birendra@midnightmachines.io, Author at Still Dragon

How to Create the Best Neutral Spirit for Gin

Posted on June 17, 2021July 15, 2024 by birendra@midnightmachines.io

Well, here we are preparing to discuss a topic that could create a discussion that could last forever: how to make gin.

I like to compare this discussion to making chicken soup. Chicken soup can be made in more than 150 different ways, none of which are necessarily wrong. Why? Well, because chicken soup is delicious no matter whose recipe it is.

Think about it:
What part of the chicken provides the best meat? Bones, or no bones? Celery, or no? Carrots? Adding vegetable stock, chicken stock, beef stock, or just plain water? Parsley? Can you see where I’m going with this? It never ends.

The only true requisite ingredient for making chicken soup is, well, chicken.

Gin production is similar in that in order to be a gin, it has to have been flavored with juniper berries in the same vein that without chicken, it’s not chicken soup. Like chicken soup, the remaining flavoring compounds are entirely up to the cook.

It can be easy to assume that if the cook strays too far from their gin medley flavoring, the finished product may not be well received. In this regard, there are gins that include some additional, common ingredients that appeal to the broader gin enthusiast’s sensibilities.

In other words, the gin has to taste like gin. Gins can certainly taste differently from one another, but it must taste like gin.

The gin has to taste like gin in other words. Gins can certainly be different in taste, but they must taste like gin.

The overriding consensus among gin enthusiasts is that the base spirit must be very clean. And by that, I mean a very strictly distilled to a neutral spirit. A neutral base spirit allows all of the botanicals to influence the finished product.

If your spirit is less than neutral, you’ll increase the chance of having poorly distilled spirit mask some of the more delicate notes in the finished product. Clean spirit absolutely helps achieve a more well-balanced final product.

How do we create the cleanest neutral for gin production? Having the best tool for the job always helps best. A 30-plate distillation column really is where you want to be if you want to do a “one and done” neutral.

However, not everyone can work one of those into the budget. And not everyone has the required ceiling height often needed for a 30-plate column. Notwithstanding simply buying NGS from the open market, what are our alternatives if we really want to stay strictly true to the “craft” moniker? Well, we must distill the base spirit more in order to arrive at an acceptable level of cleanliness.

Understand that 95% abv from a 10 or 12 plate column is not at all the same finished product as 95% abv from a 30-plate column. My point is a 10-plate single pass is not really enough to produce a premium neutral even if the 10 plates can achieve 95% abv.

There will always be less desirable hanger-on flavor notes clinging to our ethanol molecules with only 10 plates worth of phase change cycles. To further compound the dilemma, running high reflux ratios will ultimately serve as a catalyst for carboxylic acid formation.

This is seen clearly when we examine an analysis of sample spirits from 3 separate types of distillation apparatuses.

Exhibit:

Here on this analysis, we see some interesting numbers. The Beverage Panel shows a predictable trend with the decrease in all of the constituents as we incorporate more plates into the distilling process.

The most noteworthy being the Ethyl Acetate concentration. Accordingly, as we increase the plate count, the concentration of Ethyl Acetate is then reduced as the higher rate of phase change cycles does a better job of scrubbing that particular compound off of our ethanol molecules. Seems to make perfect sense. No?

But then as we look at the Fusel Oils, we can see that all of the listed constituents have actually increased with adding plates to the distilling process. How can this be? Two words. Reflux ratio.

The reflux ratio is the term used to characterize how much condensed liquid at the top of the apparatus is sent back to the column to be redistilled vs the amount of vapor that the dephlegmator (reflux condenser) allows being sent to the product condenser as the final product. For shorter columns, the reflux ratio can help boost and maintain proof.

The problem here is that shorter columns require a higher reflux ratio in order to keep the proof high enough to achieve the desirable abv. But the abv is not necessarily an indication of clean spirit as we see in the analysis table. Higher reflux ratios essentially allow the fusel to have more opportunity to infiltrate the top of the apparatus.

The higher RR literally drags more fusels to the top. In order to mitigate this behavior, we need to reduce the RR. But in doing so how will we maintain our desired proof? Well, we go back to the beginning and use the best tool. A tool that requires a smaller reflux ratio needed to maintain our proof. The best tool? Oh, a 30-plate column.

Try as I may, I can’t seem to stop this circumlocution. Ok, stop. Let’s fix this.

We know some excellent gin base has been produced with pot stilling techniques. We know some excellent gin base has been produced with short columns. And we certainly know that a mighty fine gin base has been produced with tall rectifying columns.

So, what gives? Well, the tall column is the tool of choice. But not at all necessary to produce a good clean, neutral. Notwithstanding the use of carbon filtering, here is what you do if you don’t have a proper rectifying column; Distill more than once.

That’s it. But how much more? Distill as many times as it takes to render your spent kettle charge perfectly clear. As in crystal clear. Then, as much as your budget can tolerate, once the spent kettle charge is crystal clear, continue stripping until the subsequently spent kettle charge is as odorless as possible.

This applies to all stills. Naturally, there will be some loss of alcohol yield with each run, and so you’ll need to make the judgment call on how many times distilled is too many (or too little).

Also diluting the fresh kettle charge with clean water will also help the undesirable congeners release their bond from the ethanol molecules.

Another trick to help reduce odor is to steep a measure of baking soda in the diluted kettle charge for a day or so, prior to distilling.

And finally, lots of emphases should be placed on making very strict cuts for your final spirit run. Finding the center of the heart’s cut is critical and should involve your sensory awareness team if you have a hard time finding the center.

Initially, this can be done by collecting all of your distillate in smallish, individual collection vessels. This will allow each part of the run to be isolated and therefore prevent heads or tails from contaminating the heart of the run.

Once you’ve dialed in the procedure and have achieved repeatable outcomes, you can move on to collecting larger quantities on the fly.

Good luck making your own NGS.

Distilling News: May 2021

Posted on May 27, 2021July 15, 2024 by birendra@midnightmachines.io

There has been a lot of distilling news in the last month and it is far too much to cover in a single post. Whether you get your distilling news from the American Distilling Institute, the American Craft Spirits Association, or DISCUS, distilling popularity in 2021 seems to be spiking and there are a few stories that stand out from the rest. It’s always difficult to hit all the highlights in a single post so please comment and let us know if there’s more that you would like us to cover in future articles.

