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BDC Distilling Class
November 11th
Ron Grazioso
Owner/Distiller – PostModern Distilling
BDC Distilling Class
November 11th
Ron Grazioso
Owner/Distiller – PostModern Distilling
Outline
+Regulatory
+Federal
+DSP, COLA, FONL, Bond, Excise Tax, Monthly Reports….
+State
+Distribution, Brand registration….
+Distillation Theory
+Water-Ethanol Equilibrium Curve
+Rectification
+Distillation Equipment
+Pot Still, Column Still, Hybrid Still
+Dephlegmator/Bubble Plate Operation
+Practical Spirit Manufacturing Processes
+Standards of Identity
+Mashing
+Fermentation
+Distillation
+Proofing
+Maturation
+Bottling
Regulatory (Federal)
+The TTB (Tax and Trade Bureau) regulates all DSPs (Distilled Spirits Plants) in terms of licensing, spirit definitions and formula/label approvals.
+The TTB uses other federal agencies to regulate and determine approval, such as the FDA and NRC.
+In order to start and operate a distillery, you must, among other things:
1. Obtain a DSP basic permit (owner information, location w/lease, bank statements, business creation, operating agreement and management, equipment, spirit production, bond insurance, etc..)
2. Get formula (FONL) approvals – some spirits require formula approval
3. Get label (COLA) approvals – all spirits require label approval
4. Submit monthly reports (production, processing and storage)
5. Pay federal excise tax (every 2 weeks)
6. Submit to inspections and audits
Start selling product
Start making product
Regulatory (Federal): TTB Monthly Reports and Audits
+You must file Production, Processing and Storage reports every month to the TTB.
+Monthly reports are used to track every aspect of your distillery operation. The creation and loss of every gallon of spirit in your DSP must be accounted for in one of the three reports.
+Production reports are used to show what class/type of spirit you produced and how much. It also includes the amount of raw materials used so the TTB can understand your yield.
+Processing reports are used to show what class/type of spirit you bottled. This will be used to make sure you pay your correct excise tax.
+Storage reports are used to show what class/type of spirit you are storing, whether in barrels or just in tanks. This will be used to show you are aging product or storing bulk spirits.
+During an audit, the TTB agent will go through your monthly reports and your own tracking information to determine, for example: what month a bag of corn came in to produce your bottle of bourbon that is in a serialized case packer that came from a serialized barrel.
Regulatory (State)
+The TN ABC (Alcoholic Beverage Commission) regulates all distilleries in terms of licensing, taxes, distribution and brand registration.
+In order to start and operate a distillery in TN, you must:
1. Obtain local county/city zoning approval
2. Get a TN Distiller’s License (after obtaining your DSP permit from TTB)
3. Dept of Ag inspection
4. TN ABC inspection
5. Sign up with a distributor (no self-distribution in TN)
6. Register your brands (using your approved TTB COLA labels)
7. Pay state and local licensing fees
8. Yearly registration of brands and brand fees
Start selling product
Start making product
Distillation (Theory)
+Distillation is the process of separating 2 or more liquids from a liquid mixture by exploiting their difference in boiling points (or volatility).
+For beverage distillation, we are specifically talking about separating ethanol from water. Water boils at 212F and Ethanol at 173F.
+Ethanol and water are miscible meaning when combined they will form a homogenous mixture or solution. This new solution will boil at a specific boiling point between the boiling point of water and ethanol depending on the amount of each of the two components. This is shown in the Ethanol-Water Equilibrium Curve.
+When the new solution is heated to its boiling point, both ethanol and water will be vaporized but a higher proportion of ethanol will be turned to vapor since its boiling point is lower (i.e. volatility is higher).
+If you then condense that vapor, the condensate will have a higher amount of ethanol than the original solution.
+This can be repeated many times to achieve a higher concentration of ethanol.
+If I boil a bottle of beer on the stove in a pot, am I distilling?
Distillation (Theory)
+The Ethanol-Water Equilibrium Curve (aka Vapor-Liquid Equilibrium of Ethanol-Water Mixture) provides the boiling point and ethanol concentration in the vapor for different starting %ABV washes.
+Example - Two whiskey distillations
+W1: %ABV of starting solution (beer @ 8%ABV)
+T1: Boiling point of W1
+V1: %ABV of distillate after first distillation
+W2: %ABV of second solution (V1=W2)
+T2: Boiling point of W2
+V2: %ABV of distillate after second distillation
+What should I do in the above example if I want my whiskey to come out of the still at a lower proof??
