Author: birendra@midnightmachines.io

Choosing the Right Bubble Cap for Distilling

Posted on by birendra@midnightmachines.io

One consistency among distillers is that everyone has their own idea of the right way to distill, down to the equipment. You’ll hear people tell you all copper, some say less copper, some use plates in their column and other’s prefer pot stilling. We’ve written about the pluses and minuses of copper, now let’s talk about the bubble plate column theory.

Bubble Plates and Bubble Caps for Distilling

Bubble plates are used to create more reflux in the column, ultimately to create multiple distillation cycles during one run. In review, a distillation column is phase change occurring over and over until it reaches the final the final condenser. The Bubble Cap is the main factor of creating the phase change. As your vapor rises out of the kettle and into your column, it is going to flow through the path of least resistance. The Bubble Cap is designed in 2 parts, the underside, which is basically a tube with windows at the top, and the mushroom top – designed with many arches around the edge. The vapor flows up the tube and through the windows where it is pushed back down towards the plate and typically out of the arches. As you continue through the run, a waterbed will develop on each plate, this is caused by the vapor being knocked down as it hits cooler temperatures of the plate or the column itself. As vapor passes through the bubble cap, it is pushed back towards the plate, where the vapor will condense, heating the water bed and creating a vapor of higher proof distillate. This happens on each plate you have, so if you are working on a vodka and you have 22 plates – that’s 22 times distilled. StillDragon also offers the ProCap which is a bubble cap and downcomer integrated, which allows for a speedier run.

Let’s not forget the benefits of the copper being so predominant in the vapor path. Each plate and Bubble Cap works to extract the crap out of the liquid. The more plates you have the vapor going through, the cleaner and purer your distillate is going to be.

Of course, not every distillery only wants to do vodka or gin which require the flavorless, higher purity distillate created from having all the plates. Enter the pot still. Whiskeys and rums need a less pure, more flavorful spirit to create the final recipe so they would be better off with a pot still or use of a whiskey hat versus the plates. The pot still and whiskey hat create some reflux as the vapor hits the sides that are exposed to the lower external temperatures. The vapor can also go straight through to the lyne arm and into the product condenser.

The downside is the expense of having two different stills. You’ll need twice the money, twice the plumbing, twice the heating elements, heck you’ll need almost 2 of everything. Don’t forget to take into consideration the space requirements for both stills. Using all of these factors, StillDragon developed the DoubleDragon. It incorporates both the pot still and the bubble cap still design onto one kettle. The kettle allows you to create multiple product types without much added labor, time, or expense.

Check back next month for a deep dive into the benefits of the StillDragon® DoubleDragon.

> For more commercial distilling needs, browse StillDragon equipment.

 

7 Questions to Ask Yourself When Purchasing a Still

Posted on by birendra@midnightmachines.io

When choosing the best configuration for your custom still, the primary tool of your craft, it’s best to do your homework and understand what equipment you want, need, and why.

1. What spirits will you be making?

The spirits you’re producing are the cornerstone of the still design, but each category of spirit has rules that must be adhered to. With that said, you have many options on how to achieve those desired results. A great example is bourbon whiskey, a focus of many new US craft distilleries, and without getting into all of the detailed requirements from the TTB, it must be distilled from grain only fermentables, of which at least 51% must be corn. Bourbon whiskey must be distilled at 160 proof or below and barreled in new charred oak containers at 125 proof or below. On the other hand, if you decide you’ll be making vodka as well, TTB regulations are much simpler, but keep in mind that doesn’t mean the production is. Vodka may be distilled from any material at or above 95% ABV (190 proof) and not bottled at less than 80 proof. With these details in mind, you must then decide on your preferred distillation method for each product.

2. What process or processes do you prefer to use in making your spirits?

Continuing with bourbon whiskey and vodka as examples, as they are most often distilled using different processes at the craft scale.  Do you prefer to pot still your bourbon, if so, how many passes? Or perhaps you’re fond of doing a single pass through a plated column, or maybe you want to try and catch up to the big guys and use a continuous distilling process? You could do a combination of these processes or use a specific process for different SKUs or products. On the vodka side of the world, pot stilling could be entirely too inefficient, and a batch column or continuous column is a must.

3. What volumes of product will the still need to be capable of and in what timeline?

Desired output is the best metric to decide the size of the equipment needed. This goes for the still and all supporting equipment- mashing, fermentation, storage, blending, bottling, etc. By starting with the desired output and timeline, we can effectively size all the equipment starting with the still, the center of production, and working out both directions from there. Bottlenecks in production can happen anywhere in the supply and process chain, but if the still is undersized it can be the most difficult obstacle to overcome.  

4. What are the space requirement for the still(s) and the supporting equipment?

Now that you’ve decided what products you’re making, how you’re making them, and have figured out what size equipment you’ll be needing, the next step is to decide where the still will go. Often the still is considered a beautiful showpiece or the center of attention, but it is also the key component in your production process where accessibility and usability are of the utmost importance. Center of attention is fine, but first it must fit in the space. Do you have the ceiling height to accommodate an 18-foot Vodka Column?

5. What infrastructure needs to be in place to effectively operate the still?

When installing the infrastructure for the still it breaks down into simple categories, heating and cooling. It is paramount to have clear communication between the operator, the facilities contractors, and manufacturers. Make sure everyone is on the same page and the numbers work. First is heating, without applying heat you’re not going to be distilling anything. What will be your heat source, steam, electricity, or some form of direct flame? Each heating system requires different infrastructure, all with a different safety focus. If you’re going to be heating using electricity, does the building have enough power to properly heat the system that you want to procure. No sense in vaporizing the spirit without the ability to condense and collect, how are you going to cool your product? Again, you will have a few options on cooling protocols, crunch the numbers and plan according to your processes. You will most likely be using these same heating and cooling systems for other parts of the process such as mashing and fermentation. All these factors are going to affect your budget, make sure to account for everything and then a little extra.  

