The best distilleries across the United States readily welcome enthusiasts into their operations. Distillery tourism has become almost as popular as enjoying the spirits themselves. If you’ve ever taken a distillery tour, you will see a large amount of distillery equipment. It can be hard to know what you’re looking at. With over 2,230 active distilleries in the US, they all do things a little differently. This guide will help you better understand distillery operations, what to expect, and how the operations can vary with the different distillery equipment options. 

Mill

The first step in turning grains into alcohol is the mill. The first piece of distillery equipment grinds the grains up and prepares them for distilling. Two primary types of mills are used in distilling: hammer and roller. 

Roller mills come in a range of sizes dictated by the number of rollers the mill has. This type of mill is common in breweries. Because professionals move between these two industries, they bring their knowledge of equipment with them. Roller mills then get commonly used in distilling as a result. A simple roller mill will have two rollers. These are used for processing rye and wheat because these grains are small. Larger roller mills can have four to six rollers, giving a finer grind to the grains. Roller mills are the more expensive option, but they can last four times longer than a hammer mill. 

Hammer mills are slower than roller mills and require more maintenance. However, they can get a much finer grind. Hammer mills are commonly used in processing grains for flour. This use requires fine milling, and this quality gets carried over to their distillery usage. Some distilleries value the fine grind because it decreases the mashing time and increases the yield. It takes less heat and effort to cook the finely ground grains in the next phase of the distilling process. 

Cooker/Mash Tun

After the grains go through the mill, they get processed in a cooker or mash tun. This piece of distillery equipment converts the raw material into a form that can be distilled. The raw sugars and starches in the grains get heated and “cooked” to the distiller’s desired temperature. It’s important to note that non-sugar-based spirits do not go through this process, so a mash tun is unnecessary. 

The defining feature of a mash tun is the heating mechanism. Small tuns that are less than 100 gallons will use direct electric heat. This isn’t an ideal method for larger tuns because it is harder to maintain uniform heating. Larger tuns could have direct or indirect steam injection as the heating method. These are more efficient and effective at heating larger mash volumes. 

The second thing distilleries consider is the agitation method. You need to stir the mash during the cooking process. If it’s done by hand with a paddle, the top of the tun must be open and fairly narrow. That way, the person stirring can reach across the tun to stir the mash effectively. Tuns that are larger than 500 gallons will have a mechanical agitation method. The most effective agitation methods have a high shear system. That way, it breaks apart the dough balls and grain particles that inevitably form during this part of the process. 

Fermenters

After mashing, the next step is to allow fermenting. This phase expels the CO2 in the mash, wort, or wash. The simplest option is the traditional one. The mash gets moved from the tun to the fermenting tank. The tank is large with an open top. The mixture foams and bubbles, so the tank is typically larger than the amount of mash in it. This gives the mixture enough room to ferment without overflowing. Some distilleries cover their fermenters with a mesh or grate to protect the mash. This keeps out the pests and vermin. 

Another type of fermenter is a closed-top style. These fermenters have an airlock with a hose that gives the escaping CO2 a place to go. These fermenters are also able to control the temperature of the mash. Different types of yeasts act differently when exposed to different temperatures. The result is widely different flavor profiles. If a craft distillery wants to produce consistent results, temperature control is a must. Otherwise, something as simple as a seasonal change could result in widely different tasting spirits. 

Still

The still is the most important piece of distilling equipment because this is where the magic happens. There are two primary types of stills: pot and column. The type of still a distillery uses will depend on its operations. Smaller distilleries focusing on craft distilling will do fine with a pot distiller. Large distilleries that distill spirits in high volumes will use column stills. Operating a still can be dangerous, which is why you should leave distilling to the experts. 

When taking a distillery tour, you may notice the distillery has two setups. Large copper pot stills are impressive to look at. Distilleries will use them to create an enticing display for visitors to view. This lets the distillery show off its operations in an engaging manner. However, they may use column distillers in the production part of the distillery. That way, they can maintain production volumes. 

Pot Stills

A pot still is what most people think of when they talk about distilling spirits. These are the large round tanks with narrow tops. They are the traditional still style for distilling, made of copper. The process is straightforward. You fill the tank, distill the liquid, clean, and refill. The result is a rich and flavorful spirit. Spirits distilled in pot stills include Jamaican rums, mezcal, tequila, and malt whiskey. Some cognacs and Scotch whiskeys are also distilled in pot stills. 