Distillation Equipment: Pot Still
+Pot Still (most basic still type/Scotch still)
+Used for batch distillation
+Single distillation per batch
+Components
+Pot/Kettle
+Used to boil beer/wash
+Neck/Column
+Where vapor rises after distillation
+Lyne Arm
+Transports vapor from column to condenser
+Condenser
+Condenses vapor to liquid form
Lyne Arm
Condenser
Neck/Column
Pot/Kettle
Distillation Equipment: Column Still
+Column Still (mostly industrial use/vodka)
+Used for continuous distillation
+Multiple distillations
+Components
+Analyzer Column
+First distillation: separates alcohol and water from beer/wash solids
+Rectifier Column
+Further separation of alcohol and water by multiple distillations using bubble plates
+Bubble plates
+Used to increase proof of alcohol by increasing reflux
+Condenser
Wash in
Spirit Out
Analyzer Rectifier
Condenser
Bubble Plates
Distillation Equipment: Hybrid Still
+Hybrid Still
+Used for batch distillation
+1 or more distillations per batch
+Basically a pot still with a column attached
OR
+Basically a column still with the pot being the analyzer and the column being the rectifier
+Components
+Column bypass
+Dephlegmator
+Column with 4 bubble plates
+Condenser
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spirit
+Advantages over a Pot Still
+Can run with or without column by turning off dephlegmator
+Better separation of heads, hearts and tails by adjusting dephlegmator
+Multiple products can be made with one still
+Faster and more efficient processing
Distillation Process: Passive Reflux
+Reflux: the process of condensing vapor in order for it to return to the wash to increase distillate proof. Water vapor will preferentially condense over ethanol vapor thus increasing proof.
+All stills (even pot stills) will produce some amount of reflux as hot vapors touch the cooler sides of the still neck or column.
+Passive reflux is can be produced by using raschig rings packed into the column of a still to increase the surface area available for vapor to condense. The reflux will be proportional to the surface area and the distillate proof will increase with more surface area and column height.
+Advantages
+Very cheap
+Disadvantages
+No control and not easily adaptable to different products
Coldest/Higher Proof
Hottest/Lowest Proof
Distillation Process: Active Reflux
+Reflux: the process of condensing vapor in order for it to return to the wash to increase distillate proof. Water vapor will preferentially condense over ethanol vapor thus increasing proof.
+All stills (even pot stills) will produce some amount of reflux as hot vapors touch the cooler sides of the still neck or column.
+Active reflux is produced and controlled by using a dephlegmator(or pre-condenser) and bubble plate(s). The water flow to the dephlegmator can be controlled to increase or decrease condensation to flood the bubble plates which act as filters to condense proportionally more water vapor than ethanol vapor.
+Advantages
+Better control and more adaptable
+Disadvantages
+Higher initial cost
Hottest
ColdestDephlegmator
Water in/out
2nd distillation78% ABV
1st distillation46% ABV
3rd distillation86% ABV
8% Beer ABV
Bubble Plates
86% ABV vapor to condenser
Distillation Process: Detailed Active Reflux Process
Hottest
ColdestDephlegmator
Water in/out
2nd distillation78% ABV vapor
1st distillation46% ABV vapor
8% Beer ABV
Bubble Plate
78% vapor to condenser
Liquid Temp: 202°F
Vapor Temp: 181°F
Liquid Temp: ~181°F
Vapor Temp: 176°F
Water vapors
condense in liquid
while alcohol vapors
“bubble” through
Distillation Process: Basic Hybrid Still Operation
+Step 1: When wash comes to a boil, run water through dephlegmator so that all vapor condenses and plate fills with liquid.
2nd distillation80% ABV
Partial reflux
Hottest
Coldest
Water in/out
1st distillation46% ABV
2nd distillation78% ABV
+Step 2: Once the plate is full, that liquid is now acting as a filter to condense more water than ethanol. Reduce water flow to dephlegmator to allow alcohol to pass without condensing.
8% Beer ABV
~100% reflux
Hottest
Coldest
Water in/out
1st distillation46% ABV
8% Beer ABV
Spirit Manufacturing Processes(Standards of Identity)
+Before you can manufacture your spirit, you must first understand what defines your spirit.
+The TTB Standards of Identity is the federal law that defines the types or classes of spirits. It gives requirements on:
+What material the spirit may need to be made from → Ex: Rum must be made from sugar cane
+How the spirit should taste → Ex: Gin must have a predominate juniper flavor
+What proof it can be distilled to → Ex: Bourbon can not be distilled high than 160 proof
+If it must be aged or not → Ex: Most Whiskeys must be aged
+What proof it can be bottled at → Ex: Vodka must be bottled at 80 proof or higher
+This is defined in the Code of Federal Regulations 27 CFR 5.22. There are 12 classes of spirits and about 50 total types of spirits within those classes.