6. How important is the still aesthetic to you?

We’re all human, we are all consumers whether we like it or not- priorities and preferences will vary greatly. As touched on earlier, the still is often a showpiece or functioning work of art; entire distilleries have been built around the idea of tours and visitor experiences,  in these cases the still is almost always the primary focal point of the experience after the spirits themselves. In these cases, wow factor is a must, on the flip side of the coin, many distilleries see the still as just another tool to be wielded by the distiller. In these cases, a pretty still may mean little or nothing to the operator as long as they can produce the quality and volume the distiller expects.

7. What’s in your budget?

The still is one of the most crucial components of the distillery, and you should purchase a distilling apparatus that best accomplishes your product goals, but don’t forget to factor in financial goals. Once you’ve decided what you’re going to produce and how much of it, you need to factor in other variable costs such as the ingredients and bottles, these numbers can change based on the size of the still you procure. Budgeting doesn’t stop there though, the cost for rent, electric (especially if heating and cooling with electric), and any other overhead should be factored into your budget.

The best piece of advice for anyone thinking about upping their hobby game is to do your research! Research every facet of the what it takes to open a distillery, and keep it running- from what type of spirits you prefer to make, to whether you want a more aesthetically pleasing distillery, to the cost of the water and electricity in the downtown warehouse district. This is one of those times that too much research isn’t possible! If you’ve got more questions, give us a call, we’d be happy to discuss your distillery needs and help you get your still on the right side of the books!

> Looking to upgrade your still or expand your production floor with new distilling equipment? Contact StillDragon North America for advice.

Triple Distilled Whiskey Techniques

Posted on by birendra@midnightmachines.io

By: Larry Taylor

When we talk about distilling, we are more precisely referring to phase change or a phase change cycle. We all remember (or should remember) the term “phase change” from our eighth grade science classes, right? Simply put, phase change is a change from one state (solid, liquid, or gas) to another. For example, freezing water is an example of phase change in that liquid water will change to a solid once frozen. Or once brought to boil, liquid water will change to a gas or vapor. Similarly, once the water vapor (gas) is condensed, it will change to a liquid. And so, distilling is nothing more than phase change. Simply put, distilling is the evaporation of liquid followed by the condensation of the resulting vapor created by evaporation.

Triple Distillation = Three Phase Change Cycles

Triple distilled whiskey is put through three of these phase change cycles. Often times, whiskey consumers might think that a triple distilled whiskey has a lighter, smoother quality than whiskies that have been double distilled. At first glance, this thought process seems to make sense since the distilling process is a form of liquid purification.

It seems simple. Heat up the kettle charge until vapor forms and rises to the top of the apparatus. Then the vapor makes its way over to the product condenser to be turned back into liquid form. In doing so, the lighter, rising vapor will leave behind a measure of congeners that have a higher temperature boiling point. And so, each time we distill the resulting distillate, we assume that we are leaving behind yet another measure of congeners that were previously bonded to our ethanol molecules.

Indeed, this is true. But what is also true is that some congeners will not get left behind after phase change. Not all congeners are equal. Not all have the same boiling point. Not all have the same polarity. Not all are 100% infinitely miscible with their neighboring constituents. So, while we can distill to leave behind different flavors, we can also distill to intensify (both good and bad) flavors.

So, how do we intensify the desirable flavor profiles without rendering an insipid finished product? (Oh, hey…is smoothness a code word for insipid? Asking for a friend.) Well, let’s have a look at a common protocol used to render whiskey. Let’s start with the understanding that our finished product will be put into the barrel at what would be considered “barrel strength” or “cask strength”. And, let’s start with the understanding that there will be some changes that occur in the distillate during the aging process.

First, the Stripping Run

Stripping speeds can vary among distillers. Distillers also have an opinion on whether or not to make any cuts on the stripping run. Some distillers are so fearful of having what they perceive to be Heads (or a foreshot) in their finished product, that they will insist on making at least a small Heads cut for safe measure. Some even make the tails cut. Making any cut on the stripping run will absolutely remove potential (good or bad) flavor from subsequent runs. In fact, some distillers likely add back Heads and Tails from previous runs in order to boost proof and carry over additional complexity.

One of the primary goals of stripping is simply to reduce the volume of water while dragging over as much alcohol (and flavor) as possible for the next run. Some distillers prefer to micromanage the heat input to the kettle for the sake of optimal separation during this first step in the process. Others prefer to throw as much heat as possible at the kettle for the sake of processing speed and to exploit the inefficiency of separation. And by that, I mean that during stripping, a faster collection speed will allow for more grain flavor to carry over into the low wines distillate compared to running more slowly.

Stripping for optimal separation will often times mean that the distiller will then need to dilute their low wines in order to achieve the desirable abv for the second run. Distillers often use water to dilute low wines.

Water Dilution = Less Flavor

To be clear, diluting low wines with water accomplishes two things:

  1. It adds additional material handling to the final product.

  2. It aids to break the bond of (both good and bad) congeners that are attached to the ethanol molecules.

Therefore, I would personally prefer to strip as fast as possible for the sake of processing speed, and to allow more grain flavor to carry over into what will become the next kettle charge. I would also strip far enough into the run to ensure that the aggregate abv of my forthcoming kettle charge does not have to be diluted. Perhaps to 18% or 20%? As mentioned, this eliminates additional material handling and ensures that robust grain notes are carried over into the second run.

