Author: birendra@midnightmachines.io

Diversity In Distilling

Posted on by birendra@midnightmachines.io

It’s no secret that most people attribute dudes with beards to being the creators of the spirits, but did you know women are starting to make a name for themselves in all things distilling? From owning the business to being the master distiller, more and more women are getting into the game. It’s no surprise that women are moving up in the distilling world, after all, there have been studies showing that women have a slightly better sense of smell and a more sensitive palette. Mix that with an interesting career path, a world of opportunity opens for women who want to get out of the administrative life. 

Women Distillers

A huge advantage to more women being in the industry is that it means it will become easier to visit a distillery that empowers diversity in a male-driven industry. Women in Distilling, a database created in Portland, Oregon, explicitly highlights distilleries that are owned and/or operated by women. It doesn’t stop there, the database also highlights marginalized people. The site offers an interactive map to consumers that enables them to locate distilleries in their area. As the consumer looks up local distilleries, the map indicates if the distillery is Woman-Owned, Woman Distiller, BIPOC, LGBTQ, and if the distillery is open to the public. 

As more women make their way into the spirits industry, more avenues open as well. Women of the Vine and Spirits is an organization that offers global membership to support the beer, wine, and spirits industry, where women can network with other women and education. The site offers a paid membership that gives women access to like-minded individuals and companies to network, collaborate, and learn from each other as well as opportunities to advance their careers. WOTV offers a job board, education, and resources to members to advance diversity in the industry.

The American Distilling Institute offers a Women’s Summit at their yearly conference to aid networking amongst female professionals. Not only do you get the benefit of the conference, but ADI creates a great networking luncheon specifically for women in any area of the field. 

With fewer than 1% of distilleries owned by women, the female presence in the spirits industry is growing year over year; the knowledge and networking that is available to women continue to grow. Take advantage of the resources that are available and become the next female empowered distillery!

The Double Dragon or the Pot Belly Kettle

Posted on by birendra@midnightmachines.io

What is a DoubleDragon Kettle?

The DoubleDragon concept was originally inspired by a request for a distillation system from a customer with extremely limited floor space. We initially thought we could solve some floor space issues by mounting the product condenser to the kettle. Nothing new there really. It had been done before and seemed a reasonable solution to help recover a bit of floor space. But the customer also wanted a traditional Alembic hat for pot stilling/stripping and a small column for flavored spirits production but did not want to waste the floor space of the more common divorced side column arrangement. So, we created a simple solution that allows for two types of distillation heads to be mounted to a single kettle.

The vapor circuitry for this system as well as the column bottoms return for this design is what makes the design more specifically useful than simply plopping two heads on a kettle and allowing vapor to find the easiest path. The vapor circuitry is set up so that the vapor can only exit the kettle from connection #1. At that point, the vapor can be directed to the finished product condenser or routed to the base of connection #2.

Connection #1 or #2 can have any type of distilling head. The most popular head for connection # 1 seems to be the traditional Alembic head. This head provides for traditional pot stilling as well as satisfies the more traditional, old-timey aesthetic that many distilleries are looking for. Connection #2 more often is the mount for a short column that can be used for flavored spirits. However, it would be no problem to outfit the kettle with a short column on connection #1 and yet a taller column (or the same size) mounted to connection #2. The choice of stilling head configurations is really predicated upon what goals the distiller has with respect to the mouthfeel and the brightness of the finished product.

The vapor path of the system is controlled by several 3-way valves that can direct vapor accordingly. As always, safety matters so we do outfit the kettle with a pressure relief valve so that the vapor pathways do not accidentally get closed off and create an unwanted pressure build-up in the kettle.
The ability to direct vapor to either distillation head allows the operator to create multiple flavor profiles from the same base fermentation. The modular nature of the assembly also allows for an easy gin basket addition or even a more typical divorced side rectifying column.

If flexibility is a key consideration for your production still, you should seriously take a look at the DoubleDragon kettle.

The Benefits of a Caribbean Rum Still

Posted on by birendra@midnightmachines.io

Caribbean Rum Still Video With StillDragon

Caribbean Rum Still Basics

Distilling has been around for centuries and has mostly developed over time through trial and error. While we do get a fair amount of questions about different types of systems and all-in-one setups that do a little bit of everything. These systems are fantastic if you have limited space or want to switch between several seasonal products but sometimes if you’re looking to make a unique spirit in a traditional way you need to have very specific equipment. 

