Dealing with spirits distillation problems

Distillation is one of the most critical stages in spirits production, directly determining the flavor, aroma, and quality of the final product. However, various technical issues can emerge during this process, affecting production efficiency and potentially leading to substandard products. As a professional distillation equipment manufacturer and distillery construction service provider, Tiantai draws upon years of industry experience to provide an in-depth analysis of common issues in whisky and other spirits distillation and their professional solutions, helping distilleries optimize processes and ensure product consistency.

Over- or Under-fermentation

Abnormal attenuation is an important indicator affecting product quality. Inaccurate Original Gravity (OG) measurements can lead to misjudgments of fermentation efficiency. Solutions include:

• Laboratory Verification: Conduct OG determinations in the laboratory for washes from at least six fermentation vessels (washbacks), calculating the allowance for loss in gravity due to fermentation and temperature.
• Instrument Calibration: Regularly check saccharometers and thermometers for accuracy against standard solutions and reference thermometers. The precision measuring instruments provided by Tiantai ensure data accuracy and prevent production deviations.
• Standardized Measurement: All worts and final wash should be tempered to 20°C before readings are taken.

Common Causes of Potential Spirit Yield Loss

Solutions for Poor Mash Tun Extraction Efficiency

Insufficient extraction efficiency in the mash tun directly leads to loss of fermentable sugars in the draff. Improvement methods include:

• Checking sparge-to-grist ratios
• Optimizing mashing temperatures, especially for the first water
• Avoiding overloading the mash tun, which exacerbates fermentable sugar loss

Tiantai’s custom-designed mashing systems employ intelligent temperature control technology and optimized fluid dynamics, increasing mashing efficiency by over 15% and maximizing the extraction of fermentable sugars.

Prevention and Control of Bacterial Infection

Bacteria competing with yeast for fermentable sugars lead to reduced yields and flavor defects:

• Implement strict cleaning regimes, focusing on mashing and fermentation equipment and piping systems
• Eliminate all “dead legs” to prevent bacterial harborage
• Set appropriate fermentation temperatures according to ambient conditions, preventing exceedance of 33°C

Tiantai’s fully enclosed fermentation systems feature sanitary design and CIP (Clean-in-Place) automated cleaning systems, effectively eliminating the risk of bacterial contamination.

Equipment Maintenance and Thermal Energy Management

Fouling of Heating Surfaces

Heating surfaces of stills, whether directly or indirectly fired, are prone to fouling due to solids and unfermentable sugars in the wash, which impede heat transfer, increase distillation times, and waste energy.

Cleaning Protocol: Treatment with a 1-2% caustic soda solution for the still or heating elements

Ambient Temperature Management

High ambient water and air temperatures (especially in summer) elevate the temperature of distillates entering the safe. Countermeasures include:

• Slowing the distillation rate
• Ensuring low wines, feints, and spirit are collected at temperatures as close to 20°C as possible

Tiantai’s integrated distillery solutions include environmental temperature control systems to maintain optimal production conditions year-round.

Steam Leaks and Equipment Integrity

An almost inaudible high-pitched hissing noise may indicate a steam coil leak, which not only dilutes the charge but can also allow charge to enter the condensate system, causing losses and contamination.

Inspection Focus:

• Integrity of all flanges
• Cracks or pinholes in copper equipment
• Verdigris (blue-green) staining on surfaces of still components, indicating vapor leaks above the charge line

Conclusion: The Importance of Partnering with Experts

Whisky distillation is a complex process requiring precise technical control and continuous monitoring. By implementing strict cleaning protocols, conducting regular equipment inspections, utilizing accurate measurement techniques, and maintaining temperature control, distilleries can significantly reduce process issues and enhance product quality and consistency.

Our technical team has deep knowledge of every detailed challenge in the distillation process and has developed numerous innovative solutions:

• Intelligent Monitoring Systems: Real-time monitoring of production parameters with automatic adjustments and optimization
• Modular Design: Flexible scalability according to production needs
• Energy Efficiency Optimization: Reduced production costs and improved sustainability
• Lifetime Technical Support: Ensuring continuous and stable operation

Contact Tiantai’s expert team today for personalized distillation solutions to elevate your whisky production to new heights!