adding beverage alcohol distillation to an existing … 150423, … · 23/4/2015 ·...
TRANSCRIPT
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TITLE
ADDING BEVERAGE
ALCOHOL
DISTILLATION TO AN
EXISTING BREWERY
Presented by Stephen Harkness, P.Eng., President, cemcorp LTD.
MBAC District Ontario Spring Technical Meeting, April 23, 2015
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HISTORY
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CANADIAN DISTILLERS 2015
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RETAIL STORE POT STILL
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DIFFERENCES
1. NOMENCLATURE/
TERMINOLOGY
2. RAW MATERIAL
3. MASHING/COOKING
4. FERMENTATION
PROCESS
DIFFERENCESBREWERY VS. DISTILLERY
5. DISTILLATION
PROCESS
6. FINAL PRODUCT
7. BUILDING DESIGN
8. LICENSING
REQUIREMENTS
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NOMENCLATURE – PROOF STRENGTH
1. NOMENCLATUREPROOF STRENGTH
U.S. DEFINITION: 1 PROOF = 0.5% A/V
i.e. 200 PROOF = 100% A/V
BRITISH DEFINITION: 100 PROOF = 57.06% A/V
i.e. 175.25 PROOF = 100% A/V
METRIC DEFINITION: 1°GL (GAY LUSSAC) = 1% A/V
i.e. 100°GL = 100% a/v
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NOMENCLATURE
1. NOMENCLATURE
• BREWERS MEASURE VOLUMES IN HECTOLITRES
1 HL = 0.85 US Barrels = 0.61 UK Barrels (BBL)
DISTILLERS MEASURE VOLUMES IN LAA (LITRES ABSOLUTE
ALCOHOL) OR PROOF GALLONS
• CANADIAN CASE OF BEER IS 24 BOTTLES 341 ml
CASE OF LIQUOR IS 12 BOTTLES 750 ml
• CANADIAN BREWERS STATE STRENGTH AS %A/V
(AMERICAN BREWERS STATE STRENGTH AS %A/W)
DISTILLERS STATE STRENGTH AS % OF LAA
• REFLUX, DEPHLEGMATOR, DOWNPIPE, WEIR, CONGENERS
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RAW MATERIAL
2. RAW MATERIAL
WHISKY/WHISKEY, including CANADIAN WHISKY, AMERICAN
WHISKEY & BOURBON
– CORN, RYE, MALT
SCOTCH WHISKY AND IRISH WHISKEY
– MALT
RUM – MOLASSES OR CANE JUICE
VODKA – ANY STARCH OR SUGAR
GRAPPA, LIQUEURS, BRANDIES SNAPPS
- FRUIT
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MASHING/COOKING
3. MASHING/COOKING
1. BATCH COOKERS
2. CONTINUOUS COLUMNAR COOKERS
3. U-TUBE CONTINUOUS JET COOKERS
4. EXTRUDERS
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FERMENTATION
4. FERMENTATION
BREWERIES
FERMENT 5 – 20 DAYS @ 12°C. – 20° C.
@ 3% – 9% A/V
DISTILLERIES
FERMENT 54-72 HRS @ 32°C. - 34°C.
@ 8% – 16% A/V
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DISTILLATION SYSTEMS
5. DISTILLATION SYSTEMS
1. BATCH STILLS
SIMPLE BATCH
KETTLE W/ COLUMN(S)
2. CONTINUOUS STILLS
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Simple Batch Still
SIMPLE POT STILL
• GIN
• MALT WHISKY
• SCOTCH WHISKY
• IRISH WHISKEY
• TEQUILA
• RUM
• PISCO
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Alambic Batch Still & Kettle with Column
ALAMBIC POT STILLGRAPPA, BRANDY, COGNAC,
ARMAGNAC
KETTLE WITH COLUMNBOURBON, AMERICAN WHISKEY,
HEAVY RUM, LIQUEURS
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Mulitple Batch Kettles (Stills) with Columns
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Scotch Whisky Plant
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DISTILLATION SYSTEMS
5. DISTILLATION SYSTEMS
2. CONTINUOUS STILLS
W/SIEVE TRAYS
W/BUBBLE CAP TRAYS
W/PACKING
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Continuous Beer Still
CONTINUOUS
STILL
• GRAIN ALCOHOL
• VODKA
• GRAIN WHISKEY
• BOURBON
• CANADIAN WHISKY
• IRISH WHISKEY
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SIMPLE DISTILLATION
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Series of Interconnected Pot Stills
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PCflow® control of 3 column ENA Distillation System
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FINAL PRODUCT
6. FINAL PRODUCT
BEER IS 0.5% - 8.0% A/V
DISTILLED SPIRITS ARE DISTILLED TO:
• WHISKY/WHISKEY 70% - 94% A/V
• GIN 80% A/V
• RUM 70% - 94% A/V
• VODKA (NEUTRAL SPIRIT) 96% A/V
• BOURBON 80% A/V MAX
• BRANDY, COGNAC 70% A/V
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BUILDING DESIGN
7. BUILDING DESIGN
ALCOHOL CLASSIFICATION CHART
CHARACTERISTICS CLASSIFCATION
20% ALCOHOL AND GREATER WITH
CLOSED CUP FLASH POINT < 38°C
CLASS 1B FLAMMABLE LIQUID
6% - 20% ALCOHOL WITH CLOSED
CUP FLASH POINT >38°C AND < 60°C
CLASS II COMBUSTIBLE LIQUID
0 – 6% ALCOHOL WITH CLOSED CUP
FLASH POINT 60°C AND <93°C
CLASS III COMBUSTIBLE LIQUID
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BUILDING DESIGN
7. BUILDING DESIGN
• CLASS 1 DIV 1 ELECTRICAL WHERE ALCOHOL STRENGTH
20% A/V OR MORE (STILLHOUSE, ALCOHOL STORAGE).
