full of spirit: designing multi-spirit...
TRANSCRIPT
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Full of Spirit: Designing Multi-Spirit Distilleries
James Ludford-Brooks,
Briggs of Burton
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Quickly – Who are Briggs of Burton?
• US Engineering Company • Equipment Design and Manufacturing
• Project Management
• Process Design
• Health and Safety
• Long history working in the brewing and distilling industries
• Head office in the home of brewing • Burton on Trent, UK
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Briggs – Distilling
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Distilled Spirits Market
• Markets shift ∴ • Focus on modular and flexible systems
• Capable of producing a range of spirits under one roof
• Premiumisation: • Malts
• “Grain-to-Glass”
• “Single Estate”
• Cross-over from Craft Brewing • Diversification
• Excess wort production for spirits
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Talk Outline
Processes to make these:
• Whiskies • American
• Bourbon
• Single Malt
• Scotch • Single Malt
• Grain
• Irish • Pot Still
• Neutral Spirit • Gin • Vodka
Grain Processing:
• Grain Cooking
• Mashing / Lautering
Fermentation
Distillation
• Column
• Pot
“Brewstilleries?”
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Grain Processing
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Grain – Alcohol Yields Starch Alcohol Yields
L / Te lbs per gal ETOH
Maize (Corn) 387 20
Barley
Malted Barley 379 22
Wheat 334 25
Rye 321 26
Oats 278 30
Rice
Potato
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Mashing – Starch Gelatinization Temp.
Source: Briggs et al., Brewing Science and Practice, page 38.
Starch Gelatinization Temp. Range
°C °F
Maize (Corn) 62 – 77 143 – 171
Barley 60 – 62 140 – 144
Malted Barley 64 – 67 147 – 153
Wheat 52 – 66 126 – 151
Rye 49 – 61 120 – 142
Oats 52 – 64 126 – 147
Rice 61 – 82 142 – 180
Potato 56 – 71 133 – 160
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Example – Mash Bills
Bourbon Tenness
ee Rye
Scotch
Malt
Scotch
Grain Irish Pot
Neutral
Spirit
Maize (Corn) 70 80 ✓
Barley 60 ✓
Malted Barley 15 10 15 100 20 40
Wheat 80 ✓
Rye 15 10 85 ✓
Oats *
Rice
Potato ✓
*Oats low yield but recognised as a filter aid
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Mashing – American Whiskies
Grain Milling
• Not typically milled • Corn (Maize) • Buckwheat • Rice • Oats
• Milled • Barley • Wheat • Rye
• Using Hammer Mill or closed gap 4 Roller mill
Mashing Process
Mash Conversion Vessel (MCV) or pot still
• “All Grains” = No husk separation
• Atmospheric vessel (MCV)
• Backset ‘ Sour mash’ • 10% Mash Water vol.
• MCV Cooling • Mash Water – (Single Vessel Decoction) • Malt addition
• Dual purpose jackets • heating (steam medium) • cooling (cooling water inlet).
• Mash Cooler • Heat recovery • Tubular or Wide gap Plate HEX
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Grain Cooking
Briggs
Masher
Roller Mill
Malt Grist Case
Cold Water
Mash
Coolers
Briggs Mash Conversion Vessel
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Mashing – Grain Cooking
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Grain Cooking / Mash Conversion Systems
Heating and Cooling
• Jacketed vessel
• Direct steam injection • Preference for clean
steam generator
• Avoid taint from boiler feed water
• Internal heating coil • Cleaning
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Grain Cooking - Decoction Mashing Process (Rice)
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Mashing – Scotch, Irish and Japanese Whiskies Grain Milling
• Course grits requirement for malt • MCV / Lauter Tun • 4 roll mill
• Un-malted Barley • 4 roll mill with close
gap setting • Or separate Hammer
mill
Mashing Process
Options:
• 100% Malt Whiskey • Mashed directly to Lauter Tun
• Irish ‘Pot’ Still Whiskey • Malt and Barley • Mashed into Mash Vessel then
transferred to Lauter Tun
• Clear Worts Obtained
• Wort Cooler • Heat recovery • Tubular or Wide gap Plate HEX
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Distillery Lauter Tun
• Malted Barley • Malt Whiskies
• American
• Scotch
• Irish
• Japanese
• Husk forms filter bed
• Influence Wort Clarity • Clear (Beer)
• Cloudy
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Lautering
Spent Grain
Briggs
Masher
Cold Water
Cold
Water
Mash/Sparge
Weak worts
Tanks
Roller Mill
Malt Grist Case
Briggs Distillery Lauter Tun
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Grain Cooking + Lautering (Irish Style)
Spent Grain
Briggs
Masher
Cold Water
Cold
Water
Mash/Sparge
Weak worts
Tanks
Roller Mill
Malt Grist Case
Briggs Distillery Lauter Tun
Cold Water
Mash
Coolers
Briggs Mash Conversion Vessel
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Distillery Lauter Tun - Operation
• Sparge weak worts to improve yield
• Question on payback at Craft Scale
• Without weak worts collection the mash in the Lauter Tun is thicker
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Distillery - Mash Filter
• Design for high volume, Mash separation in the brewing industry
• Consistently clear wort
• Two in Scotland • Diageo Teaninich
Distillery
• InchDairnie Distillery
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Fermentation
• Materials of construction • Wooden • Stainless Steel
• Variables (Control) • Time • Temperature • Yeast strain • % ABV
• largely affected by extract yield
• Foaming • Nitrogen Content (FAN)
• Grains are FAN deficient • Compensated with Backset?
