traditional set up. A dephlegmator can be added to increase your reflux ratio, or you may add a thumper or doubler to your process or even a full column.

Column Stills

Column stills offer a different technology that can give you a different flavor profile in your final product. Column stills are a little more complex than pot stills, but they offer more control and more efficient alcohol extraction.

A column still adds plates that further separate the different components and give you the ability to make cleaner cuts. This can remove congeners and alter the flavor compared to a pot still, but you also get a “cleaner product.

If you’re making vodka (or hand sanitizer) for instance, you’d want to have at least 10 plates to get to the purity required. Some distilleries use over 30 plates to get the flavor they’re looking for, so there is a lot of flexibility in how these alcohol stills are set up.

By adding more plates, it adds more separation steps so the need to double or triple distill a product may not be necessary since a 30-plate column has three times the separation steps built into it than a 10-plate column has. If you’re looking to make a whiskey, this may be counterproductive. An alcohol still with four plates may be a better option, if you don’t want to use a pot still for your whiskey. This will allow more congeners, and therefore more flavors, to come through into the final product.

In Conclusion

There really is no simple answer to what the best alcohol still on the market is. Different alcohol stills can help accentuate or subdue certain flavors, but they can’t add anything that’s not coming through in your fermentation. Distillation is a separation process, and it cannot add in anything that’s not already present.

The craft of distilling is a complex and nuanced process that can produce a wide range of products that will hit different palates differently. Are you looking for something clean, something smokey, something fruity, something with a bite, or some combination? The best flavor is subjective, and the equipment used to get it is up to the distiller and the way he or she chooses to run it. Therefore, the best alcohol still on the market is ultimately the one that matches up with the flavor that speaks to you.

>>When in doubt, contact StillDragon for help choosing your equipment.

Why Use a Thumper on a Distilling Kettle?

Posted on by birendra@midnightmachines.io

So you have taken up distilling for spirits production and have decided that, since you are a whiskey enthusiast, you’ll be pot stilling to produce the most authentic flavor profile. After all, pot stills have the oldest pedigrees on the planet, and pot-stilled whiskies, rums, and brandies are some of the most sought-after spirits on the planet.

However, the rub here is that pot stills are not really the most efficient tools to use if production speed factors heavily into your planning. The main limitation is that a pot still can really only render an aggregate ABV of 35% to 45% alcohol from an 8% to 10% beer with a single distillation.

Furthermore, because of the pot still’s inherent inefficiency, the resulting distillate from a single distillation can be highly contaminated with high and low boiling-point constituents that can impart an unpleasant quality in the finished distillate. For this reason, most operators choose to run the distillate a second time to produce a more desirable finished product. Of course, this all adds up to the utilization of more resources to produce the most desirable pot-stilled finished product. Namely, more heating, more cooling and, especially, more man hours.

What Is a Thumper?

A thumper is essentially a parasitic kettle connected to the primary distilling kettle. The thumper gets heated with the heat already produced to feed the primary kettle. Evidently, the thumper gets its name from the sound it makes while in operation.

Thumper or No Thumper?

A thumper setup allows for a secondary distillation without having to run the distillate a second time. Based on the design parameters, the use of a parasitic kettle may require more BTUs to run than a single distilling kettle, but likely not as many BTUs when compared to running two completely separate distillations. In addition, since the thumper contains a measure of liquid to facilitate another phase-change cycle, there will be heat exchange occurring within the thumper that may reduce the amount of cooling capacity required to cool the finished distillate.

Again, these variables would be predicated upon the design and size of the parasitic kettle. The noteworthy savings, however, will be man hours needed to render a product that is more desirable for consumption.

The operator can choose to “charge” the thumper with water, alcohol, or even an additional flavoring component that may result in the formation of additional carboxylic acids that can add to the complexity of the finished spirit. Similarly, the operator can also add botanicals to the thumper for gin production. Doing so allows the operator to keep the larger, more time-consuming-to-clean, primary distilling kettle from being contaminated with botanical oils.

Enter the Double Thumper

In addition to a single thumper, a double thumper (or double retort) can be used. Like the single thumper, the double thumper further adds to the ABV enrichment of the finished product by stabilizing the ABV of the resulting distillate.

Perhaps the most widely known version of a double thumper (retort) system is the alcohol still used for making traditional Jamaican-style rum. In this application, one of the retorts is charged with low wines, and the other with high wines. The primary distilling kettle is charged with the rum beer. This process facilitates an additional boost in ABV as well as enhances the likelihood of desirable carboxylic acid formation, as previously mentioned. This is all meant to maintain a more stable ABV collection strength as well as to install more complexity into the finished product. You could say this type of arrangement adds more “rummyness” into the rum.