• FIRE CODE SECTION 4 PART 9 APPLIES WHERE >20% A/V.
• CLASS 1 DIV 2 ELECTRICAL IN WAREHOUSE AND XP OR
PNEUMATIC PACKAGING UP TO FILLED BOTTLES.
• NO FLOOR DRAINS TO SEWER IN THESE AREAS.
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BUILDING DESIGN
7. BUILDING DESIGN
• LEL “SNIFFER” IN STILLHOUSE INTERLOOCKED TO XP
CEILING FAN.
• 4 HOUR FIREWALL SEPARATION FROM MAIN PLANT.
• NFPA 68 CODE (EXPLOSION VENTING) WHERE >20% A/V.
• SPRINKLER DELUGE SYSTEM, W/SPRAYS UNDER ALCOHOL
STORAGE TANKS.
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LCBO LICENCING
8. LCBO LICENCING
(DIFFERENT LICENCES THAN BREWERY LICENCES)
1. LCBO
2. CRA EXCISE
3. AGCO (IF RETAIL STORE, 3173 APPLIES)
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LCBO LICENCING
8. LCBO LICENCING
AGCO 3173
• MUST HAVE CRA MANUFACTURING LICENCE
• RETAIL STORE MUST BE ON SAME PROPERTY AS DISTILLERY
• SPIRITS SOLD MUST BE BRANDS OWNED BY MFR.
• MINIMUM BATCH STILL CAPACITY OF 5,000 LITRES OR
MINIMUM CONTINUOUS STILL CAPACITY OF 150 LAA/HR.
• MFR. MUST MAKE AT PRODUCTION SITE FROM START TO
FINISH 50% OF VOLUME OF SPIRITS SOLD AT RETAIL STORE
• REMAINING 50% MUST BE DISTILLED, BLENDED, AGED OR
BOTTLED AT PRODUCTION SITE.
http://www.agco.on.ca/pdfs/en/guides/3173_a.pdf
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PLANNING 9 STEPS
PLANNING STEPS
1. PREPARE CONCEPTUAL DESIGN
2. CONDUCT MARKET STUDY TO DETERMINE CAPACITY,
PRODUCTS
3. FEASIBILITY STUDY (CAPITAL & OPERATING COSTS, BUILDING
CODE , LICENCING, TECHNOLOGY)
4. PROJECT JUSTIFICATION (CHECK FEASIBILITY STUDY
ASSUMPTIONS)
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PLANNING 9 STEPS
PLANNING STEPS
5. FINANCING
6. PROJECT PLANNING (EPCM?)
7. CONSTRUCTION/IMPLEMENTATION
8. FINAL INSPECTION/TESTING/LCBO APPROVALS
9. COMMISSIONING, STARTUP, OPERATION MANAGEMENT
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FINAL THOUGHTS
Key Message
1. UNDERSTAND THE DIFFERENCE
2. THOROUGH PLANNING
3. GET PROFESSIONAL HELP
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End
Thank you for your attention
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End
ADDITIONAL INFORMATION
Contact: Stephen Harkness or Michael Coulter at cemcorp LTD
2181 Dunwin Drive, Mississauga, Ontario L%L 1X2
TEL: (905) 566-7227 or TOLL FREE: 1-888-6PC-BREW
Email: [email protected] www.cemcorp.com
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PLANNING
ADDITIONAL PLANNING
STEPS
GO TO CEMCORP/COM/ARTICLES FOR FULL DETAILS
BUILDING A MICROBREWERY OR BREWPUB
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CONSULTING ENGINEERS
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Continuous or Batch Distillation?
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MICHAEL COULTER
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Woodford Reserve Batch Bourbon Whiskey Stills
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Glenfiddich Batch Whisky Stills
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Continuous Column Stills
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Continuous Distillation Methods
CONTINUOUS DISTILLATION
• COFFEY PATENT STILL (2 COLUMN SYSTEM)
• BARBET DISTILLATION
– OPTIONS: 2,3,4,5 COLUMN SYSTEMS
• GUILLAUME DISTILLATION (EXTRACTIVE/AZEOTROPIC
DISTILLATION)
– OPTIONS: 2,3,4,5 COLUMN SYSTEMS
• PRESSURE/VACUUM DISTILLATION SYSTEMS
– OPTIONS: 2,3,4,5 COLUMN SYSTEMS
• COMBINATION FERMENTATION/DISTILLATION/STILLAGE
SYSTEMS
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RC ALCOHOL PROFILE
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PHASE EQUILIBRIUM DIAGRAM
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Pot Still
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Series of Interconnected Pot Stills
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Simple Gin Pot Still
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McCABE THEILE DIAGRAM
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McCABE-THEILE DIAGRAM
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Section – Column with Perforated Plates
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Contraction of Vapors to Pass Through Perforation
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BUBBLE CAP TRAY
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Bubble Tower with Single Cross-Flow Trays
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Packing for Packed Columns
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Jamaican Rum Pot Still
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Bourbon Still with Doubler
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3 Column Continuous Distillation System
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3 Column Continuous Distillation System
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PCflow® control of 3 column ENA Distillation System
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ALCOHOL HAZARDS
Flammability
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ALCOHOL HAZARDS, Ethanol MSDS
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DISTILLERY WEBSITES
www.distill.com
www.distilling.com
www.canadianwhisky.com
www.cemcorp.com
Do you want to learn more?
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DO YOU WANT TO LEARN MORE?
Also, Contact Niagara College for their new Master Distiller training program,
expected to begin in 2016