One of the biggest stories recently has been the changes in cocktails to go in several states. There were several changes to alcohol regulations over the past year to combat the pandemic and several states have made the measure permanent.

Every state except for South Dakota and New Mexico has at least temporarily allowed some form of alcohol take out during the pandemic. While not all are signed into law yet Florida, Iowa, West Virginia, and several other states have at least partially passed legislation to make to-go alcohol permanent. Alabama and Ohio have actually passed laws allowing home alcohol delivery.

A recent poll conducted for the Center for Alcohol Policy shows that overall Americans support individual states set their own regulations for consumer alcohol sales. The poll found that 83% of the respondents support these measures with little variation by political affiliation, making this a solidly bipartisan view. Similarly, 85% of respondents were at least somewhat satisfied with the existing alcohol purchase system in their state.

These numbers have been pretty steady overall since the survey started in 2008, despite the growing popularity and support of less restrictive alcohol laws, there is still an incredible amount of support for maintaining some regulations. The Center of Alcohol Policy also found that 87% of respondents indicated that they felt it was important to keep the alcohol industry regulated, while only 12% overall felt that their state’s regulations were too restrictive.

There are a lot of changes being proposed in the laws around distilling and distribution and it can be a challenge to keep up with everything that’s happening. Distilling popularity in 2021 is on the rise and there will likely be more changes coming.

If this is an issue that is important to you then reach out to one of the groups listed above, talk to your local distiller’s association or give us a call. Even a quick email or sharing a post can help spread the word and hopefully steer the changes in the right direction.

How To Create Income Now: Start With Vodka

Posted on May 11, 2021July 15, 2024 by birendra@midnightmachines.io

So we’ve talked about generating income right away in the past in regards to white whiskey but vodka will more likely than not be the more profitable expedition.

Vodka doesn’t require any barrel aging which is perfect for start-ups looking to create income right away. While your other spirits are aging you’ll have something available for sale immediately. Have to cover your overhead costs somehow, right? Vodka is also SUPER cut and dry when it comes to production. Feel free to check out our youtube video on how to calculate your still size for your very first vodka distillery!

There obviously aren’t too many whiskey variants due to the fact that whiskey can only be made from corn, grain, and/ or wheat. There’s so much more freedom involved with vodka production. You can literally make vodka out of anything, fruit, potatoes, grain, kale (yes, kale), etc. We’ve tasted some pretty amazing vodkas made from out-of-the-ordinary ingredients. Be sure to check out our blog on fermentables to gain a better understanding of how sugars affect fermentation, in order to make the best spirit.

If you aren’t too keen about making your own mash at first, you can always partner up with local wineries and breweries to make your first vodka batches. It’s a great option for networking and bringing in more locals. Using other local businesses to promote your distillery and attending craft spirit events is a great way to get your name out there! Vodka is a huge market and there are so many different kinds out there – which can be both good and bad.

With this degree of saturation, it may be difficult for consumers to find your product so networking and learning how to market your product is key when starting your own distillery. However, vodka can be flavored with almost anything, unlike (aged) rum or whiskey. This will give you the opportunity to create something super new and intricate, giving you an edge in the market.

Many of you distillery owners will want to have your own tasting spaces, which is another opportunity for quick income, depending on your state laws. From Martinis to Moscow Mules, Vodka is an incredibly versatile cocktail base that can make a huge variety of beverages for all walks of life to enjoy.

Tasting rooms are also one of the best ways to establish your reputation as a company. Using this space to host events such as bridal showers, weddings, birthday parties, etc. is a great way to bring your locals together and strengthen your community.

When you build this sense of trust in your customers they’ll want to support you as best as they can, which leads to more revenue, but also a sense of personal pride too.

Vapor Flow Pipe Sizing?

Posted on May 5, 2021July 15, 2024 by birendra@midnightmachines.io

This topic is often discussed in the hobby community and can cause some confusion about what size Lyne Arm (vapor flow) piping to use on one’s pot still. The decision to use any particular size at the hobby scale is often determined by the individual budget of the enthusiast or the availability of materials needed.

At the hobby scale, the difference between a 1.5” and 2” pipe section for mass transfer is nearly imperceptible. However, the 2” piping will be approximately 10% to 15% more expensive than the 1.5”. Ok, so there is the cost consideration.

The more technical consideration is the implication that the smaller diameter piping can increase static pressure in the vapor flow process. And therefore, increase vapor speed enough that the system’s heat exchanger may not be able to optimally condense the resulting distillate.

If you can imagine holding your thumb on the end of a water hose to increase the speed with which the water is discharged from the end of the hose. In other words, an increase in vapor speed can prevent the product condenser from providing optimal heat exchange as vapor races past the cooling surface of the product condenser. Essentially, you are creating a condition that reduces the optimal amount of dwell time needed to adequately transfer heat into the cooling media in the shell of the product condenser.

And finally, there is the more artful notion that increasing static pressure can disrupt the distiller’s ability to perform an optimal cut by introducing less than optimal turbulence into the apparatus. Basically, disrupting the ability of a batch system to allow the lowest boiling point constituents to be drawn out of the apparatus prior to collecting the heart of the run. In other words, excessive static pressure can promote smearing. This is one of the reasons we see large copper helmets and large piping on what appears to be relatively small kettles at the pro distillery level. All in an effort to keep vapor speed low enough to provide optimal separation.

So now back to the original intent of this article. How do you determine what size piping is best?

At the hobby scale, any smaller than a 3/8” (10 mm) diameter puts you at risk for increased static pressure. More importantly, if you distill with solids in the kettle for whiskey production for example, you could risk a clog.

Clogging represents a catastrophic pressure build-up that could have life and death consequences you will be moving into dangerous territory for clogging. So, absolutely no ¼” diameters.

Anything on a hobby-sized pot still is fine from ¾” to 2”. Anything larger and you’ll simply be overspending with no real measurable benefit being applied to collection speed or quality of the finished spirit.

