Vivian Marlowe
Double distillation is a process that can be used to increase the proof of alcohol. It involves collecting 700 ml of alcohol from a first run and putting it back into the boiler, adding water to reach the maximum level, and then running it through a second stripping run. This process can be repeated multiple times to improve the taste of the alcohol. The Air Still is a device that can be used for double distillation, allowing people to produce their own alcoholic spirits and liqueurs at a lower cost than retail prices. It can also be used to distill water and essential oils.
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The first run
To begin the first run of double distilling alcohol with an Air Still, you will first need to add 4 litres (1.1 US gallons) of cleared wash into the Air Still. Then, distil to obtain 700 ml (23.6 US fl oz) at 60% ABV neutral alcohol. This first run will be a “stripping run”, which will be used to create a cleaner base for your second distillation.
After obtaining the 700 ml of alcohol from the first run, dilute it to 40% ABV. This is necessary for the filter to operate properly and to ensure that you are not cooking flammable materials. Rinse the carbon cartridge under running water for 20 seconds to remove excess mineral salts. Then, fit the carbon cartridge to the top Filter Holder, ensuring that the foam washers are fitted between the filter and both ends of the cartridge. Place the top Filter Holder into the top of the larger filter container.
After filtering, dilute the alcohol further so you have 4 litres (1.1 US gallons) for the second distillation. The ABV will be around 12% at this stage. If you are doing a sugar wash, you can run this next "spirit" run as per the manual, but the collection rates will differ due to the higher ABV. It is recommended to regularly check the ABV and stop when it reaches about 10% ABV running off the Air Still.
If you are making a whiskey or rum-type wash, follow these directions: run the diluted alcohol back through the Air Still and collect the output in small numbered jars (about 100 ml or 3.4 US fl oz each). This is also called a “spirit” run and involves making cuts. You can then add your selected flavouring and make up to the final volume of 1 litre (1 US qt).
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Diluting the alcohol
Firstly, collect the alcohol from the first run. For most air stills, this will be around 700 ml (23.7 US fl oz) of alcohol at about 60% ABV. This alcohol will be put back into the boiler for the second distillation.
Next, dilute the collected alcohol with water. You will need to add 300 ml (10.1 US fl oz) of clean water to the 700 ml of alcohol to bring it down to 40% ABV. This dilution is necessary for two reasons: firstly, it improves the purity of the alcohol, and secondly, it ensures that the alcohol is below the burning level, so you don't end up cooking flammable materials during the next run.
After diluting the alcohol, it's time to filter it. Use a carbon filtration system, such as the Still Spirits Air Still Carbon Filter System, to improve the purity even further. Rinse the carbon cartridge under running water for 20 seconds to remove any excess mineral salts before use. Then, fit the cartridge to the top Filter Holder, making sure to include the foam washers between the filter and both ends of the cartridge.
Finally, prepare the diluted and filtered alcohol for the second distillation. Top it up with more water to reach the 4 L (1.1 US Gal) max line in the boiler. This step may vary depending on the size of your batch and the specific instructions for your air still, but generally, you will want to dilute the alcohol to around 30% ABV before running it through the still again.
Remember, distilling alcohol can be a complex and regulated process, so always refer to the instructions and guidelines specific to your air still, and ensure you are complying with any relevant laws or regulations in your region.
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The second run
Step 1: Dilute the collected alcohol from the first run. Take the 700 ml (23.7 US fl oz) of alcohol you've collected from the initial distillation and dilute it. Add 300 ml (10.1 US fl oz) of clean water to bring it to a total volume of 1 litre (1 US qt). This dilution step is crucial for two reasons: it improves the purity of your alcohol, and it's necessary for the optimal functioning of the filter in the next step.
Step 2: Filter the diluted alcohol. Utilise the Air Still Carbon Filter System, or a similar carbon filtration system, to filter the diluted alcohol. This step further enhances the purity of your alcohol by removing any remaining impurities. Remember to rinse the carbon cartridge before use to eliminate any excess mineral salts.