To conclude this section, there is one more, lesser-discussed result of throwing more heat at the kettle during a stripping run…

Maillard Reaction

Maillard reaction is a term more familiar to cooks and bakers. Maillard reaction is a chemical reaction between amino acids and reducing sugars that gives browned food its distinctive flavor (and smell). Seared steaks, fried dumplings, cookies, biscuits, bread, toasted marshmallows, and many other types of foods undergo this reaction.

Throwing an adequate amount of heat at a kettle full of beer can also produce a Maillard reaction within the kettle charge. The Maillard reaction adds flavor to the beer and the resulting distillate.

BTW, the positive influence of Maillard reaction is why vacuum distillation will never (ever) be the preferred method for whiskey (or brandy) spirits production. Vacuum distilled whiskey? Don’t.

Second Distillation

Is the second run superfluous? A gimmick simply meant for marketing purposes? An effort by Irish distilleries to distinguish themselves against the Scotch whisky producers? Or does this added distillation cycle contribute to the formation of additional carboxylic acids, and thus more esters that can add additional complexity to the finished spirit?

This second process likely allows for lots of interpretation. To make cuts? To run slowly? To run fast? Could the second run be the secret sauce? The second run could be as basic or as complicated as the distiller deems necessary. Notwithstanding all the potential variables, this second run is intended to clean up the low wines and boost the proof enough to get very good still behavior for the third, and final, spirit run. And by that, I mean that on the third run the distiller is looking for the most consistent run speed to proof ratio from start to finish.

Third and Final Distillation

Ideally, the distiller would like to render the finished spirit at a barrel strength proof without having to dilute the finished product with water. Adding water can do one of two things:

  1. Open and reveal, or

  2. Literally dilute

In this case, I’m afraid the latter would prevail.

If a strict Heads cut was made on the second distillation, then perhaps a small Heads cut would be in order on this third and final run. It’s really the distiller’s call. At this point, the distiller can throw enough heat at the kettle to dial in spirit run collection speed against desired proof.

We can assume that this final kettle charge has a bit more abv than the second kettle charge. Therefore, running faster collection speeds will not affect abv adversely. Faster collection speeds will reduce the efficiency of more optimal separation. So, run slower to collect higher abv. Or, run faster to collect lower abv. But a reduction in efficiency is exactly what we’re looking for here on this third run. In other words, the distiller is looking to exploit inefficiency by running just a bit harder on this third and final distillation. Running harder will allow for more flavor carry over.

Is triple distilled whiskey better than twice distilled? Does triple distillation produce a lighter, smoother finished product? Does triple distilling add additional complexity? It’s not for me to say, though I’m sure the debate will rage on.

Is there more than one way to make a fantastic whiskey? Absolutely. I would definitely recommend experimenting with different production variables to help develop your own point of view.

Sláinte mhaith!

> Looking to upgrade or expand your production floor with new distilling equipment? Contact StillDragon North America for advice.

Mixing Heads, Hearts, and Tails

Posted on by birendra@midnightmachines.io

By: Larry Taylor

In a previous blog post, I wrote about Heads, Hearts, and Tails. It was very basic and not a bad place for the inexperienced distiller to get an introductory understanding of how these three transitions are characterized. In a nutshell: Heads = beginning, Hearts = middle, Tails = end

The blog post was intended to make the new distiller aware that the alcohol collected during the run does not remain uniformly consistent with respect to flavor profile. The new distiller is essentially encouraged to identify and isolate each “cut” as precisely as possible, with the message being that the Hearts cut is the most desirable. With more and more experience, the new distiller will ultimately develop enough skill to isolate Hearts very adequately.

Here comes the rub. Notwithstanding the desire to render a fairly neutral spirit for vodka, an all-Hearts cut for a flavored spirit like whiskey, rum, or brandy really does end up rendering a fairly insipid final product. A clean product, yes, but without complexity, and with minimal character and mouth feel. An all-Hearts finished product can often lack those familiar, inviting flavors that make our favorite spirit stand out as a truly well-made, thoughtfully rendered final product.

Finding the Right Mix

So, when mixing Heads, Hearts, and Tails, how much Heads or Tails needs to be added back to the Hearts section in order to produce a finished product that has all the hallmarks of a thoughtfully rendered flavored spirit? Ah, that is part of the secret sauce then isn’t it?! When thinking about flavor profiles, I try and use food analogies to help me get my brain around the concept of adding back what is more often considered the flawed distillate “cuts”.

Too Much? Or Not Enough?

Let’s start with table salt as an example. Not enough salt leaves certain foods lacking and dull. Even premium foods, right? Then, if you add too much salt, the food becomes inedible. But who decides how much salt is too much salt? Why are some foods just better being a bit saltier compared to other foods that seem delicious with little-to-no salt?

Now, let’s use a cut of meat as another example. Take what at one time would have been considered a low-quality, inexpensive cut of meat with maybe too much fat. Something that may have at one time been tossed into the rubbish bin. I always think of pork bellies. On pork bellies, there is usually a bit of a lean section surrounded by a giant blob of fat. As I rule, I generally hate fatty meats. But when cooked down long enough, the fat adds an incredible layer of complexity to finished pork bellies. Slow cooked pork belly is simply amazing! And so, we have a flaw (fat) being rendered down into the finished product, making the finished product better than it would have otherwise been without the addition of the perceived flaw.

I suppose I could probably think of a dozen more food examples that can help create parallels between flavored spirits production and cooking. It really is up to the distiller to decide how far into the Heads or Tails cut they are willing to dip in order to produce the kind of complexity that creates an award-winning flavored spirit.

There are, after all, 150 ways (or more) to make chicken soup. And likely an equal amount of methods for rendering a good, inviting, flavored spirit.

