A MULTI-DISCIPLINE CRAFT COMBINING DISTILLATION CREATIVITY, PRODUCTION

TECHNOLOGY & LEGAL COMPLIANCE

ARTISAN-CRAFT DISTILLING

WELCOME TO A NEW INDUSTRY

1 July 2008 “Craft Distillery Bill” signed into law 20,000 proof-gallon production ceiling, now

60,000 proof gallons 25,236 cases @ 50% ABV 30,783 cases @ 40% ABV 50% Washingtonian raw product On-site sampling; half-ounce samples, 2

ounces per person maximum Sales; 2 litres per person per day

THE HISTORY OF DISTILLING

Babylonia, 2nd Millennium BC Egypt, 3rd Century AD Persia, 8th and 9th Centuries Holy Roman Empire, 12th Century Ireland, 14th Century Scotland, 15th Century Americas, 17th Century Laird’s, oldest American distillery, “still” in

business

DISTILLATION = SCIENCE

Fractionating action as heat liberates alcohol from aqueous solution

Change in physical state and back again many times at the molecular level

As nature’s most efficient organic solvent, beverage alcohol derives all of its color and much of its flavor and aroma from a barrel

DISTILLATION = ART

Individualized choices of grains, fruits, yeasts and nutrients; i.e. limitless variables

Subjective determination of fractions or “cuts”

Sensorial determination of maturation

Creative design of brands and labels

DISTILLATION = HRP* = DAMN!(* HEAVILY REGULATED

PRIVILEGE) Not legal without proper Federal, State, County,

City permits and licenses No level of amateur distilling permitted Revenue-earning potential for all governmental

agencies Health and safety hazards galore Burns, impaired vision and death are the most

frequent result of careless distilling Stiff penalties and/or incarceration No chance for commercial license

1:00 PM TO 5:00 PM

Distillation Engineering

METHODS OF HEATING

Open flame (gas, coal, wood, pellets)

External steam heating

Internal steam heating

Internal electric heating

REFLUX AND CONDENSATION

Reflux is a physical change in state of any matter; solid to liquid to vapor to …....….?

Reflux at the molecular level is essential to distillation of alcohol; liquid / vapor / liquid

Successive multiples of reflux strengthen and purify beverage alcohol

Condensation happens as vapor returns to liquid state due to cooling

Reflux and condensation are essential to the distillation of beverage alcohol

THE POT STILL A = Pot, or Kettle

B = Radius

C = Column

D = Gooseneck

E = Lye Pipe, or Lyne Arm

F = ?

THE CHARENTAIS STILL

THE CHARENTAIS STILL

THE COLUMN STILL(COFFEY, CONTINUOUS, PATENT)

THE FIGGINS POT~COLUMN HYBRID STILL

COPPER AND STAINLESS STEEL;COMPARED AND CONTRASTED

High heat conductivity High malleability High chemical

reactivity Difficult to weld Discolors when heated Aesthetically pleasing Requires cleaning often Costly

Low heat conductivity High tensile strength Low chemical reactivity Easy to weld Stays brilliant when

heated Sanitary Requires little care Inexpensive

COPPER STAINLESS STEEL

9:00 AM TO 12:00 PM

FERMENTATION FUNDAMENTALS

GRAIN FERMENTATION

Requires gelatinization of proteins to liberate starches into mash water (cooking, mashing)

Requires at least 5% by weight additionally of malted grain, chiefly barley

Liquid preparation of gluco-amylase enzymes used in place of malted barley by some producers

Mixture of grains (mash-bill) in any proportion, or single grain

Result of any grain fermentation is beer

MALT FERMENTATION

Requires germination and kilning

No cooking required

Abundance of enzymes

Higher potential gravity than grain

More expensive than grain

Result of any malt fermentation is beer

TUBER FERMENTATION

Potatoes or sugar beets

Requires cooking and mashing to release starches

Requires enzymatic conversion of starch

High-yielding

Neutral, and thus perfect for vodka

FRUIT FERMENTATION

Mono-saccharide (glucose, fructose)

Requires nutrient additions to prevent H2S formation

High levels of acids and phenols

High potential alcohol, especially from grapes or fruit concentrates

Result of any fruit fermentation is wine

SUGAR, MOLASSES, HONEY, SORGHUM AND AGAVE SYRUP FERMENTATION

Requires dilution with water Requires a buffering agent to ~ 3.6 to 4.0 pH Requires cellulose and nutrients Extreme control over strength Can result in excellent yields Low SO2 production Result of a honey fermentation is mead

YEAST, NUTRITION & OXYGEN SUPPLY

Choose appropriate yeast strain(s) Freeze-dried (dormant) or liquid (living)? Complex substrates require feeding B vitamins ~ Thiamine, Niacin, Pantothenic