A More Flexible Double Thumper

The StillDragon double thumper (retort) system takes this concept a bit further by providing additional features to allow the operator more flexibility during operation. In the StillDragon system, the vapor supply manifold (lyne arm) is equipped with three-way valves at each retort to give the operator the ability to bypass either or both retorts. This is helpful if the operator chooses to do a more basic stripping run or to send vapor to a completely separate distilling apparatus. In other words, the operator is not limited to only running the system solely as a double retort.

Each StillDragon retort is also typically equipped with dedicated heat input capability and a conventional column attachment feature. This allows the distiller to utilize either retort as a smaller, primary distilling kettle for smaller batches, if needed.

Other features can also be included. For example, StillDragon can create a custom piping solution that will allow for multiple product condensers, additional vapor infusion hardware, and even a rectifying column by controlling the vapor path with valves.

Below is a classic example of how multiple types of distillation tools can be incorporated together to make the most versatile distilling apparatus. The below system can be configured to run as a traditional pot still, single or double thumper, small column for bright clean mouth feel on flavored spirits, and finally a full rectifying column for more neutral spirits.

This system is also outfitted with a dedicated product condenser to reduce the need for cleaning on the rectifier side of the system. The valved manifold even allows the operator enough flexibility to simultaneously run the primary distilling kettle and the retorts independently, so that each kettle on the system can be used to produce a completely different finished product.

> For more information on how to incorporate a thumper into your distillery planning, contact StillDragon’s sales team at info@stilldragon.com or call 561-845-8009.

How Much Heat Do I Need to Run My Still?

Posted on by birendra@midnightmachines.io

One of the most common questions asked by newly minted pro distillers is: “How much heat do I need to run my still?” The answer ultimately depends on how important your time is to you. Though the investment into upgrading one’s ability to provide an adequate still heat source can be dear, time is something that really can never be recovered. And time really does equal money – especially when it comes to distilling.

Distilling and Heat: Why Time Is Money

For the spirits entrepreneur, the longer it takes to produce a competitively priced finished product (vodka, for example), the more your margin will suffer. Having user-friendly equipment that gets the job done in a timely manner is paramount to running a safe and profitable distillery. And, like it or not, distilling for profit really is about exploiting economy of scale to the full extent possible.

Another consideration that we try to help the new craft distiller understand is that (as with nearly every business) labor costs will almost always be greater than the expense of the equipment over a given period of time. It should be the goal of the spirits entrepreneur to do the same production volumes with 3 or 4 workers as their competitors do with 8 or 10 workers. And, to do that while not completely burning out the workforce… which in turn can more broadly affect morale, productivity, etc. I digress.

The fact is: still heat-up times can gobble up precious time. Longer (or shorter) heat-up times can mean the difference between getting home at night in time to prepare a family meal or being handcuffed to the distillery until all hours of the night to complete a distillation run.

Still Heat Times

As a rule of thumb (notwithstanding kettle design), we would typically say that it takes about 70 watts of power (238.7 BTUs) per every liter of 10% ABV beer to heat to boiling within 1 hour. Similarly, it takes 35 watts of power (119.35 BTUs) per every liter of 10% ABV beer to heat to boiling within 2 hours. So, twice the power means twice as fast.

For example, let’s use a 1000L kettle charge of 10% ABV beer. 1000L x 70 watts = 70,000 watts of power for a 1-hour still heat-up time. And, 1000L x 35 watts = 35,000 watts of power for a 2-hour still heat-up time.

Naturally, after heat-up temperatures are achieved, you won’t need quite that much heat. Although, your Authority Having Jurisdiction will require that your power supply be sized according to maximum draw capacity.

Hopefully, this article has provided useful insight into still heat. For more information about equipment sizing and production speeds, contact StillDragon via email at info@stilldragon.com or call 561-903-4729.

Looking for an Alcohol Still? You’ll Need This Software for Your Distillery, Too.

Posted on by birendra@midnightmachines.io

Guest Post by Donald Snyder, President of Whiskey Systems

There are two certainties in this world; Death and Taxes. Although Whiskey Systems can’t do anything about death (yet…), this software is a distiller’s best choice to make taxes one less thing to worry about. After a distillery buys a StillDragon alcohol still and receives their approved federal Distilled Spirits Plant permit (DSP), they are on the hook to understand and follow the strict regulations handed down from the Tax and Trade Bureau (TTB).

For example, every month a licensed DSP must report to the TTB their Production, Storage, and Processing reports, even if the are not in production yet. Every quarter (or every 15 days depending on the size of the distillery), every DSP is required to file a Federal Excise Tax Return, even if they didn’t sell any bottles. Distillers of every size, from the largest whiskey and vodka producers in the US to the smallest nano-distilleries making a few gallons a day, all fill out the same monthly TTB production reports and are regulated by the same set of compliance rules.

