The Art of Distilling Spirits: From Grain to Glass
Spirits, or hard liquor, are high Alcohol By Volume (ABV) products (from 20% up to 90%1) yielded through the yeast-based fermentation of grain, fruit, vegetable, or sugar liquids. Creating your favorite whiskeys, bourbons, brandies, gins, vodkas, rums, tequilas, moonshine, pisco, mezcal, and cachaça through spirit distillation is a science and an art.
The ingredients, process, and the distiller’s unique choices and touch are critical. Turning the raw plant materials into a spirit by applying the principles of yeast physiology and chemistry takes knowledge, ability, and a compelling vision.
What Is Distillation?
Distillation relies on fermentation, the natural breakdown of carbohydrate-rich organic materials. When carbohydrates and yeast are present, fermentation increases the ethyl alcohol concentration in the mixture. Distillation then separates the alcohol from water by taking advantage of their different boiling points. Once an ethyl alcohol-containing liquid is heated to over 78.5 °C but under 100 °C, the resulting vapor is condensed with a higher alcohol concentration.
Distillation is straightforward, requiring just a heated closed container with a condenser and a condensate receptacle – a pot still. It also requires experienced subtlety and skill in a technique that dates back thousands of years.
A History of Distilling
Carbohydrates and yeast are prevalent worldwide, with the natural fermentation process prompting several ancient civilizations to create distilled beverages as early as 800 BCE. These include the Chinese using rice beer and arrack from sugarcane and rice in the East Indies. The Greeks, Romans, and Arabs recorded distillation methods, and Europe adopted the process after contact with the Middle East. Early government control was reported in the 1600s, yet spirits yielded thriving revenue.
By the early 19th century, simple stills had evolved into a series of column (continuous) stills not unlike what the industry uses today. Fuels used depend on the local availability of resources, including coal, peat, wood, oil, and natural gas. Equipment and technique refinements occurred in the early 20th century, with advances in gas chromatography identifying previously undetectable flavor components.
The Distillation Process
Raw materials can either be naturally high in sugars or contain carbohydrates readily converted into sugar through enzymatic processes. These sugary mixtures are obtained from sugarcane products, sugar beets, grapes, peaches, apples, and Agave tequilana (a cactus). Cane is pressed, sugar crystallized, and fruit or vegetable juice is concentrated.
Carbohydrates, previously limited to grain crops available locally, are now mainly determined by price and include corn, rye, rice, barley, potatoes, and other starchy roots. Essentially, grain lends the distilled spirit its unique flavor profile.
Grains are milled, pressed, and wetted, and fruits are crushed and pressed to allow more effective enzyme activity. Mashing also allows the proper proportions of grains to be mixed and converts starches into fermentable sugars. The desired mixtures are then heated, and the temperature is raised under pressure to boiling or higher. A dry malt meal or a water slurry is added to feed the yeast and contribute flavor.
Advances in Distillation
While the distillation process is remarkably like its earliest version, advances in techniques offer distinct advantages, including the following:
- Column stills allow continuous distillation across batches and a higher alcohol concentration. In contrast, pot stills require emptying and cleaning between batches.
- Heating improvements help control the still temperature beyond a fire under the pot. High-tech boilers, steam jackets, and coils allow greater control over the outcome.
- Modern still testing and monitoring help control temperatures and maintain consistency.
- Vacuum distillation reduces the chamber pressure, lowering the alcohol boiling point. This reduction helps concentrate alcohol volumes and is ideal for de-alcoholizing. It also protects delicate flavors and aromas frequently lost through conventional distillation.
Today’s stills may consist of several columns and modern heating and monitoring that speed up production, reduce waste, and increase economies and gains. Manufacturers rely on natural, concentrated flavor and aroma ingredients for appealing distilled products.
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1 https://vinepair.com/spirits-101/what-are-spirits/