Lena Savoie
Distilled spirits are alcoholic beverages in which the concentration of ethyl alcohol has been increased above that of the original fermented mixture. Fermentation occurs when a raw material in liquid form that contains sugar is mixed with yeast. The yeast feeds on the sugar, and the byproduct of this consumption is alcohol and carbon dioxide. The distillation step is unique to spirits and is used primarily to increase the alcohol percentage in the final product to 30 percent or higher. The majority of vodkas and all whiskies are distilled from a wash that is essentially beer made by fermenting cereal grains. The ethanol alcohol is then separated from the water since ethanol has a lower boiling point. The vapor is then condensed back into a liquid, and the resulting liquid is then packaged into glass bottles.
| Characteristics | Values |
|---|---|
| Fermentation phase | All forms of alcohol undergo this process |
| Alcohol concentration | 5-10% |
| Distillation | Used to increase alcohol percentage in the final product |
| Alcohol percentage in distilled spirits | 30% and higher |
| Purpose of distillation | Separation and removal of alcohol |
| Raw materials | Grapes, fruit, sugarcane, potatoes, cereals, etc. |
| Additives | Sugar, honey, glycerol, citric acid, fruit flavorings |
| Containers | Glass bottles |
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What You'll Learn
Alcohol percentage in blended whiskey
Distillation is the process of concentrating alcohol. It does not produce alcohol but separates the alcohol from water as ethanol alcohol boils at a lower temperature than water. This process is complicated by the presence of congeners—chemical compounds that give spirits their flavour and character. Some congeners are desirable in small quantities, while others should be removed during distillation.
The distillation process is used to increase the alcohol percentage in spirits to 30% and higher. However, the alcohol concentration becomes toxic to yeast at around 14-18%halting further fermentation. The distilled spirit is then matured and/or mixed with additives to produce the desired flavour and consistency. The final product is then packaged in sterile glass bottles to prevent the alcohol from reacting with its container.
Blended whiskey is a product of blending different types of whiskey and sometimes neutral spirits, colourings, and flavourings. It typically contains a minimum of 20% straight whiskey, with the rest made up of other styles of alcohol, such as grain-neutral spirits. This allows for a lower-priced product, although more expensive "premium" varieties exist. Most Canadian whiskies are blends, and regulations require them to be aged for at least three years. Similarly, all spirits in a Canadian, Scottish, or Irish whiskey must be aged for at least three years, with any age statement referring to the minimum age of the spirits used in the blend.
The alcohol percentage in blended whiskey can vary depending on the specific blend and the country of origin. In the United States, blended whiskey must contain a minimum of 20% straight whiskey, with no upper limit on the whiskey content. American "blended whiskey" or "whiskey – a blend" must contain at least 20% straight whiskey, and if it contains a minimum of 51% straight whiskey of a particular grain type, the grain type is included in the label description. Spirits containing less than 20% straight whiskey but more than 5% whiskey of any kind can be labelled as "spirit whiskey".
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Distillation methods
Distillation is the process of separating the components of a mixture by exploiting differences in their volatility. It is important to note that distillation does not produce alcohol but merely concentrates it. To produce a distilled spirit, one needs to start with an alcoholic liquid ('wash') that is then distilled. The majority of vodkas and all whiskies are distilled from a wash that is essentially beer made by fermenting cereal grains.
Pot distillation
Pot distillation is a discontinuous distillation method where the still is filled with portions of wash to distil alcohol. This process is less efficient due to the diminishing alcohol concentration in the beer under continuous boiling. It requires about three times as much energy as an equivalent continuous distillation system. However, the pot still is still widely used for the elaboration of some fine alcohols, such as cognac, Scotch whisky, Irish whiskey, tequila, rum, cachaça, and some vodkas.
Continuous distillation
Continuous distillation is suitable for the mass production of spirits. In this process, mash is added continuously for distillation. This process was invented by Scotsman Robert Stein in 1826 and later improved upon by Irishman Aeneas Coffey. The Coffey distillation apparatus consists of several copper columns and is also known as a column apparatus.
Hybrid methods
Some producers utilise a hybrid of the pot and continuous distillation methods. Another option is to skip the second distillation and steep the neutral spirit in botanicals for days or weeks, then filter out the solids and package the resulting liquid.
Fractional distillation
Fractional distillation is used in the midstream operations of an oil refinery for producing fuels and chemical raw materials for livestock feed. It is also used to produce alcoholic beverages with a high content of ethyl alcohol.
Freeze distillation
Freeze distillation is an analogous method of purification that uses freezing instead of evaporation. It is not a true form of distillation but a recrystallisation process. It is used in the production of ice beer and ice wine to increase ethanol and sugar content, respectively. It is also used to produce applejack, though many countries prohibit it as a health measure since it concentrates poisonous congeners.
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Fermentation
During fermentation, yeast breaks down fermentable sugars at temperatures ranging from 24 to 29 °C (75 to 85 °F). At these temperatures, fermentation typically takes between 48 and 96 hours to complete. Fermenting grain involves cooking it in water and treating it with enzymes to break down the starch, resulting in an alcohol concentration of roughly 5-10 percent. The finished concentration, often referred to as "beer," depends on factors such as the amount of water used, the type of grain, and the quality of fermentation.