When a distillery buys a StillDragon alcohol still, compliance with TTB production reporting and audit preparation is probably the last thing the distiller wants to worry about. This is where Whiskey Systems can make lives easier, as distillers are making cuts off those beautiful customized, plated columns.

Whiskey Systems offers a place to log and track fermentations, distillation runs and yields, barrel fills and harvests, bottling runs, and even cases removed from bond and sold. Keeping all this data in a corruptible excel spreadsheet or on a home-grown solution puts the distiller’s license at risk. Short of reading the hundreds of pages in the Code of Federal Regulations (CFR) Section 19, distillers cannot be sure that they are logging their daily operations and data points as required by the TTB.

If audited, can a distiller quickly grab the appropriate daily logs? Are they collecting all the required transaction data? Worse case, even with all the data collected, how can a distiller be sure they are filling out the operations reports correctly? For as little as $199/month, Whiskey Systems takes that stress away from a distiller so they can focus on want really matters – making high quality spirits.

Beyond TTB Production Reporting and Audit Preparation

But TTB regulations and audit preparation aren’t the only stress on distillers. Eventually their accountants will come knocking looking for their Costs of Goods Sold (COGS). This is where Whiskey Systems really shines alongside those beautiful copper StillDragon alcohol stills. Distillers can’t just be concerned with how much grain or molasses and yeast they used for their fermentation; they will be asked how much it costs to make.

Whiskey Systems makes batch costing and inventory tracking easy by automatically consuming raw materials and pushing the raw material costs into Work in Progress (WIP). Whiskey Systems will track the cost of materials through the entire process so when bottles are filled, distillers know exactly what each case costs. Better yet, as customers are enjoying samples or cocktails in their tasting rooms, distillery owners know exactly how much profit margin they are making on every bottle.

The Whiskey Systems team has a motto: “If everyone did it perfectly, we’d be out of a job.” The truth is, every distiller worries about ensuring their distillery is in full compliance with local and federal regulations. Even if a distillery has been distilling for awhile using a home-grown pencil and paper log, the team at Whiskey Systems can help get the distillers caught up on their past reports, amend incorrect reports if needed, and get them trained and up to speed on Whiskey Systems quickly.

Distillers who tried to handle TTB production reporting on their own often say they stay up at night worrying about their compliance. Once they get on the Whiskey Systems platform, caught up with any missing reports, and see the benefit of using a time-tested system, they sleep much better at night. Schedule a demo today to see how Whiskey Systems can make your life easier. Email Sales@whiskeysystems.com now or visit www.whiskeysystems.com for more information.

Now, back to your quest for the right alcohol still…

> Contact StillDragon today for helping choosing your equipment.

How Do I Get a TTB License and Permit?

Posted on by birendra@midnightmachines.io

So you’ve decided to start a commercial distilling business and you’re doing your research on what to do to be within the law. First off, congratulations! This is a big step and, like any permitting process, it can be a challenge – but thankfully there are some resources that can help you along the way.

The first thing you’ll need to do once your building and commercial distilling equipment are in place is register with the TTB and figure out which of the TTB permits online is best for your business. There are several options here and picking the right one will help make the process as streamlined as possible. Most of our readers will likely need a Distilled Spirits Permit (DSP) but some may desire a Fuel Alcohol Plant Permit. We’ll focus primarily on the DSP, but touch on the other as we go along.

Obtaining your TTB license is a vital step because you cannot legally begin production until your permit is approved. In order to get it approved, you will need to have your all your equipment, including your tanks, housed in a separate area in such a way that “the revenue will be jeopardized or the administration of TTB regulations will be hindered.” This means that you cannot have your equipment in a private home, on a boat, or anywhere that an inspector cannot easily access.

The TTB advises that generally construction should be completed and the necessary equipment is in place before you begin the application process. This will allow inspectors to do their job more quickly and efficiently and help prevent return trips and further delays. Both types of permits have very similar requirements but fuel alcohol plants are not expressly forbidden from operating outside of a home but due to the various requirements in each state please cross reference with your local authorities and contact the TTB directly with questions.

Now that you know what you’ll need to get started, you’ll want to select the correct permit for your needs. Generally if you plan on producing ethanol for human consumption, you’ll need a DSP. If you’re using it as a fuel source or as an intermediary for a fuel source then you’ll need an Alcohol Fuel Plant Permit.

(Another type of permit called a Specially Denatured Spirits and Tax Free Alcohol Permit can be much more complicated and is beyond the scope of this article.)