Acid, Biotin most important Nitrogenous compounds needed for cell

mitosis Oxygen absolutely essential

1:00 PM TO 5:00 PM

DISTILLATION FUNDAMENTALS

VODKA Must be distilled at or above 95% ABV Must be “neutral” in flavor and aroma Can be made from any raw product provided

that the first conditions are met Usually made from a potato, corn, wheat

starch base, though rye and malted barley are more flavourful

Available in bulk at high strength (190° to 196° proof) as grain neutral spirits (GNS)

No maturation Diluted to beverage strength and filtered

through activated carbon, with coconut carbon being of a superior grade

GIN Made from vodka Re-distilled with botanicals suspended in

vapor or liquid; or Infused with botanicals Juniper berry is the chief botanical Proprietary mixes of botanicals No maturation, though some Dutch genever

is aged Diluted to beverage strength

RUM

Made from cane sugar or molasses No beet sugar allowed No honey allowed No agave syrup allowed Matured and non-matured styles Called cachaça in Brazil and made from cane

juice, not granulated or molasses

MESCAL / TEQUILA

Made from the syrup pressed from roasted agave

Use of Tequila name only if made in Mexican state of Jalisco

100% from agave; inferior grades are blended with grain neutral spirits

Matured and non-matured styles, e.g. Plata or Blanco, Reposado, Añejo

WHISKY / WHISKEY U.S.: “Distilled at no higher than 95% ABV

(Bourbon, 80% ABV) but stored in oak containers and bottled at no less than 40% ABV”

Grain, malt and grain-malt blends Bourbon at least 51% corn in mash-bill; aged for ≥ 2 years in new charred barrels Scotch is all-barley, grain or malted; aged for > 3

years in prior-use barrels Irish is all-barley and is aged for ≥ 3 years Canadian whisky, chiefly rye, is aged for ≥ 3 years

and must be at least 92% whisky

BRANDY AND EAUX-DE-VIE Made from any fruit-based wine Brandy is aged for a minimum of 2 years for

grape, except if a modifier is used Eau-de-vie not recognized by TTB All Cognac and Armagnac is brandy VS, VSOP and XO nomenclature Grappa is pomace brandy from the spent

skins of the winemaking process Pisco is young South American brandy

LIQUEURS, OR CORDIALS

Any spiritous mixture containing a combination of spirit blended with a sweetener, herbs, botanicals, spices or a dairy product

Generally fall between 17% and 38% ABV, though absinthe is much higher

6:00 PM ODDFELLOWS RESTAURANT

RAINIER ROOM, TRUITT BUILDING102 W MAIN ST

AUBURN, WA 98801

NO-HOSTSPIRITS TASTING

AND DINNER

9:00 AM TO 10:30 PM

GAUGING OF SPIRITS

WEIGHT, VOLUME AND TEMPERATURE

If weight, volume and temperature are known, proof can be extrapolated

TTB gauging manual is essential % ABV x 2 = ° proof Proof-Gallon = one U.S. gallon of spirits having a

strength of 100° proof (50% ABV)

HYDROMETRY

Uses the principal of specific gravity Adapted to liquids, a hydrometer floats

proportional to density of the liquid The alcohol hydrometer is usually calibrated

to a scale of % ABV and/or ° Proof Some hydrometers have an integrated

thermometer with correction gradations

DENSITOMETRY

Uses oscillation technology to determine specific gravity and hence, density of a given sample

GAS-CHROMATOGRAPHY

Uses fractional distillation to separate constituents of a liquid matrix and analyzes them for density and volume

Used to most accurately measure percent of alcohol in a given sample

Usually carried out by a commercial laboratory, but some larger distilleries own a GC unit

10:45 AM TO 12:00 PM

SPIRITS PACKAGING

BOTTLE, CLOSURE AND LABEL

Clear (flint) for spirits Brown or antique green for liqueurs Cork, Zork®, glass stopper or screw cap Bar top or screw top Tin, poly-laminate or PVC capsule, or wax

seal Hand-applied or machine-applied label Silk-screened label Cost varies; $15.00 to $30.00 per case

STANDARDS OF FILL

Federal requirements mandate that the actual fill cannot vary more than 0.5% of stated volume for spirits

Spirits can only be bottled in 1.75 L, 1.0 L, 750 mL, 375 mL, 200 mL, 100 mL and 50 mL volumes; no filling into 500 mL since 1986

Calibrate any filling device with an accurate graduated cylinder after stabilizing the bottling room at 60 °F / 15.6 °C.

BOTTLING, SEALING & LABELLING

Calibrate any filling device with an accurate graduated cylinder after stabilizing the bottling room at 60 °F.