+Example: Class (2) - Whiskey, Type (1i)– Bourbon Whiskey
Spirit Manufacturing Processes(Standards of Identity)
+Standards of identity of some common spirits:
+“Neutral spirits” or “alcohol” are distilled spirits produced from any material at or above 190° proof, and, if bottled, bottled at not less than 80° proof.
+“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.
+“Whisky” is an alcoholic distillate from a fermented mash of grain produced at less than 190° proof in such manner that the distillate possesses the taste, aroma, and characteristics generally attributed to whisky, stored in oak containers (except that corn whisky need not be so stored), and bottled at not less than 80°proof, and also includes mixtures of such distillates for which no specific standards of identity are prescribed.
+“Bourbon whisky”, “rye whisky”, “wheat whisky”, “malt whisky”, or “rye malt whisky” is whisky produced at not exceeding 160° proof from a fermented mash of not less than 51 percent corn, rye, wheat, malted barley, or malted rye grain, respectively, and stored at not more than 125° proof in charred new oak containers; and also includes mixtures of such whiskies of the same type. (Still needs to be bottled at 80 proof or higher since it’s a whiskey)
Spirit Manufacturing Processes(Standards of Identity)
+Why is it important to understand the Standards of Identity??
+Example: You’ve made a great tasting spirit from Sorghum Syrup and it tastes like a Rum…what can you call it….
+Rum? No, Sorghum is a grain; Rum must be made from a product of sugar cane.
+Whiskey? Yes! as long as it was aged in oak AND was distilled at <190 proof AND bottled at 80 or higher proof.
+Vodka? Yes, as long as you distill it to 190 proof or above AND bottle at 80 or higher proof.
+Liqueur? Yes, as long as you add at least 2.5% sugar by weight. What unit is: “sugar by weight solution”??
+If you can’t produce it like any of the above, then it’s probably a Distilled Spirit Specialty since it fits no class. You need a fanciful name, maybe: “SorgRUM Spirit” and a statement of composition, maybe: “spirit distilled from sorghum” somewhere on the front label. You’ll also need to submit a formula.
+Can I distill beer and call it a whiskey??
Spirit Manufacturing Processes(Mashing→Production report)
+Mashing for distilled spirits is in theory the same for mashing for beer: extracting starches and converting them to sugar….assuming you aren’t already starting with sugar!
+They only differ typically due to the source material used for the spirit vs malted barley for beer
+Distilled spirits (depending on their class) may be made from potatoes, grain, sugar, fruit, etc..
+Each of these fermentable materials have their own requirements for optimal mashing. Where they typically differ from malted barley is:
+Gelatinization temperatures or no gelatinization at all (sugar, fruit, molasses, etc..)
+Yeast nutrient requirements (sugar washes need additional yeast nutrients added)
+Types of enzymes needed (amylase, pectinase, etc..)
+Typically lautering will not work or not necessary
+Ex: Typical whiskey mashing takes 2-4 hours and will use off-the-shelf enzymes, especially using corn due to the high gelatinization temperatures. The mash is typically not lautered and the wort is not boiled before fermentation.
Spirit Manufacturing Processes(Fermentation→Production report)
+Fermentation for distilled spirits is in theory the same for fermenting beer: converting sugars to alcohol(s).
+The main differences will again come from the main fermentable material which determines the types of sugars produced in mashing and the type of yeast strain necessary.
+Typically a distiller is trying to optimize the fermentation in terms of attenuation and less-so for flavor (congener production).
+The fermentation for some unaged spirits are more important since much of the flavor will come from the fermentation process, such as an unaged rum.
+Typical whiskey fermentations last 4-7 days and end with 90-100% attenuation. The fermentation will occur at higher temperatures, as high as 90F. Many are not temperature controlled.
+Typical whiskey yeast is Saccharomyces cerevisiae and will commonly be pitched new for every batch since the price is typically 10x lower than most beer-specific yeasts.
+Fermentations will be done on- or off-grain (or if not a whiskey on- or off-fruit, must, etc..)
Spirit Manufacturing Processes(Distillation→Production report)
+The distillation process and equipment can vary dramatically from spirit to spirit.
+Typically whiskeys are produced on pot stills or hybrid stills:
+For a pot still, 2-3 distillations are typically made:
+The first distillation is called the stripping run which “strips” out all the alcohol in the wash from the spent grains
+The second (and/or third) are called the spirit run(s) to separate and collect the heads, hearts and tails.