If you have your commercial distillery equipment and operation set up (or at least almost set up) and you know what type of permit you’ll need, it’s time to gather the required paperwork to complete your application. This will involve a bond, corporate documents, a lease agreement or proof of ownership of the property, proof that the applicant has signing authority within the organization, a diagram of the facility itself, and a source of funds declaration.

The corporate documents include the articles of incorporation for your corporation, LLC, or partnership. If you submit a lease agreement, it must show that the owner of the building knows that you plan on distilling alcohol on the premises. This even applies to owners leasing the building to their own business. The signing authority authorization can consist of any of the following: an excerpt from the Articles of Incorporation (Corporations); an excerpt from the Articles of Organization (LLCs); an excerpt from the Partnership Agreement (Partnerships); copies of a relevant resolution; official company meeting minutes; TTB Form 5100.1, Signing Authority for Corporate and LLC Officials; or TTB Form 5000.8, Power of Attorney, if someone other than an employee, such as a consultant, will act on behalf of the business entity.

The diagram of the premises has several requirements and must:

  • Indicate the dimensions of the premises in feet and inches;
  • Identify which areas are bonded;
  • Show where all doors are located; Indicate which direction is “north”;
  • If applicable, identify any areas used as general premises;
  • If applicable, show where cased goods will be stored on bonded premises;
  • If applicable, show where the tasting room and/or retail store will be located.

Finally, all partners must declare the source of funding; whether from loans, gifts, or personal accounts.

When your business is set up, you’ve got all your paperwork together, and you know what permit you’ll be applying for, the next step is to apply for one of the TTB permits online at the TTB website. In order to do that, you’ll need to create an account and walk through the New Applications Wizard. Any partners in the organization, officers, directors, trustees, or anyone holding at least 10% of the company will need to fill out a personal questionnaire on the site. An Application for Original Entity and Commodity Operators Application will need to be filled out as well.

If you’ve made it this far then congratulations! You’ll be given a tracking number, and you can relax a bit before the next steps. The TTB will process your application and one of two things will happen: either your application is approved or you will be asked to correct something on your application. The current average processing time for a DSP is over 80 days, so be sure to check back regularly to see if any correction requests come in.

Once you receive final approval, you’re fully licensed and ready to go. You can now legally distill alcohol and hopefully start having some fun!

> Contact StillDragon today for help choosing your commercial distilling equipment.

What You Need to Open a Distillery: 3 Building Requirements

Posted on by birendra@midnightmachines.io

So you’ve got your business plan completed, your building is picked out, and you’re ready to buy equipment for your new distillery or expansion. But before you sign your lease or buy that shiny new equipment, there are a few easy-to-overlook building requirements for a distillery that may be worth double checking. It takes getting a million things correct to be a success, but often one tiny miscalculation can mean the difference in being up and running or facing more delays (and more costs) than you had anticipated.

What Do You Need from the Building Itself to Open a Distillery?

Think about the height restrictions in the existing structure. What about power – what kind do you have available? How easily can you change anything in the space without incurring extra costs that cut into your bottom line? It’s important to know what you have to work with in your space so that you can make informed decisions about your distillery equipment placement and configurations in order to avoid having to pay to change the building to accommodate the custom equipment you may have already ordered.

3 Key Building Requirements for a Distillery

  1. Ample ceiling height is a very easy factor to overlook when you’re selecting your facility but it can be the most difficult to work around. It may sound obvious, but many building owners don’t like their tenants to knock holes in the roof of their building. Normally it’s not a problem but what happens when you decide to add a vodka column to your system? Or worse, what happens when the inspector decides that everything needs to be 18 inches higher off the ground to minimize explosion risk? These scenarios may or may not apply to you directly but they are worth considering before you find yourself faced with some tough decisions. Our post on space requirements for a distillery is a great guide on this topic and floor space considerations.
  2. Available power is another potential bottleneck that can be easy to forget about until it becomes an issue. Does the building have enough power to run all of the equipment that you’re planning on using? Does it allow room for growth when demand exceeds your expectations? Single phase 120V power may be enough to get started but it would be wise to give yourself some wiggle room so that you can add on a chiller, upsize your boiler, or some other piece of equipment to help you run more efficiently in the future.
  3. Water availability and quality have always been on a distiller’s mind, there’s a reason certain world renowned spirits are from the areas they’re from. These days it can be as simple a hooking up a RO system to your water line to obtain a pure water source but there’s more water that goes into producing a quality spirit than what goes into your kettle and mash tun. You’ll likely need water for your heat exchangers, both for your steam and your coolant. The gallons can add up quickly if you’re not careful and the regulations for what to do with it after it’s been through your system can vary from municipality to municipality. Disposing of or treating these streams usually isn’t a big deal or much of a hassle but you’ll want to think about it so that you make sure you’re in compliance with your local ordinances.