The larger systems at StillDragon are typically outfitted with the 2” vapor piping as we know our heat exchangers are designed well enough to provide adequate cooling capacity relative to the amount of heat input applied to the kettle. Therefore, 2” piping is more than adequate for your small recipe development or hobby still.

Learn more about Piping & Lyne Arms Here.

What is Cooling Management?

Posted on April 5, 2021July 15, 2024 by birendra@midnightmachines.io

Within the context of distillation, Cooling Management refers to the method in which alcoholic vapor is extracted from the distillation apparatus and sent over to the product condenser to be collected as a product.

In or to provide some context, we should start by explaining the four types of distillation management systems: Power Management (PM), Liquid Management (LM), Vapor Management (VM), and of course Cooling Management (CM).

Power management (PM):

This is the most basic type of management system. Essentially, power management refers to heat input or BTU/h provided to the boil kettle as the only way to control the proof, collection speed, and flavor profile of the resulting distillate. In other words, more heat or less heat is the only control the distiller has over the system.

The most obvious example of this type of management system is the humble pot still. Basically, an alcoholic vapor is formed during heat up, then the pressure in the system routes the vapor toward a heat exchanger that acts as a product condenser where the vapor is then condensed and collected as a distillate.

Liquid Management (LM):

This refers to the way the alcoholic vapor in the system is routed upward via pressure in the column riser, then makes contact with a reflux condenser that is capable of recondensing 100% of the rising vapor back to the liquid phase.

This is referred to as reflux or phlegm. The resulting reflux falls back down into the column riser to be re-vaporized while a smaller percentage of that falling liquid is collected in a small cup or slant plate within the column. This liquid is then slowly and continuously drained out of the cup (or slant plate) during the course of the distillation run. During this time depending on collection speed, liquid in the cup may overflow and fall back into the column riser to be redistilled as well.

Reflux returned by the reflux condenser as well as overflow from the collection cup will work to ensure optimal purity while collecting distillate. Therefore, the collection speed from the collection cup will also influence the ABV of the distillate.

To summarize, a percentage of liquid within the apparatus is isolated/collected within the apparatus and drained off as finished distillate. This is the essence of liquid management.

Vapor Management (VM):

With VM systems, rather than collecting material out of the apparatus as a liquid-like the LM systems, the finished product is routed out of the column as vapor. Let me explain. Vapor rises toward the reflux condenser that can condense 100% of the vapor it comes in contact with as with the LM method.

However, 100% of the resulting reflux is sent back down to the column riser to be redistilled to a further degree of purity. As the column becomes fully enriched with alcohol, a product valve installed at the head of the column is used to draw off a small percentage of vapor and direct that vapor toward a product condenser to be collected as a finished product.

Drawing off the small amount of vapor ensures that most of the vapor in suspension will be recondensed and sent back to the apparatus for further distillation. Like the LM system, this reflux returning process allows the system to maintain a high level of purity.

Cooling Management (CM):

Lastly, with the CM system, the column riser again sends vapor to a reflux condenser. However, this condenser uses the controlled flow of cooling media to determine how much of the vapor will be recondensed as reflux, and how much of that vapor is allowed to continue to be routed toward the product condenser.

The flow rate combined with the temperature of the cooling media is managed with a valve. This method allows the operator to directly influence the ABV/proof of the finished distillate.

Questions or concerns? Give us a call! We’re happy to help.

5x What? What counts as a distillation cycle?

Posted on March 24, 2021July 15, 2024 by birendra@midnightmachines.io

By now you likely know the basics of the distillation cycle, process and the stages of distillation but some people still get confused about what people mean when they talk about double distilled, triple distilled (or even 18 times distilled!) spirits.

Whether you’re using a pot still or a plated column it’s pretty easy to count the number of separation steps in the equipment. A single pot still runs and each plate in a reflux column counts as a separation step in case you were wondering.

Packed columns can have a lot of variation so it’s more difficult to consistently calculate the number of equivalent separation steps. So if you’re using a still that has four plates attached to it does that mean that your spirits are five times distilled (one pot and four plates)?

(Tenth Ward distilling Co.) Photo by Matt Sprague

Not according to the TTB’s updated guidance in April of 2020:

“5.42(6) Distilled spirits may not be labeled as “double distilled” or “triple distilled” or any similar term unless it is a truthful statement of fact. For purposes of this paragraph only, a distillation means a single run through a pot still or a single run through a column of a column (reflux) still. The number of distillations may be understated but may not be overstated.” – TTB

This appears pretty straightforward, in order to legally claim something is distilled multiple times you need to run it through your equipment multiple times. Bear in mind that we are not lawyers, do not claim to be lawyers, and don’t even play lawyers on TV. Always seek licensed legal counsel to make sure you are in compliance with all labeling and regulatory requirements.

So even though several separation steps can happen in a single run using a plated column it doesn’t count as however many times distilled according to the TTB. One of the practical reasons for that is that it’s common practice to do cuts when you’re pot stilling but pretty impractical to make them at each plate level. This means that even though you’re going through several separation stages in a column the distillation process as a whole only completes one full cycle.

Separating the heads, hearts, and tails isn’t only another separation step, it’s where a big part of the craft of distilling comes into play. You may be going for the heart of the hearts, you may want to capture some of the fruit notes in your heads, or there may be some leftover flavors at the end of your run that adds to your final product. Choosing where to make your cuts and what makes the best spirit for you is a big part of the process and one of the most important stages of distillation.

Making spirits using a plated column does have a lot of advantages over pot stilling. Running higher reflux ratios and using multiple plates will help you achieve better separation and allow you to have a more efficient separation per run. This means less energy input and less waste for your process, which means lower costs in the long run.

The cost of making spirits increases dramatically with the cost of heating the kettle multiple times, the cost of materials that get thrown out when making cuts, and the increased labor costs for having personnel on-site for running multiple batches where one or two would suffice with the proper equipment.

For example, when you’re making vodka in order to achieve higher purities and consistently high ABV over the course of a run it’s important to have enough separation steps to keep your purity up and prevent smearing.

There’s a lot that goes into the distillation cycle and it can be confusing when you’re researching new practices and trying to do something experimental. We’re more than happy to help and discuss your needs and what you’ll need to help you make the best spirits possible.

Give us a call at 561-845-8009 with any questions you may have, we are happy to help!