Caribbean Rum Still Set Up

Traditional Caribbean rum systems are just that, very traditional. The underlying double thumper technology hasn’t changed much in the past few hundred years but it’s still the best way to make a traditional heavy, funky Caribbean rum. The problem is that these systems are designed to do one thing and lack the versatility to make much else without some modifications. They often also lack the quality of life improvements that make operating modern equipment more user-friendly and less labor-intensive. There are some counterintuitive benefits of these systems as well that aren’t immediately apparent without a deeper dive into the way these stills operate. 

Caribbean Rum Still Details

One of the most interesting counterintuitive properties of these traditional systems is that while they allow more of the “funky” Jamaican run esters to come across in the final product, they can actually have less fusel oil carry over that using a reflux column. This statement comes with a pretty big asterisk since the data is focused specifically on the funky, heavy Caribbean-style rums that have far more components than most comparable lighter rums.

The wash is a completely different animal between the two styles and likely is a huge contributing factor to why more fusels carry over with a plated column.

Another big difference is that columns can make the spirit “too clean” if you’re trying to make a funky rum. Distillation is inherently a separation process and typically doesn’t add anything that isn’t present in the wash. Columns are wonderful for making a silver rum or even a lighter aged rum you’re planning on blending later but they likely won’t allow those super flavorful esters to come across without blending some of the heads and/or tails back in.

Caribbean Rum Still CAD De

If you’re trying to make a few different expressions and don’t have the floor space to spare we can always hybridize the systems to get the best of all worlds in the same space. The drawing below shows an example of one configuration that uses our DoubleDragon kettles and some creative valve work to not only make a traditional heavy Caribbean rum but also lighter products as well.

Traditional ways of making spirits are time-tested and still have a place in the world but new technologies keep adding tools to help make products in new and different ways. We’d love to be a part of helping you design the right system to accomplish your goals and help you make the products you’re looking for. Leave a comment below or give us a call to let us know how we can help you make your next project a reality!

A Whiskey by Any Other Name: American Single Malt and Indiana Rye

Posted on by birendra@midnightmachines.io

Whiskey in all its forms has been going through a renaissance in the last few years and there are some “new”, at least officially, categories that show how the identity of whiskey in the US is maturing. Indiana Rye and American Single Malt were categories that didn’t exist a year ago and may not have been on everyone’s radar.

Indiana Rye was adopted by state law as its own category on July 1st 2021 and the Tax and Trade Bureau (TTB) has announced it has officially added the discussion of creating an American single malt category to its agenda for December. Both of these are significant additions to the list of American whiskey categories but to really understand how significant we’ll need to know more about each change.

Indiana Rye follows very close to the TTB definition of rye whiskey but with a few important differences. In addition to the normal rye requirements of at least 51% rye in the mash bill is distilled to no more than 160 proof, entering the barrel at no more than 125 proof, and using only charred new oak barrels,  Indianna Rye is manufactured and rested for two years within the state of Indiana. The definition of “manufactured” is not spelled out in the bill but with the significant amount of rye whiskey produced in the state even if you are sourcing your wash from another producer it shouldn’t be difficult to find one in Indiana.

It is important to note that the Indiana Rye Whiskey designation is a state law and not a federal category recognized by the TTB. The TTB does not officially recognize state-specific designations so Indiana Rye will join Tennessee whiskey as a state-wide designation.  

American single malt has been proposed to be a federal category as early as Spring 2022 if the TTB maintains its expected December announcement and everything runs smoothly. How likely this is to happen remains to be seen but the fact that it is officially being considered is an amazing first step.

Currently, there is no official designation for a single malt from the TTB, however, there are several categories of malt whiskey but no regulation covers the single malt category. The American Single Malt Commission (ASMC) is spearheading the lobbying efforts to create a new TTB designation for American Single Malt and the proposed definition is very similar to the definition for a single malt used in other countries but there’s no way of knowing what the final ruling will be until we get further along in the process. 

The ASMC has put forward this proposed standard for review by the TTB:

  • Made from 100% malted barley
  • Distilled entirely at one distillery
  • Mashed, distilled and matured in the United States of America
  • Matured in oak casks of a capacity not exceeding 700 liters
  • Distilled to no more than 160 (U.S.) proof (80% ABV)
  • Bottled at 80 (U.S.) proof or more (40% ABV)

If the trend of recognizing regional specialties keeps going strong, future special designations seem more likely. Will we see a New York Empire Rye or a Florida Rum next or maybe some other regional specialty next?