So your building is as ready as you can make it, you’ve got your power and water sorted out and you’re ready to go from a facilities standpoint. You’re in the home stretch now but there are a few things to double check before you’re ready. It’ll be important to make sure that the area is clean and ready to stage the equipment and you have easy access to the tools you’ll need to make installing the distillery equipment as efficient and easy as possible. There are lots of nuances with big jobs like this and there’s no way to account for every contingency that could possibly happen. If you’ve read this far hopefully you’re asking yourself what else you need to think about and what could possibly go wrong, just being in that mindset will help you pivot when something unexpected comes up and make the task as painless as it can be.

> If you have questions about the process or what kind of equipment is best suited to your current resources, don’t hesitate to contact the team at StillDragon. We’ve helped people figure out workarounds for some unique restrictions and we’d love to help you as well!

 

How Does a Proofing Parrot Work?

Posted on by birendra@midnightmachines.io

A conventional proofing parrot (for distilling purposes) is a small, cylindrical collection vessel that catches distillate long enough to get an “on-the-fly” measurement of ABV being produced in real time.

How a Proofing Parrot Works

The reservoir on the proofing parrot allows the distiller to drop in a hydrometer for measuring the density of the distillate being produced. Ordinarily, this ABV measurement is only used to assist the distiller in determining if the still is performing accordingly. The on-the-fly measurement also helps the distiller determine how much more alcohol might be remaining in the distillation apparatus over the duration of the run.

During this time, the accuracy of the ABV measurement is not supercritical and indeed will not be precise at all. What is perhaps more important to the distiller is to be able to determine when a change in the quality of the distillate occurs. Kind of like the oil pressure gauge in grandad’s old pickup truck, accuracy isn’t nearly as important as consistency. If the pressure needle on the truck’s gauge moved away from its customary position, grandad knew the old pickup needed some attention. So that’s really the only degree of accuracy needed at the discharge end of the proofing parrot.

The rub here is that even though fresh distillate enters from the bottom of the reservoir and exits from the top, there may very well be some distillate trapped in the reservoir that is several minutes old. This lag in the distillate turnover rate can be more problematic on small, experimental / recipe development batches as the transition from heads to hearts does happen more rapidly. Some operators try to overcome the turnover lag by utilizing the smallest possible diameter on the cylindrical collection reservoir to minimize the liquid volume. However, the issue with this is that the smaller diameter doesn’t cope with all ranges of collection speed. More rapid collection speeds can increase the throughput speed of the distillate as it travels through the cylinder, and the result is that this creates hydraulic lift on the floating alcometer and causes an inexperienced user / distiller to assume the ABV is actually higher than it really is.

Ultimately, the conclusion here is that an inline alcometer reading is rife with inaccuracies, if accuracy matters.

The Advantages of an Electric Distiller’s Parrot

A good way to close the gap on those inaccuracies if shooting for an on-the-fly ABV measurement is to use an electric distiller’s parrot. The StillDragon electric parrot has several benefits over a conventional proofing parrot, including an easier read out, faster response time, no temperature conversion required, no reservoir of liquid to risk smearing, and no glass smashing. The StillDragon electric distiller’s parrot takes the vapor temperature and runs it through a microcontroller that runs a few conversions. Basically, the temperature of suspended vapor in a distillation apparatus has a direct relationship with the ABV of the resulting distillate. Have a look at an ethanol phase diagram to get a better understanding of how vapor temperatures equal ABV. As long as the user / distiller gets a good vapor temperature reading, the ABV reading is solid.

“With a Cooling Management system, the probe installed just above the dephlegmator may be the easiest. Or if you need a reading at 100% RR, then just below the dephlegmator with something to protect the sensor from reflux is fine too. For Vapor Management take off, just under the take off. And anywhere in the head for Liquid Management as long the probe is shielded from cold reflux.”

No on-the-fly measurement will ever be 100% accurate. Even a much higher priced, matching set of electronic density meters has a margin of error on a side-by-side ABV test. Hopefully this article has explained enough about the functionality of proofing parrots so that you’ll understand the reliability and liability issues with using either type of measuring device.

> Need help choosing equipment and accessories for your distillery? Contact the friendly and knowledgeable team at StillDragon today!

Women of the Distilling Industry

Posted on by birendra@midnightmachines.io

Table of Contents

  • Tara Cook of Tall Pines Missouri
  • Monica Pearce of Tenth Ward Distilling

Meet Tara Cook

Posted 3/3/2020

Exciting, yet humbling is one way Tara Cook describes her overall experience opening Tall Pines Missouri. After 20+ years in growing businesses with mass retailers, Tara and her family brought a piece of her dad’s hometown to Pineville, Missouri by opening Tall Pines Distillery MO. As a distillery owner, Tara is enhancing consumer experiences through the knowledge and workings of a grain-to-glass craft distillery specializing in Moonshine.