So, if you are a fledgling distiller, first strive to identify and become intimately familiar with Heads, Hearts, and Tails as individual components. Then, slowly circle back to experiment with mixing Heads, Hearts, and Tails by adding back small measures of either “late” Heads or “early” Tails to try and create your own secret sauce. Good luck!

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

Excise Tax Relief to Continue

Posted on by birendra@midnightmachines.io

Santa came a little early this year. Thanks to the hundreds and thousands of small business owners, distillers, and supporters of local distilleries heard by Congress, and to the hashtags – such as #ToastsNotTariffs and #StopCraftTaxIncreases – covering social media outlets last month, the Craft Beverage Modernization Act was prolonged into December of 2020.

Hooray for Excise Tax Relief!

The original Craft Beverage Modernization Act initially was passed as part of the Tax Cuts and Jobs Act of 2017. As stated on Congress.gov, the now-extended Craft Beverage Modernization and Tax Reform Act of 2019 aims to:

  • exclude the aging period from the production period for beer, wine, or distilled spirits for purposes of determining whether a taxpayer can expense, rather than capitalize, interest costs paid or incurred during the production period;

  • reduce excise tax rates on beer and distilled spirits;

  • permit the transfer of beer between bonded facilities without payment of tax;

  • increase the amount of the small wine producer tax credit and expand the categories of producers covered by such credit;

  • allow an adjustment to the producer credit for hard cider; and

  • modify the alcohol content limitations that apply to certain wines for tax purposes.

The prolonged act reduces the tax rate to “$2.70 per proof gallon on the first 100,000 proof gallons removed or imported, and $13.34 on the next 22.13 million proof gallons,” as per the TTB website. A proof gallon is defined by the TTB as “one liquid gallon of spirits that is 50% alcohol at 60 degrees F. Distilled spirits bottled at 80 proof would be .8 proof gallons per gallon of liquid.” Had the bill not been prolonged, distillers would have had to pay $13.50 per proof gallon, which could have quickly amounted to hundreds and thousands of dollars in taxes for craft spirits producers.

Although the major trade groups leading the extension were searching for a permanent reduction, garnering 326 cosponsors in the House and 73 in the Senate over the summer, the one-year extension offers some reprieve. However, many distillers and owners are proceeding with caution, either by cutting back production or not hiring and expanding, citing lack of confidence in 2021.

With a tumultuous election year coming up, all craft distillers and enthusiasts are urged to join a trade group or contact their Congressional representatives to make the tax permanent!

>> Need advice on choosing the right distillery equipment? Contact the team at StillDragon today.

Will 2020 Be the Gin Revival Decade?

Posted on by birendra@midnightmachines.io

Prohibition in the 1920s catapulted moonshining into a very lucrative, yet illegal business. There were moonshiners making hooch to get people drunk quickly, rotgut – containing poisonous wood alcohol, and the ever-potent bathtub gin. While it sounds horrific, Bathtub gin references poor-quality alcohol being made in the 1920s, but due to the height of the bottle used, the alcohol was topped off with water from the bathtub tap instead of the kitchen sink. The unpleasant taste of the bathtub gin made it harsh to drink and needed to be disguised, so speakeasies mixed it with sodas, fruit juices, and garnishes to give the drink a more approachable flavor. The taste of 1920s hooch, rotgut, and bathtub gin forced speakeasy bartenders to get creative, essentially paving the way for gin to be the basis of many mixed drinks being revived today.

Since the end of prohibition, gin became less popular as other spirits became more available and consumers started caring more about flavor. In the 1950s, vodka imported from Russia replaced gin in martinis, liqueurs became popular to flavor beverages in the 1970s, and around the 1990s pop culture started to influence consumers’ priorities in adult beverages. Fast forward to today: with the farm-to-table movement and local, small distilleries popping up everywhere, gin is making a comeback due to its unique qualities allowing bartenders to be creative with their drinks. According to the International Wines and Spirits Record, gin saw 8.3% global growth in 2018 over 2017, and Statista.com states that gin sales in the U.S. are expected to grow by 1.5% annually through 2023.

Why Is Gin So Popular?

This is where many expert theories differ. Some experts believe it is the versatility, others believe it’s the changes in flavors, and still others believe it is the plant-based and craft spirits trends.

As the craft movement continues, gin is a great capital-increasing spirit. Gin can be produced using the same distilling equipment as whiskey or vodka, it just needs a botanical basket added. A good, flavorful gin can then be quickly produced and marketed while distillers are aging their whiskey and bourbon, building capital to reinvest in the distillery. Small batch producers are also experimenting with gin in ways such as pink gin, like Lawless Distilling Pink Gin, and gins with more natural botanicals from basil to oranges, like Norseman Distillery’s Strawberry-Rhubarb Gin. Distillers can also reuse their whiskey and bourbon barrels to age their gin products, like Big Cypress Distillery’s Sloe Gin Liqueur.

Consumerism today is pushing plant-based lifestyles, stating that eating more plants is healthier for oneself and the planet, and noting that the plant-based lifestyle is more sustainable. Today, consumers have a meatless option for almost everything from frozen, plant-based chicken to Burger King selling a plant-based Whopper -even milk has a variety of options made from nuts.

As the plant-based lifestyle continues to spread, eating local grows with it, and consumers want to support local markets and/or eat organically. It is believed that small-batch distillers obtaining their botanicals from local growers aids the theory that the plant-based movement is also encouraging the gin movement. Not to mention that the earthy flavors from the botanicals complement the plant-based lifestyle.