There are a few possibilities and now that the door is opening it may be time to write to your local congressperson or industry group to get your favorites on the docket! If you have a regional specialty or come under-recognized specialty spirit you’d like to produce, get the word out and let us know. 

Beginner Gin Recipe

Posted on by birendra@midnightmachines.io

When we talk about Gin, it’s quite a long story.  Gin holds a lengthy history, from a medical remedy to a cocktail spirit; and there are so many interesting things behind it.  Gin has been around since the 11th century. A lot of people might not like Gin because of its flavor or fragrance – some say it’s awful, harsh, and flavorless, but you know it’s completely not true to a true Gin lover, who might think otherwise. Despite a burn and bitter herby taste coming out at your first sip, the gin contains more than just one favor. It’s the most fruity and flavorful spirit on top of that spirit chain. Therefore, Gin is called a cocktail spirit and could be used to make any delicious cocktails in the summertime.  

What is Gin?

The word “Gin” itself comes from the French “Genièvre” and the Dutch “Jenever”, both of which mean “Juniper”. At its simplest form, Gin is a neutral spirit without any colors, which is made from fermented grain or molasses. Later, various herbs, fruits, and spices, known as botanicals, are added to the distillate to enhance the flavors and fragrance of the distillation. For some gins, distillers could add up to 30 botanicals or more. And they call it the “Botanist Dry Gin”.

History of Gin

Here is a gist of the history of Gin. By the 11th century, people had distilled juniper berries and used the distillate as a medical remedy for the disease. By the 17th century, the Dutch had started distilling malt or wine and added botanicals, mainly Juniper, to make it a medicine which was known as “Genever”. Genever made its way to England and became wildly popular in all alcohol shops in London. It’s because of how easy it was to make. People called it “Gin” as a simpler form of “Genever”. 

Later, Gin followed the footsteps of British sailors to the tropics. It became a supplementary ingredient for tonic water in which quinine was dissolved, and it was used to treat malaria. Nowadays, it is known as “the Gin and Tonic”, but bartenders make it more pleasant and drinkable for people to enjoy. Another point that you might want to know about Gin is that it was mixed with citrus fruit to help sailors avoid scurvy due to long-distance sea travels.  

Types of Gin

There are 5 various types of Gin that have ever been made in human history.

  • First is the Distilled Gin which is a redistilled white grain spirit flavored with juniper.
  • Second is the compound Gin which is a flavored grain spirit without added distillation.
  • Third is the London Dry Gin which is a redistilled grain containing other added botanicals in addition to juniper.
  • Fourth is the Sloe Gin which is a gin flavored with blackthorn fruit.
  • Last is the Old Tom Gin which is a distilled gin that has been slightly sweetened.

How to Make Gins

There are two ways to make Gins:

The first method is distilling. Gin is a spirit that has been distilled from grain or fruit (typically from wheat). Like other spirits, Gin is distilled in a process to capture the alcohol from the vapors which are generated from a boiling mash. After capturing all the alcohol and other flavorful elements, distillers commonly immerse botanicals in the vapor by running it through a chamber that contains fruits, herbs, and other spices. At the end of distillation, the distillate has no need for sugar added because the sweetness and flavors have been naturally added via the botanicals. In fact, the only thing that might be added later is water to dilute the alcohol to the acceptable point, which is 40% – the typical percentage for a spirit. 

The second method is cold compounding. For this process, distillers add flavorings to a neutral spirit, which has high strength as vodka. This process would be less time-consuming than the first one. Additionally, the flavorings can be flavor extracts, actual botanical, or a mix of the two kinds.

Can You Over-Distill Vodka?

Posted on by birendra@midnightmachines.io

Ah, here we are again at what appears to be yet another topical question with only a nebulous response to show for the effort. Oh, you needed a real answer? The answer is maybe or maybe not.

I digress. The definition of vodka according to the TTB prior to May 4th, 2020 is stated as the following: “Vodka is neutral spirits so distilled, or so treated after distillation with charcoal or other materials, as to be without distinctive character, aroma, taste, or color.” Needless to say, for some consumers, this definition describes a spirit lacking any type of character whatsoever. Speaking on behalf of some flavored spirits enthusiasts, who want to drink a spirit that by the TTB definition tastes like nothing? And even further, how will I, the consumer differentiate between X brand of vodka and Y brand of vodka if the “without distinctive character” standard applies to all vodka producers? 