On a trip to her dad’s hometown, Tara discovered Tall Pines Distillery in Salisbury, PA and quickly befriended the owners. Taking advantage of the emerging Craft Boom, Tara opened her family-owned Tall Pines Distillery in January 2020, being the first legal moonshine distillery in McDonald County since prohibition. As a licensee of Tall Pines Distillery PA, Tara is able to produce and sell Tall Pines’ Moonshine, bringing their great products west of the Mississippi. Having her own DSP, Tara can utilize her experience in business development and her passion for distilling as she plans on expanding the family distillery to offer her own products including Aged Bourbons and Specialty Vodkas.

Located close to the scenic Elk River, and about 20 minutes from Northwest Arkansas – a quickly growing area, Tall Pines MO has the ability to provide Tall Pines products to the Four State area, as well as to midwest campers and floaters visiting one of the country’s top camping destinations. Tara believes the location’s beauty, local natural springs, and limestone not only create quality shine, they add to the ambience that is Tall Pines MO. Built in 2019, the distillery features a small indoor event space for live music and smaller parties, while a beautiful outdoor space can host larger events such as weddings and parties for all occasions. After overcoming the difficulties of understanding the Federal, State, and Local Government requirements and expectations, Tara is helping her community by using local ingredients and creating memories.

As Tara continues to grow her distillery through research and continues to experiment to redefine ways to create all-natural spirits, she does have a little advice for those future distillery owners out there: “Surround yourself with experienced, highly knowledgeable people in the industry who can mentor you. Continue to educate yourself and become an expert in the field you are specializing in.”

That’s advice that Tara herself listened to when she started down her path with Tall Pines Distillery. As Tara and her family continue to bring craft spirits to Pineville, they are planning to enjoy meeting new visitors who wish to experience the grain-to-glass spirits, while overcoming any new obstacles that they face in their new distillery.

>> Looking to open your own distillery? Contact the team at StillDragon today for advice on equipment!

Meet Monica Pearce

Posted 2/27/2020

Monica Pierce

“Female empowerment is a trend right now…” Monica Pearce from Tenth Ward Distilling couldn’t have said it any better! Hopefully it is a trend that will stay.

Women are more prominent in the media, breaking glass ceilings, and building all kinds of businesses, including Craft Distilleries.

StillDragon is working to support the Women of the Distilling Industry and Monica Pearce couldn’t have been better to start with! Utilizing a Bachelor’s in Environmental Science & Policy, an Executive Master’s in Natural Resources, and a love for good whiskey,

Monica decided to indulge her passions in 2017 when she opened a craft distillery in Frederick, Maryland, following sustainable practices and leaving the smallest footprint possible.

Monica’s distillery, popularly known as Tenth Ward Distilling- named for the prohibition-era wards that Maryland was divided into, specializes in “traditional spirits with an unconventional twist” such as Smoked Corn Whiskey and Caraway Rye which goes hand-in-hand with the distillery’s slogan, Ward Off Ordinary.

After her love of whiskey drove her to make her own, the small business has tasked Monica, often referred to as Boss Lady, with playing the role of every department that a larger company would have, she still enjoys that there is always something going on and constantly being challenged to be creative.

Having to be more flexible and continuously learn new things makes her job a bit more stressful, but it also makes the job more rewarding to Pearce.

One of Monica’s more rewarding tasks since opening the distillery, and the industry challenge Monica is most proud of overcoming, is 3 years of lobbying for Maryland Craft Distilleries to have on site cocktail consumption, stating that it “has been a game changer for Tenth Ward.”

Monica Pierce 2

Prior to the law changes, Maryland distilleries were only allowed to serve 2 ounces per person, per visit; now that they can serve more than 2 ounces, and are only allowed to use the alcohol they produce, Tenth Ward has the opportunity to create a more “well-rounded end product” says Pearce.

Looking back along the process of getting to where she is now, Monica wishes she had “more technical capabilities, or a contact person, to research exactly what equipment was needed” but that hasn’t stopped her in building her business!

Monica has worked hard to build her business around many facets including sustainability through sourcing as locally as possible with used barrels from Virginia, labels from New York, grains from West Virginia and Honey and Mead from Maryland.

Monica is proud to note that her business is woman-owned and encourages other women trying to start their own distillery to “build it into your brand and story! People love supporting women-owned businesses.

Female empowerment is a trend right now and is a huge marketing opportunity that always helps me make the sale.”