+Heads: low boiling point alcohols (tasty but poisonous), Hearts: mostly ethanol, the part that becomes your product, Tails: highboiling point alcohols (less poisonous but less tasty)
+For a hybrid still, a single pass is typically made with 1 or more bubbles plates to achieve the desired distillate proof and flavor.
+Column stills can also be used but are much more typically employed in large distilleries and especially when producing a neutral spirit, such as vodka.
+A distillation can take anywhere from a few hours to all day depending on: the type of still, type of spirit being produced and desired flavor profile of the distillate.
Spirit Manufacturing Processes(Proofing→Production, Processing, Storage reports)
+Accurate determination of proof is important in all three phases of spirits manufacturing: production, processing and storage. Final bottle proofing is performed for the processing report.
+Proof must be accurate for: TTB excise tax, TTB monthly reporting, to follow the standards of identity and for product consistency.
+Proof is given by volume (%ABV) but should be calculated using weight since the volume of liquids change with temperature.
+If the spirit has a low amount of dissolved solids, then a hydrometer or densitometer can be used to measure it’s proof. If not, the spirit must be re-distilled in order to separate the ethanol from the dissolved solids before using a hydrometer.
+Only %ABV is required on the product label and the actual spirit %ABV must be within: +0%ABV to -0.15%ABV within what is written on the label, according to TTB regulations.
+In the U.S., proof or %ABV must be determined and reported at 60F.
Spirit Manufacturing Processes(Maturation→Storage report)
+Many distilled spirits are matured even if they are considered un-aged.
+Even with unaged spirits, congener formation can continue while it is “resting” before being bottled.
+Though for almost all whiskeys, they must be aged in oak containers. Aging in oak imparts the largest amount of the flavor profile to a whiskey: 50-70%.
+In the U.S., most grain-specific whiskey types (bourbon, malt, rye, wheat, malted rye) have to be aged in new, charred oak barrels. Generic “whiskey” can be aged in used oak barrels and corn whiskey does not have to be aged.
+Flavor formation during maturation in barrels is due to a lot of processes but the two main components in the barrel that affect the flavor most are: the char layer and the toast (or red) layer.
+The char layer, which is on the outer surface of the wood, acts as an activated carbon layer to reduce unwanted (and sometimes wanted) flavors.
+The toast (or red) layer which is underneath the char layer imparts the most flavor and color to the spirit. This is where the sweet, vanillin flavors are created from the degradation of wood fibers by pyrolysis and hydrolysis.
Spirit Manufacturing Processes(Bottling→Processing report)
+One key difference in the manufacture and distribution of distilled spirits as compared to beer is all spirits must be bottled for retail sale.
+There are defined bottle sizes that must be used in the U.S., with the most common being 750ml and the largest being 1.75l.
+The volume and proof designations on your label determine the amount of federal excise tax you must pay which is why volume and proof have such tight tolerances:
+Volume: +/-2% (750ml only, tolerance varies for different bottle sizes)
+Proof: +0°/-0.3°
+Bottles must be stored in case packers and case packers need to have serialized labels on them designating what is the spirit and at what quantity.
+Once the bottles are moved out of your bonded premises, you must pay federal excise tax.
References
+Whisky: Technology, production and marketing, I. Russel, 2003
+The science and commerce of whisky, I. Buxton, 2014
+Fermented beverage production, A. Lea and J. Piggot, 2003
+Craft of whiskey distilling, B. Owens, 2009
+A treatise on the manufacture and distillation of alcoholic liquors, P. Duplais, 1871
+Chemistry and technology of wines and liquors, K. Herstein, 1935
+The manufacture of liquors and preserves, J. Brevans, 1893
+The chemistry of corn into alcohol, D. Holm, 1980
+Making pure corn whiskey: A professional guide for amateur and micro distillers, I. Smiley, 2003
THANK YOU!
What is beer? In the U.S…..
Potential Responsibilities of a (Craft) Distiller (or
the difference between a distiller and a craft distiller)
+Paperwork
+Submit TTB formula and label applications
+Submit (or document) TTB monthly reports
+Submit (or document) TTB excise tax
+Track batch and bottle inventory using software or other methods
+Fulfilling Orders
+Ordering Supplies
+Receiving Supplies (forklift/lifting)
+Extracurricular
+Tour guide
+Event representative
+Hands-on
+Mashing
+Fermenting
+Distilling
+Barreling
+Proofing
+Bottling
+Cleaning
+Equipment maintenance
+Quality control
+Re-distillation for liqueur proofing
+Spirit analysis (organoleptic)
+Spirit development