Can You Over-Distill Vodka?

For the sophomoric consumer, there are little to no meaningful descriptors beyond the proverbial “oh it’s so smooth”. And by the way friends, the smooth descriptor used in the flavored spirits world is at best only a backhanded compliment. It is the “I can’t think of anything descriptively good to say, so I’ll use the word smooth” compliment. All of you whiskey snobs know who you are.

Be that as it may, differences in aroma and taste can be differentiated among different brands as well as those vodkas made with different base fermentation ingredients. And to be as impartial as possible, there is absolutely merit in a finished spirit that quite frankly is the hardest of all spirits to produce because it simply takes more resources to scrub all of the alcohol molecules as clean as needed for a customary, purely clean vodka.

Recently, however, the budding craft distilling industry has been pushing the envelope of creativity in an effort to capture the essence of hand-crafted, small-batch spirits production and the TTB has taken notice.

Some of these more well-capitalized boutique distilleries do have a budget for a proper vodka column. Those that don’t have to find other ways to produce a vodka that satisfies the more customary “clean” alcohol vibe. 

Or more specifically, they have to send the finished product through the still more than once, or twice, or three times. Do you see where this is going?

But there is a middle ground that can be achieved with some skill. It is the space that defines a clean, yet silky mouthfeel that also allows a delicate amount of essence to be revealed on the finish. It is the space that typically would be relegated to a silver or bronze medal at the tasting competition but has sales that match or even exceed its gold medal-winning contemporary. It is the type of vodka that did not check all the boxes at the tasting competition but is a fan favorite. This is the vodka that whiskey drinkers are willing to spend money on. It is indeed the vodka that will slowly change the perception of what consumers will come to expect in premium vodka. As of May in 2020, vodka can indeed be distinctive with character so says the TTB revised definition.

What Does All of This Mean?

So, let’s get back on topic. Can you over-distill vodka? Well, if your customers don’t really like the taste of spirits, and would rather only taste whatever mixer that happens to be installed in their cocktail? Then no. You cannot over-distill. In fact, maybe you should distill more?

But, if your customers are looking for something that is otherwise hard to find and has a clean, delicate finish that faintly allows the base ingredients to be revealed, maybe distilling less is more?

Can you over-distill vodka? The better question is how well do you know your market?

TTB Classification: What is Pea Flower?

Posted on by birendra@midnightmachines.io

Sometimes things just come together. There’s been a good bit of discussion on using Clitoria ternatea, AKA the butterfly pea plant in spirit production here in the US. Mostly the discussion has been griping and a little bit of jealousy since distilleries in Canada and other countries can use it to give their spirits a wonderful blue color while the FDA and TTB kept dragging their feet and not approving butterfly pea flower for use in spirit recipes. 

What Pea Flower Does to Spirits

This might not sting so much if it weren’t for the fact that spirits with butterfly pea flower used as an ingredient could be imported into the US but not produced in the US. That all changed with the announcement that the FDA approval of the water-based solution using butterfly pea flower as a coloring additive went into effect on October 5th. 

There isn’t much information that I can find past 2018 on the TTB’s guidance at the time of writing this article but with FDA approval it should be an allowed ingredient relatively soon, if not already. The FDA recognizes the aqueous solution of butterfly pea flower as generally safe so there shouldn’t be much pushback from the TTB.

This is great news for anyone looking for a natural food grade way to get a blue or purple color. There are not a lot of naturally occurring alternatives for a blue food coloring in higher heat and/or watery applications like beverages that offer long-term stability. The other naturally occurring blue colorant approved by the FDA, Blue spirulina, can’t take the heat the same way that the pea flower extract can. 

Why Do Spirits with Pea Plant Turn Blue?

For the chemistry nerds, this shade comes over as more of a Blue #2 color than Blue #1 at 3.8 pH but the pea flower extract changes color with pH. At lower pH it produces more of a purple color but since ethanol and water have a more neutral pH of around 7 you’d really need to up the acid to get the purple to pop. 

There are a lot of different recipes you could build with pea flowers and we have a very good botanical and seasonal gin-making article to get your creative juices flowing. There’s no reason to stop at gin either, the FDA approved the use of butterfly pea flower for 15 other beverages in addition to the catch-all “alcoholic beverages category” so there are many different applications where this wonderful blue product can be used now. 