Stopper or screw-cap closure Tin capsule; spun on PVC capsule, heat-shrunk on Beeswax or plasticized wax seal Paper tag as tamper-evident seal Closure and capsule all in one (Zork®)

1:00 PM TO 5:00 PM

BUSINESS OF DISTILLING 1

THE DISTILLERY BUSINESS PLAN

BUSINESS FINANCING

PRODUCT SALES AND MARKETING

9:00 AM TO 12:00 PM

LICENSING AND COMPLIANCE 1

PHYSICAL PLANT CONSIDERATIONS

Lockable doors Impenetrable windows Signage Means of gauging on premises Gauging manual on premises Physical barrier between production & tasting

area Tasting area not in bonded area

US TREASURY, ALCOHOL & TOBACCO TAX &TRADE BUREAU

1:00 PM TO 5:00 PM

LICENSING AND COMPLIANCE 2

STATE LIQUOR CONTROL BOARD

STATE DEPARTMENT OF REVENUE

COUNTY AND MUNICIPAL CODES

LICENSING AND BONDING SERVICES

LABEL APPROVAL

4:00 PM TO 5:00 PM

BUSINESS OF DISTILLING 2

“BRANDED HOUSE” VERSUS

“HOUSE OF BRANDS”

Company name same as brand name Company name not identical to brand(s) View each brand name as an asset Each brand requires identity creation The more assets owned by a distillery, the

greater its re-sale value Multiple products have multiple markets,

requiring specific brand dynamics

SPIRITS DISTRIBUTION Retail privileges ~ bottle sales and single-

serving sales WSLCB Distribution Center WSLCB Special Order catalog WSLCB General Listing Agents and Brokers Internet sales direct to consumer Class H licensees in WA WY and NH have lowest spirits tax in USA WA has highest spirits tax in USA NY, CO, DC – no agent required

6:00 PMODDFELLOWS RESTAURANT

RAINIER ROOM, TRUITT BUILDING102 W MAIN ST

AUBURN, WA 98801

NO-HOST DINNER

9:00 AM TO 12:00 PMSIDETRACK DISTILLERY

27010 78TH AVE SKENT, WA 98032

DISTILLATION IN PRACTICE 1

DISTILLATION APPARATUS EXPLAINED

Pot, or kettle Heat source Column Lyne arm, lye pipe, swan’s neck (col de

cygne) Thermometers Condenser (heat exchanger) Spirit manifold / carbon cup Heads removal port Spirit receiver / hydrometer well

HEATING AND COOLING ESSENTIALS

Electric sources of heat; all on at first, and adjustments as temperature rises

Tap water for cooling; low flow rate Re-circulated glycol or saline as a substitute cold inlet at top and valved warm oulet at

bottom (in-flow heat exchange) cold inlet at bottom and valved warm outlet at

top (cross-flow heat exchange)

HEALTH & SAFETY CONSIDERATIONS

Never fill below heating elements, and always a fair level above, factoring in loss

Never have any contact with foreshots Never touch hot kettle or column Handle hot liquid sensibly No smoking in distillery Never under-cool condenser

STILL CONSTRUCTION

All-copper construction Silicone or Teflon® gaskets 5500-watt heating elements Tri-Clover® flanges and clamps Tube-in-Shell (Liebig) condenser Worm-in-Tub condenser Copper spirit receiver / hydrometer well

CHARGING THE STILL

Fill from bottom Watch for level to rise Do not over-fill the kettle Do not under-fill the kettle

APPLYING HEAT

All four elements on at first Apply one at a time, using audible test to

check for faulty elements Use mechanic’s stethoscope in noisy plants Reduce to three elements as lye pipe

temperature rises to 172 °F / 77.8 °C. Reduce to two opposing elements as

substrate volume decreases or if spirit proof weakens

1:00 PM TO 3:00 PMSIDETRACK DISTILLERY

27010 78TH AVE SKENT, WA 98032

DISTILLATION IN PRACTICE 2

DISTILLATION DEMONSTRATION

HEADS, OR FORESHOTS

Rich in methyl alcohol (methanol) ~ CH3OH Rich in all low volatiles (ethyl acetate,

sulphur dioxide, acetone, acetaldehyde) Toxic, injurious and fatal if ingested Discard generous proportions, at least 100 ml

per 225 litres substrate; double in actual practice

Federal regulations require plan for disposal Bio-fuel plants require CH3OH

HEARTS, BODY OR MIDDLE CUT

Begin at 172 °F / 77.8 °C Rich in ethyl alcohol (ethanol), ~ C2H5OH Trace amounts of the good congeners (esters,

fusel oils, phenols) Always in a matrix with water Begins high in strength, ~ 80% ABV Constant flow rate Ends low in strength, ~ 40% ABV Average of 60% ABV need not be re-distilled

TAILS, OR FEINTS

Low in alcohol, high in water content Keep in still, cool spent wine or pot-ale, then

discard Deposit distilled tails into separate vessel

and record volume / proof Rich in di-methyl sulphide and fusel oils Re-distill tails with next batch, if collected at

all

GO FORTH WITH GREAT SPIRIT!