TTAB Trademark Guidance: Distillery News

Posted on March 19, 2021July 15, 2024 by birendra@midnightmachines.io

TTAB Trademark News

Recently in distilling news, there was a precedent set by the folks at The United States Patent and Trademark Office Trademark Trial and Appeal Board (TTAB) about what constitutes a “deceptive” product label.

This decision applies to the wine and spirits labels so it may be worth checking, or better yet have your lawyers check, to make sure all your products are in compliance with this new decision. The clarification concerns Section 2(a) of the Lanham Act, 15 U.S.C. § 1052(a). Section 2(a) which states:

No trademark by which the goods of the applicant may be distinguished from the goods of others shall be refused registration on the principal register on account of its nature unless it—

(a) Consists of or comprises immoral, deceptive, or scandalous matter; or matter which may disparage or falsely suggest a connection with persons, living or dead, institutions, beliefs, or national symbols, or bring them into contempt, or disrepute; or a geographical indication which, when used on or in connection with wines or spirits, identifies a place other than the origin of the goods and is first used on or in connection with wines or spirits by the applicant on or after one year after the date on which the WTO Agreement (as defined in section 3501(9) of title 19) enters into force with respect to the United States.

The TTAB Trademark news boils down to a decision that if a wine or spirit is not produced in a specific region then it cannot use anything in the label or name that would confuse people to believe it’s from that region. Specific geographical references have always been forbidden, you can’t name something Catskills if it’s made in the Rockies for example, and you can’t use someone’s name who isn’t connected with the brand.

This TTAB trademark decision takes that a step further and opens the possibility to where even alluding to a person’s name can be grounds for a case if they’re iconic for certain geography. If this seems confusing that’s because it is, this guidance is new and likely will need some further clarification and refinements as it comes up in more cases.

As it stands now an American-made St. Patrick’s Day Whiskey release could potentially run afoul of the new rules since St. Patrick was Irish and not American. Then again maybe not since St. Patrick’s Day is celebrated by many and is not innately confined to one geographic location. This question is better left up to the legal professionals than the blog post writers so make sure your attorneys are earning their keep and keeping you out of a lawsuit.

New guidance and “clarifications” can be confusing regardless of how straightforward they may seem. Having your attorney look at any labels you aren’t sure of could save a lot of hassle in the long run and it’s well worth it to have peace of mind after a change in guidance.

How to Clean the Still When it First Arrives

Posted on March 15, 2021July 15, 2024 by birendra@midnightmachines.io

This is a very common question you’ll see on the forums and in the comment sections of youtube videos. You yourself might be wondering the same thing so let’s dive into the initial equipment inspection and cleaning process you’ll want to carry out before making your spirits.

Taking Delivery on your Parts

You’ll want to give your parts a thorough inspection when they first arrive. Check to see that your components aren’t damaged or missing. Next, you’ll want to ensure that you can properly set up your equipment. All of your gaskets should fit, pipping should be aligned, clamps fit nice and snug, etc. If you’d like, you can give your parts a nice surface clean with a stainless steel cleaner such as the “Aspire” Stainless Steel Cleaner & Polish.

If you’d like to give your copper parts a nice polish, mineral spirits work great to get any oils from your fingertips and discoloration from shipment right off. However, as you begin to use your copper parts, the inside will begin to develop a slight patina which is completely normal when running vapor and liquids through your still.

If you’d prefer to prevent this chemical process from happening to your copper parts, you can always clean more frequently in between runs. PBW is also a highly recommended product to use on the insides and outsides of your brewing and/or distilling equipment when cleaning.

Steam run

Now that your still is nice and shiny and fully assembled, you can execute a steam run. We typically suggest charging your kettle with a 1:1 ratio of vinegar and water to get any excess dirt and oil remnants out of the vapor path. Do NOT leave your equipment unattended. You can use this time to introduce yourself to your still (“Hello still, I’m _____”) and check to see if there are any leaks. If so, tighten your clamps down.

If there is leaking from elsewhere other than the tri-clamp connections, then please get in contact with your distillation equipment provider to address the issue as soon as possible. You definitely wouldn’t want to run high-proof ethanol through a leaky system… as we’ve seen, it can be perilous. Not only that, but you’ll end up wasting your precious beer!

Not only should you do a steam run when you first use your still, but it’s also great for in-between runs. It’s not necessary if you’re going to be distilling the same spirit but if you were to switch from a whiskey run to a vodka run, you’d want to get those strong flavors out of your still. You’ll want to keep your spirit smelling and tasting very similar every time you distill it and having a clean base to start with always makes this easier to achieve.

Sacrificial run

Now that your steam run is completed, you’ll want to do a sacrificial run to push hot ethanol through your system to kill off any remaining bacteria. You can do this first run with a sugar wash, which is a super standard and cheap option. Wineos Plain Ol Sugar Wash is a common recipe that many hobbyists use but there are plenty of other alternative recipes that can be found on the Home Distiller forum!

This will not render a drinkable finished product, hence the name “sacrificial” run. If you don’t have any contaminated distillate, that’s awesome but we still would recommend that you DO NOT drink it. Now that your still is properly sterilized, it’s time to start pumping it with the good stuff!

If this article didn’t answer any of your questions, please don’t hesitate to reach out so we can point you in the right direction when it comes to cleaning your still. You can shoot us an email: info@stilldragon.com or give us a ring here at the office line: (561)-845-8009

Cheers!

Women in the Distilling Industry

Posted on February 26, 2021July 15, 2024 by birendra@midnightmachines.io

Meet Some of the Women In the Distilling Industry

Dr. Kallie Stavros graduated from Clemson University with a BS in chemistry and Vanderbilt University with a Ph.D. in chemical biology. After graduating, she was ready to do something other than work in a traditional laboratory setting. She grew up in Florida, and her mother suggested that she should look into brewing, as Florida was pushing for more women master brewers! After spending 20+ years in school and the master brewing classes being so expensive, she was a little on the fence about this, even though it seemed like a fun way to use her hard-earned degrees. But when the distillery was opening up across the street from where she was living at the time, she took the opportunity to see if she could learn some things about distilling: “I had a lot of experience with separations chemistry and had worked with live cultures, so it seemed to be a great fit. Now I get to work with my giant chemistry set!” Dr. Stavros found that distilling was a great thing to do with her degree, other than just pure research. “Being able to taste and enjoy a final product certainly makes the job more enjoyable.”