However, fermentation has its limitations. As the alcohol concentration increases, it becomes toxic to the yeast, typically between about 14-18%. This toxicity halts further fermentation, and the distillation step is then employed to increase the alcohol percentage in the final product to 30% and higher. Additionally, the maximum ethanol concentration achievable through fermentation is approximately 12% due to yeast cell death at higher concentrations.
To address these limitations and achieve higher alcohol concentrations, distillation is used. Distillation does not produce alcohol but concentrates it. The fermented product, or wash, is distilled to separate the alcohol and volatile compounds from the solution. This process utilises the difference in boiling points between ethanol and water, allowing the ethanol to be separated by evaporation. The vapour phase, with a higher alcohol percentage, is then condensed back into a liquid and further processed.
The distillation process can be performed in a pot still, a distillation column, or a combination of both. The decision to cut" the stills outflow from heads to hearts and hearts to tails impacts the purity of the final product. The addition of various additives, such as distilled water, sugar, and flavourings, further refines the spirit before it is packaged in sterile glass bottles to prevent evaporation and reactions with the surrounding environment.
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Yeast and sugar
Yeast is a single-cell organism that multiplies in the presence of oxygen. After consuming oxygen, yeast converts fermentable sugars into alcohol. Distillers' yeast, or Saccharomyces cerevisiae, has a robust capacity to metabolize sugar and generate alcohol as a byproduct. The flavour and aroma of whiskey, rum, and moonshine are heavily influenced by the distillers' yeast used in the fermentation process.
The type of sugar used in distillation varies. Simple sugars, or monosaccharides, cannot be broken down into simpler forms. They are the easiest for yeast to consume because they are 100% fermentable. Fructose, or fruit sugar, is the sweetest part of sugar and is found in honey, fruit, and many root vegetables. Glucose, or corn sugar, is the less sweet part of sugar and is often derived from starches like potatoes, corn, and wheat.
Compound sugars, on the other hand, can be broken down into simpler forms. They are more complex for yeast to process. An example of a compound sugar is sucrose, which can be found in refined sugar or brown sugar. Brown sugar contains molasses, giving it its distinctive brown colour and higher mineral content compared to other processed sugars.
When making a distilled spirit, the first step is to ferment a "wash." A wash is a mixture of simple sugar and yeast, or it can be derived from natural sources like fruits and grains. For example, whiskey is typically fermented with sugars from barley, corn, rye, or wheat mixed with water and yeast. The amount of water, type of grain, and quality of fermentation will impact the final alcohol concentration of the wash.
The distillation process then concentrates the alcohol in the wash. Vodka and whiskey, for instance, are distilled from a wash that is essentially beer made by fermenting cereal grains. The distillation step increases the alcohol percentage in the final product to 30% and higher.
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Packaging
The packaging of distilled spirits is a crucial step in the production process, ensuring the product's quality and integrity. Here is a detailed overview of the packaging process:
Selection of Packaging Material
The selection of the right packaging material is essential to preserve the aroma and flavour of the distilled spirit. Glass bottles have been the traditional and preferred choice due to their non-reactive nature. Glass is inert and does not react with the alcohol or extract any flavours or aromas from it. This ensures that the spirit's original characteristics remain intact. Glass bottles also provide a level of transparency, allowing consumers to appreciate the colour and clarity of the spirit.
Sterilization and Filling
Before filling, the glass bottles are thoroughly cleaned and sterilized to remove any contaminants. This step is critical to prevent the growth of bacteria or other microorganisms that could spoil the product. After sterilization, the bottles are carefully filled with the distilled spirit, ensuring accuracy in volume and minimizing any spillage.
Sealing and Capping
Once filled, the bottles are securely sealed to prevent leakage and oxygen exposure, which could lead to oxidation and alter the flavour of the spirit. Various sealing methods can be employed, such as using corks, screw caps, or stoppers, each providing different benefits in terms of airtightness and ease of opening.
Labelling and Decoration
The packaging process also involves applying labels to the bottles, providing essential information such as the brand name, alcohol percentage, volume, and any legal disclaimers or warnings. Labels can also include decorative elements that enhance the bottle's aesthetic appeal and contribute to the overall brand image.
Storage and Aging
Depending on the type of spirit and local regulations, the packaged product may undergo a period of storage or aging. For example, whiskeys often require a minimum aging period, such as the two-year storage requirement for whiskeys in the United States and Canada. During this time, the distilled spirit matures and develops its unique flavour and aroma.
Quality Assurance and Distribution
Finally, the packaged distilled spirits undergo rigorous quality checks to ensure they meet the required standards. This includes inspecting the bottles for any defects, verifying the accuracy of labels, and, in some cases, conducting taste tests to ensure consistency in flavour and quality. Once the products pass these checks, they are released for distribution and sale.
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Frequently asked questions
Distillation is the process of separating and removing alcohol from a liquid mixture by adding and subtracting heat. It does not produce alcohol, but concentrates it.
Distillation is used to increase the alcohol percentage in the final product. All spirits go through at least two procedures: fermentation and distillation. The distillation step is unique to spirits.
The percentage of alcohol distillations are reduced to before packaging varies depending on the type of spirit. Vodka, moonshine, neutral spirits, most gins, and some rums and brandies are unaged. Whiskies are predominantly aged. The alcohol percentage of spirits is increased to 30 percent and higher.
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