One of the potential reasons that such a cool additive took so long to be approved was likely because there wasn’t a lot of safety data specifically for this product. The butterfly pea flower tea has been available on the market for a while now but because of the way supplements are regulated by the FDA compared to the food ingredients there can be a lag between generally recognized as safe and proven to be safe for use. 

The flowers of the butterfly pea plant have been used in teas and medicinally for centuries and are not toxic but other parts of the plant may be and have not been approved for use. There is some inconclusive evidence that butterfly pea flower tea may cause complications in pregnancy but so does alcohol so if you may be pregnant it may be best to avoid blue gins altogether.

When Will Pea Flower Get Approved?

Butterfly pea flower has had a long road to FDA approval but it’s finally happened and now there’s another wonderful tool added to the spirit maker’s toolbox. With its unique and stable color and dynamic color-changing response to pH, it is yet another ingredient to add to your mix to separate your product from the rest of the pack. 

We’d love to hear about any of your experiences with using butterfly pea flower and how you’re integrating it into your products now that it’s approved and you can start tinkering with it legally. Leave us a comment below or give us a call!

What is a Continuous System and How Does It Work?

Posted on by birendra@midnightmachines.io

Well, as the title implies, a continuous distillation still has the ability to produce distillate indefinitely. As long as the distillery has the capacity to feed the apparatus, the distilling apparatus does not need to be turned off. By comparison, a batch system has to be drained, recharged, and reheated.

Furthermore, the time needed to heat the continuous still really is a fraction of the time needed to heat a batch still that is commensurately sized to process the same volumes. Additionally, the continuous system is frequently designed with heat exchangers that can recover heat. This heat recovery feature allows the system to use significantly less heat than the common batch systems typically in use. All of this amounts to a reduction in operating costs. 

This cost savings can be further exploited by the fact that; if the startup cost is X, then putting on a second shift will reduce the cost associated with the second shift “startup” by 80%. And if a third shift is put in place, the cost associated with “startup” is further reduced by a fraction of the second shift “startup” cost. Does that make sense? In other words, the longer you run the system, the cheaper it is to run the system. This is a critical issue for an industry that really is predicated upon the economy of scale. In a nutshell, a continuous still can reduce operating expenses by at least 30%. That is an appreciable ROI.

How Does it work?

Well, basically there are two columns on the system. A beer column and a spirit column. The beer column is fed from the top side. Live steam is fed in at the base of the column. Once the live steam mingles with the injected beer, the heat transfers to the beer, and at that point the alcohol contained within the beer heats, flashes, and is then directed toward a reboiler where the spirit column is mounted. Low wines entering the reboiler are then reheated and a more potent alcoholic, low wines vapor enters the spirit column for further rectification, and finally drawn off of a designated collection port and directed toward the finished product condenser. The spent beer then continues down the beer column and is discharged from a drain port at the base of the beer column.

All of this happens automatically by employing an automated control panel with a PLC (Programmable Logic Controller) that controls any number of variables in order to keep the continuous still running at a steady-state while maintaining the desirable set points needed to create the desired finished product. Target temperature control at various stages of the process is the key variables needed for optimal, steady-state operation. Needless to say, a good, automated controller is a requisite. Some designs can be operated manually. However, unless the design is optimally engineered, the still operator more often ends up being busier than a one-handed paper hanger and would have to make minor adjustments to the operation of the still for the duration of the run. Manual operation can not at all respond to adjustments as precisely as the PLC.

Is a Continuous Still Right for You?

If you are looking to increase your production capacity, reduce your operating costs, free up some time for marketing, then the continuous still is an excellent solution to consider for your future expansion.

To learn more details about continuous distillation, contact info@stilldragon.com. Or call the StillDragon office during regular business hours at 954-845-8009.

When is the Best Time to Run Your Still?

Posted on by birendra@midnightmachines.io

Now that you have your distilling equipment ordered and you’re making plans and starting to get your production schedule together the only thing on your mind is probably what time is the best time to run your alcohol still. The short answer to the question is that the best time to run your alcohol still is whenever you can run your alcohol still! Between mashing, bottling, selling, marketing, and keeping your books in order it can be a challenge to find time to get everything done so the “best” time will vary from operation to operation. There’s no hard and fast rule on when is the best time so use your best judgment and play with different schedules to see what works best for your operation.