Since opening the distillery, Tenth Ward has moved to a larger building in downtown Frederick, that offers more bottling and barrel storage space, plus the ability to host weddings, events, educational classes, and a super-friendly atmosphere to get a couple hand crafted cocktails!

They’ll even give you the recipes to take home and recreate- just make sure you buy a bottle or two!

>> Ready to take your distilling to the next level? Contact the team at StillDragon today for advice on equipment!

How Big Is a Distillery?

Posted on by birendra@midnightmachines.io

Starting a distillery sounds fun. There is something appealing, or almost powerful, about being able to render a product that was used as currency at some point in history. Being part of distilling is somehow glamorous, right? But once you start to deep dive into the intricacies, you will learn so much more than you would’ve expected. While developing your business plan for the distillery, you’ve probably decided what types of liquor you want to distill and determined the processes needed to perfect your recipe. Now you’ve got to find a building that allows you to put the proper-sized micro distillery equipment in place.

How Big Is a Distillery?

To help you calculate your space requirements, follow these steps:

Step 1: Determine Ceiling Height

Knowing how tall of a building you need will help you weed through the real estate listings more quickly.

When considering ceiling height, you’ll want to find a space that exceeds your distillation column height. For example, the tallest column heights belong to the vodka stills. Since vodka requires a pure spirit, you’ll want to have more plates stacked up so that you can run more efficiently, rather than do multiple runs. If your vodka column sits 20’ tall, try to find a building that has a 24’ ceiling height. This extra height helps when you’re assembling or cleaning the still, or when you’re doing maintenance on those high-up areas, as you’ll be able to really get up there for those pesky fixes.

At this point, you’ve probably already done the drawings for the system that you want, so contact your micro distillery equipment supplier to finalize the height of your column so you can take that measurement when you go real estate hunting. However, if your forklift has a back rest over the carriage, you’ll also want to take that into consideration, as that back rest adds another 3′ to 4’ from the top to the forks.

Step 2: Evaluate Square Footage

After you narrow your search down to buildings with adequate ceiling height, you’ll need to figure out the necessary square footage, taking into account:

Distillery Growth

An important factor to consider is making sure the building can cope with any measure of growth. When your doors open on day one, it’s a safe bet that you may not have even one single customer. With no customers, it is easy to assume that production levels are small. Therefore, it’s easier to assume that the primary, and any ancillary, micro distillery equipment fits onto the floor rather nicely. But once you gain traction and start to grow, you’ll need to account for additional storage of fermentables, bottles, barrels, and possibly more product storage holding tanks. One can only hope, right? But don’t hope for more space. Plan for it by considering whether your building allows for growth.

Kettle Size

As for the distillation kettle, you might be surprised to find that the bigger the kettle, the more cost-conscious on a per-proof gallon basis. For example, the StillDragon 500L Baine Marie is $30.37 per liter, whereas the 1000L Baine Marie Double Dragon is $17.61 per liter. And don’t forget, it’s easier to scale down rather than scale up. In other words, you don’t always have to have a full kettle charge.

When you’ve made the decision to get the bigger kettle and ultimately save some money in the long run, you’ll need to determine the footprint of the kettle. Is it tall and slender or short and squat?

When deciding where to put the kettle, you’ll want to make sure that there is room to get around the kettle, and that the infrastructure has enough room to do its job. For example, the plumbing pipes need to be installed in a way that does not make the still less user friendly to the distiller. If a utility pipe needs to make a 90-degree turn, there needs to be enough room for the pipe to do that. Or, if you need to pull some maintenance on your agitator motor (yes, you need to check the seals and grease them), you don’t want to be standing on top of the kettle to do so. You’ll want the kettle far enough off the wall so that either you and a ladder, or you and a forklift, can get back there.

Product Discharge Location

Once you’ve got the height, know that as a rule of thumb you’ll need 10’ off the wall for the kettle placement. But where is the spirit coming out, and what size collection vessel will you require? Where is the business end of the parrot facing?

Product discharge location is especially important if you plan on adding a gin column, or a secondary column, as this adds to the length of room that the micro distillery equipment will be housed in for perhaps the next 30 years. If you do add on that gin column, you’ll be adding about 4′ more in length, so you won’t be able to squeeze the column in that 15’ x 15’ space very easily.

Hearts Storage

Where are your hearts going to be stored? Are you going to roll in a tote? If so, add the height of the tote to your kettle drawings to make sure that the parrot is at the best height for the tote. And make sure there is plenty of room to get the tote in and out of the way of the system.

All Other Micro Distillery Equipment Sizes

Now that you’ve considered the space requirements for the kettle itself, you’ll have to figure out how many fermenters and what size mash tun you want in your distillery. You should ask yourself the same questions for every piece of machinery you put in your building:

  • What is the height?
  • What infrastructure do I need?
  • What is the length?
  • How am I going to do maintenance?
  • Is this space big enough?