Step 3: Prepare for the second distillation. After filtration, you'll need to dilute the alcohol once more. Add more water to increase the volume to 4 litres (1.1 US Gal). This dilution lowers the ABV to around 12%, preparing it for the second distillation.
Step 4: Add botanicals for flavouring (optional). If you're making a spirit like gin, this is where you can add your desired botanicals. Attach the infusion basket to the underside of the Air Still lid, ensuring that the vapour inlet remains unobstructed. This step allows you to infuse your alcohol with the flavours and aromas of various botanicals during the distillation process.
Step 5: Proceed with the second distillation. Initiate the second distillation run in your Air Still. This step will vary depending on the specific model of your Air Still, but it typically involves heating the liquid to a certain temperature to separate the alcohol from the water. Collect the distilled alcohol in a separate container.
Step 6: Collect and store your final product. After the second distillation, collect your purified alcohol and store it in airtight containers. You may also want to consider additional flavouring or ageing processes, depending on the type of spirit you're creating. Remember to exercise caution and follow local regulations when distilling alcohol for consumption.
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ABV levels
When double distilling alcohol with an air still, the ABV levels will vary throughout the process. The ABV, or alcohol by volume, is the measure of the amount of alcohol in a solution, and it is important to monitor this when distilling to ensure the desired outcome and safety.
During the first run, or the stripping run, the ABV will start high, typically around 65%, and will gradually decrease as the distillation progresses. This is because, without refluxing, more water vapour is condensed, resulting in a lower ABV. At the end of the first run, the ABV is usually brought down to about 30% ABV before the second run. This dilution is important as it brings the alcohol level below the burning point, preventing the cooking of flammable materials.
For the second run, or the spirit run, the ABV will start lower, around 40-45% ABV, and will increase as the distillation continues. This is because the alcohol is more volatile and moves up the column into the condenser, while the water molecules condense on the saddles. The second run can be stopped when the ABV reaches about 10-15% to prevent the still from running dry, which could result in the same ABV as the starting wash.
It is important to note that the highest possible ABV achievable with a home still is around 90-95.6% ABV. Additionally, high-proof alcohol can be dangerous, causing irritation and even cancer. Therefore, it is crucial to monitor the ABV levels throughout the distillation process to ensure both the desired outcome and safety.
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Safety considerations
Before attempting to double distill alcohol with an air still, there are several safety considerations to keep in mind. Firstly, it is important to understand the legal implications of distilling alcohol. In many places, it is illegal to distill alcohol for consumption unless you are a commercial distiller. Therefore, it is crucial to check your local state laws and regulations before undertaking any distillation activities.
Another critical aspect of safety is the risk of poisoning from methanol, which can be present in small amounts during fermentation when working with grains or fruits high in pectin. Methanol is an optic nerve poison that can cause blindness. To minimize the risk of methanol poisoning, it is recommended to discard the "foreshots" or the first 50 mL collected per 20 L of mash for a reflux still, or 100-150 mL for a pot still. This simple step can significantly reduce the amount of methanol and other undesirable congeners in your distillate.
Additionally, always prioritize adequate ventilation when operating a still. Alcohol vapour is highly explosive and potentially very dangerous. Never operate a still indoors without proper ventilation and engineering controls in place. Hiring an engineer to manage the installation of air handlers and provide ventilation calculations is highly recommended.
It is also essential to maintain a safe distance from the heat source and to avoid any potential sources of ignition. Alcohol vapour is highly flammable, and a heat source malfunction or a spilled collection vessel containing high-proof alcohol could lead to a fire or explosion. Always shut down the still immediately if a leak develops and never leave the still unattended.
Finally, use the appropriate equipment and materials for distillation. Use glass collection vessels and 100% copper stills with lead-free solder. Always put safety first when selecting your equipment.
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Frequently asked questions
Double distillation is the process of rerunning the alcohol collected from the first distillation, known as the "stripping run", through the still again.
After the first distillation, dilute the alcohol to 40% ABV. Then, load it back into the still and run it again.
Double distillation increases the proof of the alcohol and improves its taste.
Put the 700 ml of alcohol you've collected from the first run back into the boiler and top it up to the 4 L max line with water.