Enter the Mixers

This new-age gin evolves when mixers are added. The clear liquid doesn’t compete with the color of mixers like the dark color spirits, and at the same time, the citrus, floral, and herbal notes of the gin bring out the flavors of the mixers. Not only are some bartenders going back to the basics by reviving some of the prohibition era cocktails, but they are also improving upon them by using the recipes to create more complex cocktails. The fact that no two gins are exactly the same aids bartenders’ abilities to continually innovate their cocktails with fruits, herbs, sodas, and juices to appease the consumers’ tastes.

100 years after prohibition gave us bathtub gin, New Year’s Eve 2020 is bound to bring out the gin fanatics. The Roaring 20’s is expected to be a big NYE theme this year, complete with all the classic gin cocktails. Beyond NYE, gin is expected to lead the spirits market in sales, with continued growth for the next few years. While theorists don’t expect gin to take over the U.S. like it is the UK, the peak has yet to hit. Distiller and bartender innovation along with delicious cocktails will be the key to keeping gin on top in the future. Adding some locally grown botanicals can aid in bringing in newbie gin drinkers too!

>> Be sure to check out the craft cocktail recipe posted on our social media on Friday, December 27, 2019. It’s a classic throwback to prohibition.

What is Kale Vodka?

Posted on by birendra@midnightmachines.io

By: Larry Taylor

Please tell me you’re kidding? Kale vodka sounds horrible, because, well, kale is horrible.

Everyone knows that the reason people put coconut oil on kale is so that it slides more easily into the trash bin when you scrape your plate. Right? The difference between kale and a bowling ball is that if you absolutely had to, you could eat the bowling ball (according to my friend Carl). All kidding aside, I really do like kale as much as I like kale jokes.

Is Kale Vodka For Real?

Ok, so let’s get started on this kale vodka nonsense. Firstly, a kale spirit’s alcohol source is from sugar. Usually plain table sugar. Like humans, yeast cannot survive in a healthy manner on sugar alone. There must be some other type of nutritional adjunct added to the wash to provide a more optimal environment for the yeast to produce as much clean ethanol as possible while also not producing lesser desirable compounds in the wash.

Lots of nutritional adjuncts have been used. Corn, breakfast cereal, baby food, and tomato paste to name a few. Some of these adjuncts do allow for a certain amount of flavor carry over after distillation. Some breakfast cereals do allow for a fairly respectable faux whiskey kind of spirit, for example. The grains used in the cereal carry over to the finished product during the distillation process.

Why Kale?

Kale, on the other hand, happens to be one of the nutritional adjuncts that allows for very little flavor carry over (thank gawd) after distillation. This lack of flavor also allows the distiller to operate a less than optimal rectification tower and still produce a relatively flavorless final product.

The other determining factor for kale use is that it can be very cheap and easy to grow in many regions. My friend Greg has a fairly robust kale garden. Plus, there may or may not be some other (human) health-related benefit to using kale? Certainly, the yeast don’t seem to mind at all. But yeast are super easy to trick, because, well, they’re just single-cell organisms. Just kidding. Yeast are actually terribly hard to trick and require quite a bit of careful babying in order to get them to be good, clean producers. However, yeast seem to play along quite nicely with kale.

Curious about kale? Give this a try and see what you think. It’s dead simple.

50 Gallon (200L) Kale Wash

  • 800 g kale blended with water
  • 40 kg white table sugar
  • 720 g bakers yeast

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

6 Reasons Why Copper Is Used for Distilling Equipment

Posted on by birendra@midnightmachines.io

Copper still manufacturers know that copper isn’t just a pretty face. When it comes to copper distillation equipment, the copper also serves a useful purpose. Here are six reasons why copper is beneficial in the distillation process.

1. Oldest Pedigree: According to Copper.org, “Copper is man’s oldest metal, dating back more than 10,000 years.” Simply by virtue of the technology available at the time, copper would have been the metal of choice for producing all manner of implements used to make ancient man’s life easier. And, since the practice of spirits distillation is some two thousand years old, it makes sense that copper would be the material of choice.

2. Easiest Deformation: As luck would have it, this ancient metal allows for an easy process of changing shape as copper is very malleable. Therefore, very early on in history, it seems clear that the use of copper for different types of vessels was a logical choice, given the fact that production technologies of the time were limited. For distilling purposes, one assumes the use of copper was largely predicated upon ease of use.

3. Antibacterial Properties: Interestingly, copper can eradicate certain types of bacteria and fungi. Copper is commonly used for fungus control in all kinds of agriculture. It is also no surprise that copper piping really is the preferred material for residential and commercial water supply lines as copper is commonly used as an algicide for water purification.

4.  Thermal Transfer Properties: For some miracle reason, no doubt, electrons can move freely through copper. These conducting electrons help copper be a very good conductor of heat (and cold for that matter). For spirits distilling purposes, applying heat and the removal of heat is a requisite. Copper does both very well.

5. Volatile Sulfur Compound Removal: Less than optimal fermentation practices can lead to poor yeast health as fermentation works toward completion. Aside from copper’s antibacterial qualities, the characters of copper allow it to have a chemical reaction inside of distillation equipment to remove volatile sulfur compounds released by the yeast during fermentation. These sulfur compounds can affect the final perceived quality of the finished product. The debate will forever rage on with respect to how much copper is needed in the vapor path to sequester sulfides. However, one thing is certain: you can’t have too much copper in the vapor path. Be warned. though, using copper as a crutch for practicing less than optimal fermentation techniques is not going to produce an elevated spirit.

6. Beauty: Last but certainly not least, copper is for some reason so compelling to look at. When shined up, it’s hard not to stare! Even when the patina has been fully developed, it’s hard not to stare! For some reason it’s almost therapeutic to stare at it. It is mesmerizing. It is magical.