If you’re paying for power based on peak demand prices there may actually be a time that running your still is less expensive and more environmentally friendly than other times. Since the lowest demand for electricity is in the middle of the night in most areas, trying to plan production around peak power demand is a noble goal but can be a huge hassle. Some brewers and distillers work in off-hours because there’s too much going on in a day and it’s normally less hectic at night so if that’s your style this may be a bonus. But if you’re a smaller operation and trying to get everything done with a small team you can run into the pesky problem that most humans prefer to get at least some sleep at night. 

Another thing to consider is any special considerations based on a limited release or seasonal products. Certain botanicals or other agricultural products may have a peak season you’ll want to take advantage of to make a unique product. You may need additional fermentation capacity to really take advantage of a seasonal offering in the height of the season. This raises a good question: Do you have enough mashing and fermentation capacity to feed your distillation equipment during a normal season? If you can’t produce enough wash to feed your alcohol still it can be a little difficult to keep it running productively. Everything has to work together to be an efficient process, you can’t rush the fermentation process any more than the aging process so make sure you know where your bottlenecks are will help you plan accordingly.

Hopefully, this post helped you think a little more about your production schedules and fit in everything that needs to get done into the day. We get a lot of questions about best practices and every operation is unique and has its own challenges. We’d be more than happy to discuss what works best for your operation and how we can help so give us a call! 

How Big Should Your Still Be?

Posted on by birendra@midnightmachines.io

There are a lot of different still sizes out there and it can be difficult to pin down exactly what size will fit your operation. It can be tempting to take one of the home still sizes and go “one step” bigger to use as a commercial starter still but that’s a huge mistake that a lot of first-time commercial distillers make. In any start-up not giving yourself the right tools early enough can set you back but go too big too soon is also a problem as well. There’s a sweet spot that needs to be hit and it can be a little difficult to wrap your head around where that spot is unless you have some clear production and business goals to guide you. And you absolutely need both. You can make as much as you want but if there’s no avenue to sell your product then your storage can fill up pretty quickly and having no product to sell is a double-edged sword that can lose your place on the shelf. 

Whatever still sizes you consider have to be big enough to cover fixed costs and allow you time to market and sell your product. Planning ahead will help you tremendously in the long run, If you’re aging spirits. Nothing will beat time in a barrel and it’s very difficult to cheat time. Small and scrappy is a pretty common way to start up but when you’re in growth mode in 3-5 years and have sold all your 2 and 4-year-old products you had in the Brickhouse it’s too late to turn up the production. Anything you make now will have to wait until it’s ready before you can bottle it and put it on the market. This is only a general rule though and may not apply to clear spirits or if you are working with rapid aging technologies, that is an entirely different matter and past the scope of this article.

When you’re talking about most manufacturing processes economies of scale kick in and cost per unit produced goes down significantly in bigger facilities.  As a general rule, equipment costs are almost always going to be lower in the long term than personnel and variable costs. Bigger equipment can have a minimum operating range and if you’re running your still once a month it may not be the right size for your operation. On the other hand, if your primary operation is agricultural and you’re using the still to squeeze one more product out of the acre then it can make a lot of sense to size the equipment to process as much as it can around harvest time so that you don’t lose material to spoilage.

There are a lot of variables that go into choosing the right sized equipment to suit your needs but you don’t have to go in blind. We have a wealth of knowledge and a very handy Run Speed Estimate tool. While no projections are ever 100% accurate you can try a few different scenarios side by side to see how many bottles you’ll make from each run with different equipment in different scenarios. Give us a call at 561-845-8009 to talk about your options and how they will affect your production capabilities.

What are the Electrical Requirements for an Agitator?

Posted on by birendra@midnightmachines.io

This will no doubt be one of the most asked questions by any electrical contractor bidding for your distillery build-out. And the answer is: It depends.

Thank you for coming to my TED talk. Next week we will be discussing the origin of the word “depends”.

Seriously though, let’s start with tank sizing and the specific task the tank will be used for. To do this let’s take a step back even further and determine what kind of production goals you have in mind. Let’s start at the end. The end of the day, the month, or the end of the year? That is up to you.

The Basic Electrical Requirements for an Agitator:

For the sake of this discussion, we’ll go with the smallest kettle that we feel is needed to make money right out of the gate. The 1000L kettle.