Falls Church Distillers has been open for three and a half years, so they are still pretty new. It was opened by Michael and Lorenzo Paluzzi, who wanted to use their Italian heritage and family recipes to share with the public. Dr. Stavros joined them when they opened in 2017. They are the first new distillery in Fairfax County since prohibition and the first distillery in Virginia to have a bar and restaurant. It is a fairly unique place inside the Beltway. “In terms of product specialization, I think we are still determining this. Personally, the gins are my favorite and have won several awards.”

“I love that I make a product that I can taste and other people can enjoy”

Distilling utilizes her background very well but in a way that she never expected while she was in school. “I do love people’s reactions when I tell them I’m a distiller. Many people have never met one, let alone a female distiller.” She likes that she gets to interact with a wide variety of people– in addition to her help in the DSP, she works with the bartenders, gives tours, and hosts public bottling events that allow her to interact with customers in the distillery- which keeps the job very interesting.

“There can be some mildly sexist assumptions about female distillers and how the stuff I make must be more sweet and fruity,” says Stavros, “I do kind of enjoy adding a female face to the production of our products and trying to dispel this.” Falls Church does have a large female clientele, and many drink whiskey just like the men! Dr. Stavros doesn’t consider herself a “girlie” drinker, nor would she classify what she make as falling into that category. She’s very proud of her work as a distiller and the stereotypes she has overcome within our industry.

If there is one thing Dr. Stavros wishes she knew before getting into the distilling industry it would definitely be that there is a lot of meticulous bookkeeping involved. Not just alcohol production and sales, but accounting for supplies and other materials as well. It is not a secret that the laws and regulations around the industry can be quite complicated, especially when working in a control state, like Virginia, which adds another layer of complexity.

“It is also a lot of heavy lifting. I probably would have spent a lot more time in grad school working out if I would have known then what I was going to be doing.”

If Dr. Stavros has any advice to other women master distillers trying to start-up a distillery it would definitely be to reach out to other distilleries and become part of a network. It is generally a friendly industry, and other distillers are happy to give advice as it is an industry fraught with red tape. Going to someone with experience for how-tos and getting started can speed up the process. The cost of starting a distillery can be quite overwhelming, too, and there may be ways to get started by working with other distilleries so you don’t need to invest so much capital upfront.

Alcohol Industry Terminology

Posted on February 26, 2021July 15, 2024 by birendra@midnightmachines.io

Within every industry you’ll find there is an entire language that only the industry professionals and enthusiasts use. Interacting with someone that is familiar with this terminology can make communicating so much easier with folks in the profession. But even within the alcohol industry there are different levels of terminology. There is production terminology, distribution terminology, government oversight terminology, retail sales terminology, spirits consumption terminology. A virtual cornucopia of esoteric “likker” speak to say the least.

We personally, are most comfortable with the colloquialisms most commonly (and not so commonly) used on the production side of the industry. Even within the production side, there are terms that the formally educated use, and terms that the not so formally educated use. Terms that can be considered humorous, or even quite vulgar to the lesser informed.

For your reading pleasure here is a glossary of terms typically used by distillers:

A

ABV

Alcohol by Volume, often expressed as a percentage. Example 40% ABV.

Alcohol

A member of a class of organic compounds containing carbon, hydrogen and oxygen.

Alcometer / Alcoholmeter

An instrument used to find the ethanol percentage in a strict binary ethanol-water solution. Sometimes referred to as a “Proof and Traille”.

Aldehyde

A volatile impurity found in the foreshots.

Alembic

The traditional pot still that requires several cycles of distillation in order to refine the alcohol to the desired level.

Aqua Vitae

Strong distilled alcohol; Latin for “water of life”.

Azeotrope

Liquid mixture of two or more components, which has a unique constant boiling point. Maximum azeotrope for alcohol is 192 degrees proof (96% ABV).

B

Backset

The acidic liquid left in the still after distillation of whiskey has completed. Used in the creation of sour mash whiskey.

Barm

The foam, or scum formed on the top of liquor (i.e. fermented alcoholic beverages such as beer or wine, or feedstock for hard liquor or industrial ethanol distillation) when fermenting.

Barrel

A liquid measure. Barrel measurements vary from 42-53 US gallons, 44 Imperial gallons, or 200.6 litters, or 5.6 cubic feet are all used. Or, a wooden container usually made from white oak used for the aging and maturation of alcoholic beverages. Barrels used for whiskey maturation are made of oak wood, and have a capacity of about 52 U.S. gallons. Barrels may be used only once for aging bourbon whiskey, so there is a worldwide trade in used bourbon barrels for aging other alcoholic products such as Scotch whiskey and rum.

Beer Stripping

A crude primary distillation of fermented wash. See stripping.

Bier Unser (= beer prayer in German language)

Bier unser, das du bist im Glase, gesegnet werde dein Brauer, dein Rausch komme, dein Wille geschehe, wie zu Hause als auch im Wirtshaus. Unseren täglichen Durst gib uns heute und vergib uns unsere Schuld, wie auch wir vergeben unseren Schuldnern. Und führe uns nicht in die Milchbar, sondern gib uns Kraft weiter zu saufen. Denn dein ist der Suff, der Rausch und der Durst und die Benommenheit in Ewigkeit. Prost!

Birdwatchers

See TPW.

Boka / Bokakob

A liquid management style still.

Bubble Caps

Used in a column and sit over risers. Caps provide contact between the rising vapors and descending enriching the vapors.

C

Carbon Dioxide

A colorless non-flammable gas. Composition CO2, does not support human respiration, and in high concentrations it causes asphyxiation. It is approximately 1.5 times the weight of air, and tends to accumulate in floor drains, pits and in the bottoms of unventilated tanks. When it is produced by various means, notably the combustion of fuels in an excess of air, and is a byproduct of yeast fermentation. It may be recovered from fermentations and compressed to a liquid or solid (“dry-ice”).