Ready to purchase copper distilling equipment for your commercial distillery? You’re in the right place! StillDragon.com carries a variety of copper still components. Shop now >>

A Key Piece of Distillery Equipment: The Forklift

Posted on by birendra@midnightmachines.io

By: Montvydas Banionis

Safety first! This mantra applies to all businesses, but especially to distilleries. Forklifts are commonly used in distilleries large and small, and – according to OSHA statistics – forklifts are commonly responsible for serious injuries in the workplace.

Many distilleries just starting out will purchase used equipment that may not have been properly maintained by its previous owners. Forklifts are no exception. Have a qualified person inspect any piece of equipment you add to your distillery, regardless of whether the equipment is new or used. We can’t stress this enough! Sometimes new equipment gets jostled in transit.

First off, there are several different classes of forklifts. It’s much easier to figure out what sort of daily procedures must be put into place to properly maintain a forklift if you know in which class the forklift belongs. The different classes of forklifts include:In this article, we will go over some procedures to properly maintain a key piece of distillery equipment – the forklift, as well as provide tips to stay safe while operating and working around forklifts.

  • Class I: Electric Motor Rider Trucks
  • Class II: Electric Motor Narrow Aisle
  • Class III: Electric Motor Hand Trucks and/or Hand/Rider Trucks
  • Class IV: Internal Combustion Engine Trucks with Cushion Tires
  • Class V: Internal Combustion Engine Trucks with Pneumatic Tires
  • Class VI: Electric and Internal Combustion Engine Tractors
  • Class VII: Rough Terrain Forklift Trucks

The following tips and advice will focus on Class I and Class IV industrial, sit-down, counterbalance forklifts on either cushion (indoor, smooth floor use) or pneumatic tires (outdoor, dry conditions). Class I is for electric motor trucks, while Class IV is for internal combustion engine trucks.

Before any distillery personnel can operate the forklift, they must be trained and certified by a professional instructor. If the forklift is new, the company from which it was purchased may provide an instructor who will come out to the distillery and teach those being certified in operating the forklift. A Train the Trainer course may also be offered.

If the forklift is used or the company selling the forklift doesn’t offer the training, OSHA provides a plethora of information about forklift certification here.

Maintenance Logs

After forklift certification is complete, a designated distillery employee should be tasked with performing daily routine safety maintenance logs. These daily maintenance logs are required by OSHA under article 1910.178(q)(7), which states, “Industrial trucks shall be examined before being placed into service.”

As we mentioned earlier, it’s much easier to gather the information you need to properly maintain a forklift if you know the forklift’s class. This is because maintenance logs can be found online according to the class of the forklift.

Most of the logs go over the basic information that makes up the daily checklist. Some of that information pertains to the following aspects of the forklift:

  • Frame – Make sure that the frame is not damaged or that there are no visible cracks.
  • Tires – Depending on the type of tires mounted on the forklift, check to see if there are any visible cracks or deformations.
  • Hydraulic Lines – Verify there are no visible cracks, tears, leaks, or breaks in the hydraulic lines that operate the forks. (Note: Checking hydraulic lines can be dangerous. It is recommended to perform visual checks of hydraulic lines while wearing proper safety gear.)
  • Interior – Confirm that all switches and levers operate correctly.
  • Safety Equipment – Inspect the seat belts, harnesses, mirrors, and horns to ensure they are in good condition and operating properly.

The maintenance logs found online (depending on the forklift class) will go into more detail on all the parts that should be checked and kept maintained daily. Keeping a detailed log will help identify potential issues or malfunctions, cutting down on expenses. These safety checks are also important in keeping the forklift operator safe, as well as in keeping any distillery employees who work around the forklift safe.

Electric Driven Motors vs. Internal Combustion Engines

Deciding between an electric driven motor or an internal combustion engine comes down to the type of work the forklift will be performing. For example, if you are loading heavy equipment onto a tractor trailer, it is important to consider the weight that the batteries will add to the load to know whether the truck will be able to handle the weight. Discussing the ins and outs of your distilling business with a Certified Forklift Sales Associate is helpful to determine what class of forklift is most suitable.

Internal combustion engines (ICE) have some added safety guidelines to follow, as these types of forklifts run on propane, gasoline, natural gas, or diesel:

  • It is a recommended practice to shut off and disengage the fuel source from the forklift once it is no longer in use and is being stored.
  • When using ICE forklifts, being aware of the emissions and the ventilation in your workspace is one of the most important safety factors. Be sure to check the airflow while operating ICE trucks so that emissions do not build up.
  • The same can be said about the fuel canisters that go along with the forklift. Having extra fuel on the job site is helpful, but it can become dangerous if not stored properly. Taking the extra time to do research on how to properly store any fuel for the forklifts will help create a safe work environment and prevent on-the-job accidents.

However, electric driven motors also require ventilation when charging. According to OSHA, the batteries emit a highly flammable hydrogen gas when charging, which increases at the end of the charging cycle.

Therefore, proper ventilation with any class of forklift minimizes the risk of explosion, fire, and distillery employee accidents and hospitalization.

In Conclusion

As with any equipment, proper maintenance can prolong the life of a forklift. Proper maintenance can also help identify any issues before they become huge repair expenses or hinder the distillery’s activity because the equipment is rendered unusable.

Proper safety reduces the risk of employee incident. Be sure to have a safety checklist readily available at the start of each business day and ensure that your distillery employees are following all safety procedures. When in doubt, check out the OSHA website to find documentation on safety requirements.

> Looking to explore other distillery equipment options? Shop StillDragon.com now.

The Still Is Coming!