> If you find yourself lost in all the information, give StillDragon a call at (561) 903-4784. We will help you find the right-sized equipment for all your needs. We can even help fit a still into the perfect location with the worst size restrictions!

The Beginners Guide to Thermometers for Distillers

Posted on by birendra@midnightmachines.io

Besides the question of “what kind of still do I need?”, I feel almost certain that the second most frequently asked question is “where do I put the thermometer?”.

The short answer is that the best place to locate a single thermometer is at the highest point of the apparatus.

Why? Well, there is a direct relationship to alcohol vapor temps and the ABV (alcohol by volume) of the finished spirit. By looking online, you can find an ethanol phase diagram that does a fairly good job of illustrating this concept.

The remaining considerations are largely predicated upon what kind of still are you running.

On column stills, it is not uncommon to find a thermometer located on the plate level just below the reflux condenser. The data at that location will basically tell the operator how long the operator will need to run the system in 100% reflux mode.

By that I mean how long to allow the system to enrich the liquid beds at each plate level prior to collecting product. Prior to collection, once temperatures have stabilized there will be no need to further allow the system to remain in 100% reflux mode.

Doing so would generally be considered a waste of time as a stable plate temperature indicates that the plate(s) are fully enriched. Further refluxing would waste fuel/energy and time.

Even a 5- or 10-minute savings per run could add up to dozens upon dozens (if not hundreds) of man hours at the end of a commercial distillery’s fiscal year. And so, a thermometer below the reflux condenser is clearly going to provide usable data.

Similarly, thermometers at every plate level will allow the distiller to have an even better understanding as to how fully enriched each liquid bed is. The distiller can watch each thermometer stabilize and know precisely when the column is fully enriched.

Thermometers for Distillers

Additionally, the commercial distiller will be able to read several thermometers at multiple plate levels to ascertain how optimally he (or she) is maintaining the temp gradient within the column during product collection. Bottom temps are far less stable compared to temps at the top.

Having matching temps at the top two plates indicates a very stable gradient. Having matching temps at the top three plates makes you a distillery god (or goddess)! Seriously though, maintaining stable temps at the top of the apparatus allows for optimal separation.

Then toward the end of the run when alcohol is running low, the distiller can observe the temps climb from the bottom up as an indicator that all of the usable alcohol has been collected.

For pot stills, the data is far less stable and therefore not as comprehensive. Certainly, being able to see temperatures can offer a measure of comfort to an inexperienced distiller. But as a pot stiller, you will find that you have absolutely zero control over temperatures. More on this in just a minute.

 Let’s start with the boiling point of water.

The boiling point of water is 212 degrees (100 c) F. And no matter how much heat you throw at your kettle, the liquid temp of water at boiling will never exceed 212 (at sea level). As long as there is water in the kettle, the temps of the water indeed cannot exceed 212 f because, well, that’s what water boils at. Not 250 f. Not 300 f.

Next, the boiling point of ethanol is 173.1 F (78.37 c). However, ethanol is 100% infinitely miscible with water. That means that ethanol mixes quite nicely with water. And the boiling point of that mixture is determined by the percentage of alcohol within that mixture.

In short, a 10% mixture will have a lower boiling point than an 8% mixture for example. So, a 10% alcohol to 90% water mixture will boil at some place between 212 f and 173.1 f.

For the sake of this discussion, lets assume that we will start producing vapor a 190 f. and start to collect distillate. As we collect the distillate, the liquid and vapor temperatures in the kettle must increase.

This is so because we are now changing the boiling point of the kettle charge by removing a percentage of the mixture that has the lower boiling point. And the more distillate we collect, the more temps will continue to increase.

Lowering heat input to try and stabilize/control temperatures will only serve to slow collection speed or completely stop the flow of distillate all together.

Notwithstanding the middle part of a larger kettle charge, when  pot stilling if you are able to stabilize and hold a temperature, it simply means that you are not collecting distillate.

The broader point here is that the liquid in the kettle will boil when it boils. And as long as you are collecting distillate, you’ll have no control over any of the temperatures. As the distiller you’ll be able to control heat input, but that is not at all the same as controlling or particularly stabilizing your temperatures.

Monitoring temperatures on your pot still can assist as a timing mechanism at best. Need a thermometer on your pot still?

It’s not going to hurt. But it’s also not going to help you as much as you previously may have thought. Learn to gauge the thickness of your distillate discharge stream, make your cuts according to smell, taste, and physical touch and you’ll make a far better finished spirit than focusing on temperatures.

>> Still have questions or require additional information about StillDragon equipment? Contact StillDragon today.

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