CCVM

Condenser Controlled Vapor Management: A type of reflux still which is controlled by a movable cooling coil instead of a valve typical for a VM still.

Channeling

Is the unequal wetting of the packing in the tower. If channeling occurs, poor mass transfer happens, and therefore, less efficiency of the tower.

Charge

The volume of alcoholic beverage wash, or low wines going to the still.

CIP

Clean in Place: Means cleaning without disassembling.

CM

Cooling Management: A type of reflux still which is controlled by the “management” of the rate of flow of coolant to control the reflux rate / output. The Dash series are CM stills.

CNIP

Clean not in Place: Means cleaning with disassembling.

Column

The vertical section rising off a boiler. Can consist of either a plated column; a packed section or a combination (hybrid).

Condensation

The process by which a gas or vapor changes to a liquid.

Condenser

A heat exchanger in which hot vapors are cooled and condensed into liquids.

Congeners

Impurities. These minor chemicals give liquor (spirits) distinctive character and flavors. Found in both heads and tails. Maybe considered desirable or undesirable depending on quantity and type.

COP

Clean out of Place: Means cleaning with disassembling.

Cuts

The process of separating different types of alcohol. Usually cuts are made for foreshots, heads, hearts and tails during the final distillation run.

D

DAP

Diammonium Phosphate, a yeast nutrient.

DC

Abbreviation of Down Comer.

Density Meter

Portable device that measures specific gravity thus allowing the distiller to make precise cuts.

Dephlegmator

A reflux condenser at the top of the column that sends distillate back toward the boiler increasing the purity of the spirit.

Dextrose

Basic sugar also known as corn sugar.

Distillate

A liquid condensed from vapor in distillation; a purified form.

Distillation

The process of boiling and condensing a mixture of volatile liquids that changes the relative concentrations of those liquids in the output. The evaporation and subsequent collection of a liquid by condensation as a means of purification. The separation of a liquid mixture into its components on the basis of differences in boiling points. The process in which components of a mixture are separated by boiling away the more volatile liquid.

DME

Dried malt extract. When dissolved in water and fermented can be distilled. Sometimes used as a substitute to all grain mashing of barley malt.

Double Distilling

A process where the distillate is distilled twice first to remove alcohol and second distillation is to make cuts separating heads, hearts, and tails.

Downcomer

A pipe or tube for moving fluid material downward usually transferring liquid from one tray to the one below in a bubble tray column.

Dunder

The acidic liquid left in the still after distillation of rum. Used in subsequent fermentations to produce more flavored heavy rum.

DWWG

Death Wish Wheat Germ recipe.

E

Enzymes

Proteins that assist conversion of starches into sugars that will ferment.

Esters

Fermented byproducts made by yeast action that contributes fruity characteristics, aroma, and flavor to the wash.

Ethanol

Otherwise known as ethyl alcohol, “alcohol”, “grain-spirit”, or “neutral spirit”. A clear colorless, flammable oxygenated hydrocarbon Chemical formula: C2H5OH. It forms a binary azeotrope with water, with a boiling point of 78.15°C at a composition of 95.57 per cent by weight ethanol.

F

False Bottom

In a mash tun the false bottom is slotted copper pipe, the slots of which allow wash to drain while holding back the grain, while the false bottom in a brew kettle is a perforated plate or bazooka screen.

Feints

Often used to refer to a mixture of heads and tails to be recycled into a following run. Some feel feints refer to tails only but not always defined as such on the various forums.

Fermentation

A change that takes place when yeast converts the sugar to alcohol. The anaerobic conversion of sugar to carbon dioxide and alcohol by yeast.

Fermenter

The vessel in which the process of fermentation takes place. The vessel may be fabricated from plastic, stainless steel etc. Commercial fermenters are normally fitted with an internal or external cooling system for controlling the temperature of the fermenting mash.

Final Gravity

The density of the wash after fermentation. Knowing the original and final gravity of a wash allows you to determine the percentage of alcohol of the wash.

Flocculation

The clumping and settling of yeast out of solution, forming a cake-like substance in the bottom of the fermenter.

Flute

Scaled down commercial type plated still. A name coined by “Old Dog”.

Foreshots

A small amount of low boiling distillate containing acetone, methanol, and aldehyde volatiles. Note that the fore shots are hazardous and must not to be consumed!

Fractional Distillation

A process by which a chemical compound is separated into components by distillation. In fractional distillation the compound is heated and, as each of its constituent components comes to a boil, its vapors are separated and cooled, so it can be removed in its pure form.

Fractional Still

Apparatus to perform fractional distillation. Has a vertical column still using plates and bubble caps or packing. The process separates spirits into different volatility.

Fusel Oil

A bitter oil found in tails. A liquid composed of amyl and isobutyl alcohols. A term used to describe the higher alcohols, generally the various forms of propanol, butanol and amyl alcohol, which are congeners, or by-products of ethanol fermentation – predominantly, iso-amyl alcohol. Their presence in alcoholic beverages is known to be a cause of headaches and hangovers. The fusel oils have higher boiling points than ethanol and are generally removed in the distillation process.

G

Graham Condenser

A condenser that has the coolant-jacketed spiral coil running the length of the condenser.

H

Head

The top of the still.

Heads

Spirits from the beginning of the run that contain a high percentage of low boiling alcohols and other compounds such as aldehydes and ethyl acetate. Term used to describe the impurities produced in ethanol fermentations (“congeners”), which have lower boiling points than ethanol. They include methanol and aldehydes. (Always the beginning phase of the distillation process.)

Hearts

The desirable middle alcohols from your run.

HERMS

Heat Exchanger Recirculating Mash System, see here for more details.

HETP

Height Equivalent of a Theoretical Plate.

Hybrid

A still made by adding a packed column on top of a plated column.

Hydrometer / SG Meter

An instrument that measures the weight or gravity of a liquid in relation to the weight of water. Cannot be used to directly measure alcohol already in a mixture. Sometimes referred to as wine or triple scale hydrometer for measuring sugar content in washes.

I

Infrared Thermometer Gun

Instant reading thermometer device.

L

Lees

What is left in your fermenter after the liquid is siphoned into the still usually contains spent nutrients and barm.

Liebig / Liebig Condenser

A straight-tube jacketed condenser at the product end of a still.