Posted on by birendra@midnightmachines.io

One of the most exciting parts of opening a distillery is actually receiving your custom commercial distillation equipment! All the well-spent money, and you finally get to see your dream in your distillery. Ah! It’s a great feeling. There are a few things you should be ready for before the truck shows up with your new distillation apparatus and system, though.

Shipping Commercial Distillation Equipment

StillDragon ships using Old Dominion Freight. We have a great relationship with them, and they have a great success rate! We’ve had customers schedule their shipments with lower rates where the trucks show up with holes in the floor – not Old Dominion! Old Dominion will show up with new-looking, safe trucks and a friendly driver. Another great part about the Old Dominion experience is that when the bill of lading is created, the pro number (tracking number) is assigned, so the entire shipment is tracked from our dock to yours.

In preparation to ship, we take precautions to ensure your commercial distillation equipment arrives as safely as possible. Your kettle(s) will have at least an extra 6” of skid on every side, the feet will be cleated to the skid, the kettle will be wrapped with multiple layers of protection, and then banded to the skid as well. These few steps will keep the kettle mounted to the skid throughout the duration of the journey. Once it has arrived to the local distribution center, you will get a call to set a time when it can be delivered.

Preparing to Receive Your Equipment

Commercial distillation equipment is heavy and awkward in size. Therefore, having an adequate forklift or pallet jack on hand for delivery is absolutely necessary. Typically, the forks are 48” long, so you’ll want fork extensions for any equipment larger than our 380L Still; the extensions allow you to get under the skid to safely pick it up to prevent the skid from teetering on the shorter forks. If you don’t own the proper forks, check with your local heavy equipment rental company. They will have everything you need in half-day or full-day rates. If you’re not sure what equipment you’ll need to receive your distillation apparatus, give us a call and we will happily provide the weights and dimensions.

Delivery Day!

Once you get all the pieces off the truck, you’ll need to inspect each skid and / or crate. While Old Dominion has a great success rate, unfortunately, accidents do happen. Make sure you note any damages to the packaging on the bill of lading BEFORE you sign it, and make sure you point them out to the driver. Sending us pictures will help, as we can quickly file a claim with Old Dominion. If you do experience damages, it is very important that you do not dispose of the packaging.

Once you’ve inspected the packaging, and signed the bill of lading, it’s time to unwrap your precious. It is important to take note of any damages to the distillation apparatus and system itself. Sometimes, accidents happen in shipping that won’t be visible on the packaging. If this occurs, it is imperative to notify us immediately with pictures, and again, do not dispose of the packaging. In the case of any damages during shipping, Old Dominion will send out a representative within 24 hours to inspect the packaging and equipment to issue an insurance claim.

The great news about all this is that it seldom occurs with Old Dominion, but it is still important to know what to do. Once you’ve received your commercial distillation equipment and inspected it for damages, you can FINALLY set up your long awaited still. And don’t forget to send us pictures of it set up, we love seeing our stills in their natural habitats!

3 Ways to Manage a Reflux Still Column

Posted on by birendra@midnightmachines.io

Understanding and managing a reflux still column is just one of the basic skills needed to operate distillery equipment. Balancing the temperature and alcohol by volume (ABV) is important when managing the performance of the reflux column still. Adjusting the reflux temperature can control the ABV, making it increase or decrease. A reflux column can consistently distill a high concentration of alcohol from a mixture that only has 8% or even 1% alcohol.

Here are three useful ways that a distiller can monitor ABV progress throughout the run:

  • Temperature principle (TP)
  • Concentration principle (CP)
  • Vapor-llquid equilibrium graph

Temperature Principle (TP)

Under the normal atmospheric pressure, the water boiling point is 100°C / 212°F, and the anhydrous (no water) ethanol is 78.4°C / 173.1°F. Since ethanol is infinitely miscible with water, the mixture’s boiling point will be somewhere between 78.4°C / 173.1 and 100°C / 212°F. As the mixture begins to boil, the components with the lowest boiling point will begin to vaporize first (typically the highest ABV concentration). As product collection during the run continues, the kettle temperatures gradually increase as the kettle charge composition changes. To ensure that you are getting optimal separation, it is recommended to slowly heat the kettle. Reflux Still Column | Reflux Column Still | StillDragon

Why do we need to know the relationship between the vapor temperature at the top of the apparatus and the boiling point? Because this relationship can help the distiller to determine the remaining amount of alcohol in the kettle. This also helps the distiller understand when to increase the reflux ratio in order to ensure that the requisite ABV is being rendered.

If, for example, 90°C / 194°F is the optimal head temperature for your reflux still column to collect alcohol, if the temperature increases during the distillation, the distiller can increase the reflux ratio and thereby increase the amount of ABV being sent over to the product condenser. Without an increase in reflux ratio (RR) the concentration / ABV of the distillate will decrease.

On the other hand, when the head temperature drops below the ideal temperature to separate the ethanol and water, the concentration / ABV will be higher. To resolve this problem, the distiller can reduce the reflux ratio and thereby reduce the ABV of alcohol collected as finished distillate.

Concentration Principle (CP)

The concentration principle is predicated upon the notion of positive feedback that occurs with multiple phase change cycles. For spirits distilling purposes, each time a water / alcohol mixture goes from its liquid state to gaseous state, this is phase change. And, from gaseous state back to liquid, is also phase change. Therefore, after one full cycle of phase change, the subsequent liquid rendered will always have a higher ABV content, as a percentage of water within the mixture is left behind during this mass transfer to the next higher plate on the column.

As the plate fills with enriched alcohol, the overflow will drain downward to the next plate level down. This overflow from above will also have a higher ABV compared to the liquid currently on the plate.All the while, the reflux condenser will condense a percentage of vapor to be sent back to the very top plate. This returning reflux will have a higher percentage of alcohol than what is currently on the plate.