• Agitation • Grains In
• CO2 = Asphyxiating
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Distillation
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Distillation
Wort / Wash
Steps:
• Fermentation
• Distillation
Source:
• Distillery
• From existing Brewery wort
Neutral Spirit
Steps:
• Vodka • Rectification
• Filtering
• Gin • Infusion with
botanicals
• Rectification
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Grain Whiskey Spirit (GWS)
Be
er
Str
ipp
ing
Co
lum
n
Steam Doubler
High
wines
condenser
Whiskey
Tank
Low Wine
Tank
Low wines
condenser
Low wines
cooler
Beer
Preheat
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Pot Whisk(e)y Production
Cold
Water
To Cooling Tower
Spirit
Stills Wash
Stills
Pot Ale
Tank
Low Wines
Tank
Spent Lees
Tank
Feints
Tank
ISR
Low wines
(20-23%)
Foreshots &
Feints
(28-30%)
Spirit
(68-70%)
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Industrial Neutral Spirit Production
Primary columns – GWS Secondary columns – GNS (Vodka)
Steam Steam
An
aly
ze
r &
De
ga
sse
r C
olu
mn
Con
ce
ntr
ato
r C
olu
mn
Dem
eth
ylise
r C
olu
mn
Steam Fu
se
l C
olu
mn
Str
ipp
er
& R
ectifie
r C
olu
mn
Extr
active
Colu
mn
Hea
ds
Colu
mn
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Infused Spirits (Gin)
Condense
r GNS (IBC)
Vapour
Infusion
Basket
Rectificati
on
Column
Stillage
(IBC)
Gin still
Product
Tank
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Brewstillery Concept
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Distilling and Brewing – Quick Comparison
Distilling
• Malt
• Grain Cooking
• Grains In
• Clear or Cloudy wort
• Not Boiled
• Secondary Fermentation
• Weak Worts collection (optional)
• Distillers Yeast
• Higher Temperature and %ABV
• Single-Use
Brewing
• Malt
• Grain / Adjunct Cooking • Mash Separation • Lauter Tun / Mash Filter
• Clear Wort
• Wort boiled in Kettle • Increased Gravity • Hops added
• Yeast • Ale / Lager • Temperature and flocculation • Crop and re-pitch
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Brewstillery Concept – Grain Whiskies
Briggs
Masher
Mash
Coolers
To FVs
Briggs Lauter Tun
Mash Vessel
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Brewstillery Concept – Whiskies (Irish Style)
Spent Grain
Briggs
Masher
Wort
Coolers To FVs
Mash Vessel
Briggs Lauter Tun
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Brewstillery Concept – Distillation
Briggs Kettle / Still
Briggs Lauter Tun
Spirit Condenser
From FVs
Seal pot
Spirit
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Brewstillery Concept – Beer
Spent Grain
Briggs
Masher
Wort
Coolers
External Wort /
Wash heater
Briggs Kettle
Thermosyphon
Briggs Lauter Tun
From FVs
To FVs
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Summary
Overview
Choice of spirits to make:
• Neutral Spirit Production
• Vodka
• Gin
• Whiskies
• Cereal Cooker and Lauter Tun allows a wide range of whiskies to be produced
• Similarities between malt whiskey distilleries and breweries
• Process modifications allow production of both
Questions
• Make your own Neutral Spirit?
• Excess brewery wort, how to integrate into a distillery process?
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Thanks Any Questions?
Booth #107