LM

Liquid Management: A type of reflux still which is controlled by the “management” of the rate of liquid output.

Low Wines

The spirits collected from the first distillation.

Lyne Arm

In a traditional pot still the tubing from the pot’s head to the condenser.

M

Malt

Sprouted dried grains. Malted grains contain enzymes that convert starches into fermentable sugars. Typically barley, however other grains like wheat, rye & corn are also malted.

Mash

A mixture of ground malted grains and hot water. A mixture of milled grain or other fermentable carbohydrate in water, which is used in the production of ethanol. The term may be used at any stage from the initial mixing of the feedstock in water, prior to any cooking and saccharification, through to the completion of fermentation, when it becomes referred to as “beer” or wash.

Mash Tun

A tank with a false bottom in which hot water and grains are mixed to produce wort.

Must

A fermentable liquid that uses the sugars from fruit.

MUM

Mason’s Universal Mash also known as TPW, a nutrition-enhanced tomato-paste sugar wash.

N

Neutral / NGS / Neutral Grain Spirits

95+% ABV alcohol. Most often produced from corn wheat & other grains. Used by distilling companies around the world for blending to produce vodka, gin and whiskey.

Nuked Product / Nuking

An attempt to accelerate the maturation of spirits through direct exposure to microwave radiation and its resultant rapid heating and cooling cycles.

O

Oaking

Process of aging your liquor in oak barrels, chips or sticks.

OG

Original Gravity. The density of the wash before fermentation.

P

Packing

Material that is used to fill a still’s column to increase the surface area and thus the reflux and quality of the alcohol. Common packing includes stainless steel scouring pads & copper mesh. Spiral Prismatic Packing (SPP), marbles and Scoria (a type of volcanic rock) have also been used. One commercially produced packing is “Rasching rings”.

Parrot

A device resembling a stylized bird that attaches to the still or is at the point of collection that floats the alcoholometer (alcometer, proof and Traille hydrometer).

PBW

Powdered Brewery Wash, a patented alkali cleaner originally developed for Coors, now widely used in commercial breweries across North America.

PC

Abbreviation of Product Condenser.

pH

A measure of the acidity or alkalinity of a solution. The pH scale ranges from 0-14.

Pitch

The process of adding yeast to the wash.

Plates

Sometimes known as trays, they are located horizontally at intervals in a column, often contain bubble caps that enrich the reflux.

Pot Still

A simple batch distillation unit used for the production of heavily flavored distillates for beverage use. It consists of a tank, (which is heated either by an internal element or steam coil, or by an external heat source eh gas burner), and an overhead-vapor pipe leading to a condenser. It may be used in the production of heavily flavored rums and whiskies or to strip wash.

Proof

A measure of the absolute-ethanol content of a distillate containing ethanol and water. A measurement of alcohol strength. In the U.S. system, each degree of proof is equal to 0.5 per cent of ethanol by volume, so that absolute ethanol is 200° proof.

R

RC

Abbreviation of Reflux Condenser, sometimes a dephlegmator is referred to as a RC.

Reflux

Formed when vapors condense and re-vaporize in the column of a still.

Reflux Ratio

The ratio of the amount of condensate being refluxed to the amount being withdrawn as product. Generally, the higher the reflux ratio, the greater is the degree of separation of the components in a distillation system.

Reflux Still

This still differs from a pot or alembic still in that multiple distillations occur in one single cycle. The addition of a column with packing, plates (sieve, bubble caps or valved) between the condenser and pot allows vapor to condense and trickle back down to be distilled once again. Thus, the vapor is repeatedly cleansed and the resulting purity from one cycle is much higher than that from a pot or alembic still.

RIMS

Recirculating Infusion Mash System.

S

Saccharification

The process of converting a complex carbohydrate, such as starch or cellulose, into fermentable sugars such as glucose or maltose. It is essentially a hydrolysis. The process may be accomplished by the use of heat, enzymes or acids.

SD

Abbreviation of StillDragon.

SG

Specific Gravity. SG meters are a hydrometer calibrated to measure sugar content in a wash to determine potential alcohol.

Shot Gun

A shell in tube type of condenser with multi-tubes where the vapors pass through the tubes surrounded by coolant.

Slant Plate

A liquid collection plate used in a Bokakob style reflux still.

Slop

Hot stinky spent corn mash from the still. See Backset.

Sparging

At end of mashing, a process in which hot water is sprayed on or run through the grain bed to extract additional sweet wort.

Spirit Run

The final distillation producing finished product.

Spirit Still

A still designed to do the final distillation, often referred to when producing finished whiskey.

SPP

Spiral Prismatic Packing used in reflux type stills.

Stripping

The process of running low ABV wash through a still with no head or tails cuts to increase alcohol concentration before being re-distilled.

Sugar Head

Grain ferment that sugar has been added to achieve a higher alcohol potential.

Sweet Spot

Head temperature in a reflux still between 78.89C and 82.22C. This range produces a sweet tasting spirit and is considered the heart of the distillation run.

T

Tails

A distillate containing a high percentage of fusel oil and little alcohol collected at the end of a run. The term is used to describe the alcohol that falls below 80 proof during the distillation process – also known as the end phase.

TC

The Abbreviation of triclamp, is also known as tri clover.

TPW

Tomato Paste Wash sometimes referred to as “Birdwatchers”. A simple wash used for creating a clean simple neutral “vodka like” spirit.

U

UJSSM

Uncle Jesse Simple Sour Mash. Faux bourbon recipe made from corn and sugar.

V

VM

Vapor Management: A type of reflux still which is controlled by the “management” of the rate of vapor output.

W

Wash

Fermented substrate containing alcohol.

Wort

The solution of grain sugars strained from the mash tun (unfermented beer).

WPOSW

Wino’s plain old sugar wash recipe.

Y

Yeast

Any of a certain unicellular fungi, generally members of the class Ascomycetaceae. Many types of yeast are capable of producing ethanol and carbon dioxide by the anaerobic fermentation of sugars. Yeasts are composed of approximately 50 percent protein and a rich nutritional source of B vitamins.