We then have the plates being enriched from above as an alcohol-rich measure of liquid is being returned and distributed down to the next lowest plate level. while the distilling column is also being simultaneously fed alcohol from the kettle, and then being purified by way of phase change cycles that occur during mass transfer toward the top of the distilling apparatus.

Reflux Column Still | Reflux Still Column | StillDragon

This technique of enriching or concentrating the alcohol content with the reflux condenser at the top of the distillation apparatus while slowly drawing off distillate to maintain a high level of ABV during the run is the essence of the concentration principle. Careful and deliberate operation of the equipment can create a consistent ABV in the vapor, allowing the distiller to replicate flavor profiles over the course of multiple runs.

Vapor-Liquid Equilibrium Graph

Using an alcometer at the distillate discharge of the column can help the distiller understand what ABV of the distillate is. To run more efficiently and precisely, distillers can formulate an ABV rough estimate throughout the run using the different temperatures available. A vapor-liquid equilibrium graph is helpful to estimate the ABV in the reflux still column.

Collecting correct temperatures is an important factor in estimating the ABV during the run. You will need a thermometer at the top of the vapor path, after the dephlegmator (reflux column still condenser), and a thermometer to measure the liquid mixture temperatures in your kettle.

As always, should you have any questions or concerns regarding the use of your StillDragon distilling equipment, please don’t hesitate to contact us.

What’s in Your Glass?

Posted on by birendra@midnightmachines.io

For some people, understanding the differences in various types of liquor can be confusing. Many people who enjoy adult beveraging (our new, made-up word) really have no idea of the origin, composition, or even historical significance of their favorite distilled spirits.

For some basic background, let’s try and roughly define the four most well-known categories.

Brandy

Let’s start with brandy. Anything made with fruit would be considered brandy.

For the sake of this discussion, it is also worth noting that there are some linguistic differences in what constitutes similar or the same types of liquor that may be produced in non-English speaking regions. For example, as I mentioned brandy is made from fruit. But the word brandy originates from the Dutch word brandewijn. This seems logical based on the spelling similarities. But in the Balkans, this very same brandy that is pronounced brandewijn by the Dutch, is pronounced slivovitz. And in Chile the popular brandy is called pisco. Confusing no?

Notwithstanding varieties of fruit, growing techniques, regional weather conditions, fermentation, and distilling technologies, these examples are all brandies. With this single category of distilled spirits as an example, we can see that without some basic understanding things can get confusing quickly for an inexperienced enthusiast trying to make heads or tails of all the different choices at a big box liquor store.

Rum

Further adding to the potential for confusion, let’s look at rum. Or maybe we should say rhum? Either word is pronounced the same. Notwithstanding white table sugar, rums are made from sugar cane. More specifically, fresh pressed cane juice or molasses. The most notable difference is that r-u-m is made from molasses, a by product of sugar production, and likely the most familiar ingredient for the average person that enjoys a rum and Coke, for example. R-h-u-m on the other hand, is made by using the fresh pressed cane juice. Rhum does taste distinctly different as it has a grassy back note that reminds one of the cane fields. The other lesser known cane spirit is cachaca (pronounced kah-cha-sah), found in Brazil. This spirit is very similar to rhum in that it is also made from fresh pressed cane juice. Here again, we likely see the influence of different languages and regions used to describe and classify distilled spirits that are otherwise very much the same.

Whiskey

And now, for my more recent personal favorite; the whiskey category. Anything made with grains is whiskey. Spirits made with corn, barley, oats, wheat, rice, or any combination thereof is whiskey. There are dozens of sub-categories that can drive the discussion about whiskey down the rabbit hole of esoteric oblivion. Bourbon, Straight Bourbon, Scotch, Canadian Whiskey, Irish Whiskey, Rye Whiskey, American Whiskey, Tennessee Whiskey, Japanese Whiskey, etc. The list goes on. So, for the sake of simplicity, anything made with grains is whiskey.

Vodka

Finally, vodka. Vodka can be made from all manner of fermentable resources, but must be without distinctive character, aroma, and taste. Usually this is done by distilling to a very high level of purity compared to other types of liquor. Vodka’s popularity with mixed drinks is largely due to the fact that it is by definition very clean, and therefore will take on the qualities of whatever is being mixed with your vodka. There are also people out there that do enjoy and indeed critique the purity and clean mouth feel of a strictly distilled vodka served neat or with ice. There is a trend among some vodka drinkers to place their vodka into the freezer to give the spirit an even cleaner mouth feel. The thinking being that this is what is supposed to be done to smooth and improve the drinking experience. This is a flawed way of thinking if a true evaluation of quality is being assessed. Chilling the vodka will mask some undesirable qualities. It will also suppress some desirable qualities that can only be evaluated at room temperature. But, for the sake of enjoyment, enjoy your vodka the way you enjoy your vodka.

Historically speaking, the type of distilled spirits produced would have been predicated upon what fermentable resources were most readily available in any given region. For example, wherever there is an abundance of fruit, there would have likely been someone distilling brandy as the most readily available spirit. Similarly, rum production thrives in those regions that are best at growing sugar cane. And whiskey would have been the spirit produced in grain-growing regions.

The modernization of production technologies and the implementation of mass transportation has allowed some areas that may not have previously had access to more varieties of fermentable goods to now have the ability to produce distilled spirits farther away from traditional growing regions. This modernization has enhanced creativity by throwing a new spin on what and where your favorite spirits can be produced. So, get out there and do some sampling. Slàinte.

Questions?

Got questions about distilling equipment? Contact the team at StillDragon North America.

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