As a general rule, the StillDragon 1000L distillation kettle is outfitted with a 1.5kw / 1700 rpm agitator motor and a gear reduction transmission that has a 30/1 reduction ratio. This means that for every time the agitator motor spins 30 times, the agitator paddle will spin once. The gear reduction helps ensure that the motor is functioning with minimal stress. I digress.

 The motors are set up as NEMA-rated explosion-proof motors that use 3 phase power. However, 3 phase power is not a requisite. By adding a variable frequency drive (VFD) to the agitator motor, it is possible to run the 3 phase motor on single-phase power.

With 3 phase power, the 1.5kw motor only draws 5.15 amps at 240 volts and 2.57 amps at 480 volts.

When running the 3 phase motor (via VFD) on single-phase (240 volts) power the amp draw will be 9.11

By comparison, a 5 kW / 3 phase / 240volt motor will draw 17.18 amps. And when running the same motor (via VFD) on single-phase power the draw will be 30.41 amps.

All of this can sound confusing to the average layperson. The good news is that all we really need to do is provide your electrical engineer or contractor with a photo of the motor spec plate that will be mounted to the frame of the motor. The spec plate contains all of the information needed to help your electrical contractor calculate the total supply of power to your agitator.

Why You Should Have a PRV and How It Works

Posted on by birendra@midnightmachines.io

Purchasing distilling equipment can be quite an investment, maintaining and protecting that investment should be a high priority in every distillery. The easiest way to protect the investment in your still is with a proper Pressure Relief Valve installed on anything that might create pressure.

If you’re not doing regularly scheduled inspections and maintenance on your systems, issues could arise such as clogs in your packing or plates. If you overfill your tank, run it too hard, don’t leave enough headroom a foam up could happen to push the solids into the column and obstructing the vapor path. With a cumulative lack of inspections and maintenance, pressure can build during your run, without a PRV on your system the results could be disastrous. Another possible cause for pressure buildup can be a valve in the wrong position. With manual operation or automation, an incorrectly closed valve or valves the system can be totally closed, no longer open to the atmosphere.

StillDragon recommends that you install a ½ Bar PRV on the kettle itself, as well as a 1 Bar PRV on the jacket if your kettle has one. This will ensure that unwanted pressure cannot build in either location. StillDragon also recommends that you follow this protocol for any system you have where a pressure buildup can occur including Mash Tuns and Fermenters.

Parts of a StillDragon PRV

In the event the system becomes over-pressurized, a StillDragon Pressure Relief Valve allows air, or liquid, to escape through the round windows in the PRV body. The PRV has 4 main parts:

  1. The Cap, which is sometimes known as an Adjustment Screw, can be turned (either by hand or ¼” square drive) to adjust pressure.
  2. A Spring holds the pressure by pushing on the valve disk to hold it in place.
  3. The Valve Disk seats into the PRV body creating a seal until over-pressurization is reached.
  4. The Vacuum Spring attached above the valve disk allows for backward airflow to protect against imploding and rupturing.

As pressure rises in the system, the valve disk lifts compressing the spring. Once the valve disk rises above the windows in the body air or liquid begins to escape. The PRV is dual function, in case of immediate vacuum pressure the valve allows air to flow into the kettle.

Testing a PRV

Step 1: Make sure the PRV is clean and fully assembled

Step 2: Quick check the bottom is able to move up and down when you push it

Step 3: Connect a pressure gauge and air compressor to the PRV, fill with more than 1 Bar (15 PSI)- once 15 PSI is achieved, you should be able to feel and/or hear excess air pressure escaping.

If when you test your PRV and if your pressure gauge reads above 15 PSI and you don’t feel and/or hear air escaping, there is a malfunction, do not use it, investigate further to find out the cause.

If you only have a 1 Bar PRV but don’t want that much pressure to be able to build, you can turn the cap to decrease the amount of allowable pressure. To test this function, keep the pressure gauge and air compressor attached to the PRV while turning the cap. You should see the PSI on the pressure gauge go down, once you achieve the desired PSI stop turning. Add more air to do a secondary test that the air starts escaping at the desired PSI.

The cost of the PRV is not nearly as substantial as the disaster caused by an over-pressurized vessel. Save yourself some money and some headache by adding the PRV to tanks and the jackets. Buy one here  StillDragon PRV. If you have any questions or need some troubleshooting, reach out to us, we are happy to help keep you and your distillery safe!

Safety is sexy, add that pressure relief and maintain it often!

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