Things You Need to Assemble Your Still

Posted on February 24, 2021July 15, 2024 by birendra@midnightmachines.io

Style of Stills

In the past we’ve discussed how to get a license, what you’ll need from your building (especially if you’re getting started in whiskey or gin), and various parts of a still. But lots of people call in and ask us exactly what they need to effectively set up their still, so if you feel confused by it you’re not alone. There are a multitude of variations and styles of stills that you can use to make high quality spirits and depending on what type of still you want to use will help you decide what things you need to assemble your still.

Main Types of Stills

The two main types of stills are pot stills and reflux column stills. Both have pluses and minuses and depending on the type of spirit you’re creating so selecting the right still plan will be essential to getting the best final product possible. There are a lot of similarities in the basic setups and the types of things you need to assemble your still. Both still plans require some kind of vessel to hold the fermented material, a way to heat the vessel, piping for the vapor to pass though, a condenser to turn the vapor into liquid, and something to collect that liquid. While that sounds easy enough in principle, there are endless variations on the types of equipment you can incorporate into the still plans, just make sure you have a plan!

Create Your Still

If you’re going to create a still from scratch that’s a very different skill set and tool requirement than buying something that is already welded together and just needs assembly. If the still you purchased uses tri clamp fittings and you decide to pot still, the only things you need to assemble your still are something to cut the hose to your product condenser and your hands to tighten the tri clamps. If you decide to go with a column and purchase one of our Dash or Crystal Dragon set ups then you’ll just need to add a level and a wrench to assemble the caps and tighten some connections on the smaller systems. Once you get into heavier equipment you may want to invest in something to help you move it but by that point you’re likely starting a commercial distillery and that’s a whole now can of worms. Heating the kettle can be a little trickier if you’re not used to working with electrical wiring but it is fairly straightforward to assemble. For this you’ll need a set of wire cutters and a soldering iron added to the list of things you need to assemble your still. We highly recommend using a properly wired heating element on a small system instead of a more traditional open flame because of the fire hazard involved. Ethanol vapor is heavier than air and having an open flame below your kettle may not be the most intrinsically safe design. On that note, make sure your welds are solid and you don’t have any leaking connections, if not for the sake of safety then at least don’t waste good alcohol!

Another thing to keep in mind while you’re developing your still plan is that you may want to make sure your components are interchangeable and that you leave room for customization. It can take a lot of tinkering to get your recipe just right and sometimes you’ll want to switch up the tools a little to see what kind of affect that has on the final flavors that come through. There are dozens, if not hundreds, of ways to put together a still so experiment with a few and try what works best for your favorite flavor profile. We’re more than happy to help you pick out a system and help you figure out what type of still will best suit your needs. Just give us a call at (561) 931-6746 to discuss the different options!

Is Silicone Safe for Distilling?

Posted on February 23, 2021July 15, 2024 by birendra@midnightmachines.io

As far as distilling goes, the question of whether or not silicone is okay to use in your equipment has been quite controversial and we aren’t quite sure why. Silicone gets a pretty bad rep within the distilling community and many hobbyists will argue that PTFE gaskets are the better option, but are they really?

Silicone Gaskets

Silicone is extremely flexible, heat resistant, and sanitary – all the things that you could possibly want when creating liquid and vapor seals in your system(s). So why is silicone demonized so often? The answer to that question isn’t a simple one because there is just not enough extensive research done on plastic’s effects on alcohol and vice versa, alcohol’s effects on plastic. Now, there are several videos online of people sharing their experiences with silicone for distilling purposes, but the variables within their experiments aren’t complex enough and aren’t regulated fairly well. Many factors like heat, humidity, and strong chemicals, all present in distilleries, are not as easily controlled. Because of these common uncertainties, silicone has often been demonized within the community. From what we’ve seen in the field, silicone can handle a lot of wear and tear, though gaskets should often be replaced on your system as a preventative maintenance measure. There definitely isn’t enough long-term experimentation on plastic gaskets, as the craft boom happened less than a decade ago. We recommend that you switch out your gaskets every one to two years, regardless of the material they are made out of. As far as safety goes, we’ve seen that there is almost no foul with silicone gaskets; They are FDA approved, and most third-party safety inspectors never seem to have any issues with them.

Like I mentioned before, silicone is highly flexible which is great for tri-clamp fittings.

If your piping isn’t completely flush, a silicone gasket is super malleable and with the simple tightening of a clamp, you’ll have a wonderfully made seal. They’re super easy to install and remove, making cleaning and maintenance a breeze.

PTFE Gaskets

PTFE (or Teflon Polytetrafluoroethylene) gaskets might give you more problems while trying to configure your still. This material isn’t as flexible as silicone and changes under extreme pressure and heat. Let’s say you’re using PTFE gaskets to put together your still, and you go to start your run. Once the still gets hot and steamy, these gaskets will begin to change texture. You may begin to notice that your tri-clamps aren’t as tight anymore and you don’t have the best seals. Now, this is fine on a little hobby-sized or recipe development still, but if you’ve got a crazy tall vodka column… having to suspend yourself 15-20+ feet up in the air to tighten your clamps is never a fun time. It’s a pain in the derriere if you ask me. However, PTFE is definitely food safe and FDA approved, as long as the fillers, inks, and dyes added to make the gaskets are too. If you don’t mind dealing with the occasional inconveniences of PTFE gaskets, then maybe these gaskets are the right option for you!

EPDM Gaskets

EPDM (Ethylene Propylene Diene Monomer) is a very versatile material that’s weather-resistant, heat resistant, and another option that’s FDA approved as food safe. It does have a higher rating than silicone but it can be a little more expensive, depending on the width of your column. Of course, it’s not a ridiculous difference but some people do tend to think about that sort of thing when it comes to budgeting. In the long run, you may save yourself some money by going with the silicone, especially if you plan on being more adamant with your preventative preventive maintenance measures and frequently replacing your gaskets.

There seems to be a lot of variances in opinion within the distilling community on which material makes the best seal, so it’s really just up to you to decide what you’d like for your system(s). Everyone definitely has their own preferences, and their very own “ride or die” products and materials that they will stick with forever.

If you need any help getting your distilling equipment together just give us a ring here at the office (561)-845-8009 or shoot an email to info@stilldragon.com and we’ll be happy to help you out! Cheers!