Column Still 

The second most common type of still is a column. These can run continuously and are best used for high-volume distilleries. A small distillery may have a single column still. Larger distilleries will have multiple columns running simultaneously. Inside, several plates break up the column into multiple compartments. This still style works best for neutral spirits as they produce a milder flavor. This makes them a popular option for gin, vodka, and some rum distillers. 

Holding and Receiving Tanks

Holding and receiving tanks become the unsung heroes in the distillery. These single-walled tanks are large, holding several hundred gallons of liquid. Distilleries use them for blending, fermenting, filtering, and storage. The larger the distilling operation, the larger the holding tanks need to be. The larger the distillery operations, the more holding tanks it will have. This enables them to maintain continual operations by holding several batches at various stages in different holding tanks. 

Mash Pump

There are two types of mash pumps that are commonly used: centrifugal and impeller. A mash pump is a necessary piece of distillery equipment that moves the pre-distilled liquid. These pumps are delicate, helping to keep the mash intact. They effectively move high-density liquids. They also aid in maintaining hygienic conditions that prevent contamination. Finally, they make the distillation process safer. Mash pumps can safely move highly flammable liquids safely. 

Transfer Hoses

The transfer hoses are what connect the different distillery equipment pieces together. They are what move the liquid around. Hoses are required because a distillery needs to maintain a hygienic and sanitary environment during distilling. Doing so protects the quality of the distilled spirit and the end drinker. The hoses could transport fresh water, potable water, cleaning fluids, or the final distilled spirit. These hoses are food grade and will not impact unwanted flavors into the spirit. They are also made of materials that are safe to use with liquids containing alcohol or at high temperatures. That way, the distillery can safely use them during distillation and sanitize them. 

Barrels 

After distilling, some spirits require aging. This is when the spirit sits for a specific amount of time. Typically, this aging process happens in wood barrels. American and French oak are the most commonly used wood to make the barrels. However, some distilleries will also use maple, walnut, cedar, cherry, hickory, or chestnut. Oak is the most popular because it has a tight grain and imparts a strong flavor. The barrels are constructed from narrow planks that get held together with metal hoops. 

Spirits that get aged include tequila, whiskey, bourbon, brandy, port, scotch, gin, and absinthe. Some spirits will always use a fresh barrel for each batch. However, some spirits will use previously used barrels. Ex whiskey and bourbon barrels will find a second life, aging vodka, rum, and tequila. 

Bottle Filler

After distillation, the next set of distillery equipment needed is the bottler. This is what gets the spirit from large tanks into manageable bottles for consumption. While some small-batch craft distillers will bottle by hand, this is not ideal for larger distilleries. An assembly line style of bottler gets used. It will wash, sanitize, and fill the bottles. There are two common types of fillers: gravity and pneumatic. 

Labeler

A bottle of spirits is not complete without a label. Home distillers in states where it is legal may not need a professional labeler. They are only making spirits for personal consumption. However, distillers intending to sell their spirits must label their bottles properly. First, it is legally required. Distilleries planning to sell their spirits in the United States must meet federally mandated requirements. This means affixing a label to the bottle with all of the legally required information. 

Second, labeling allows the distillery to brand its spirits. This helps with marketing so that the bottle stands out among the competition. It also helps consumers more readily recognize the spirit. 

Typically, labelers can affix two labels to each bottle, front and back. The most widely used labelers are set up to process round or flat bottles. The biggest consideration for distillers is the accuracy and consistency of the labeler. They don’t want the label to get affixed to the bottle crooked or off-center. 

Corker or Screw Capper 

After bottling, the final step is securing the bottle with a cap or cork. This is the final piece of distillery equipment needed. This puts a method of closure on the bottle to seal out air and keep the liquor in the bottle. Depending on the type of liquor, the bottle, and branding, a distillery may use a screw cap or a cork. Traditionally, it was thought that higher-quality spirits use a cork. However, this isn’t always the case in modern times. 

Finishings 

Some distilleries add additional embellishments to their bottles. Maker’s Mark is famous for this, with its wax seal finishing the top of the bottle. Tanqueray is another spirit brand that uses wax on its bottles. There is a prominent round red seal on the front of the bottle. Patron sells its tequila bottle with a colored ribbon around the neck. All of these additional elements require specialized equipment. 

FAQs About Craft Distilleries

Are craft distilleries profitable?

A craft distillery can be profitable when operated correctly. The typical successful craft distillery can expect margins between 20-24%. This makes operating a craft distillery more profitable than running a craft brewery. 

Is it hard to make your own distillery?

Establishing a distillery typically requires a large upfront investment. This is because you must secure a location, raw materials, and equipment. There is also a profit delay as you wait for the first batches of craft spirit to be ready for sale. 

Why is home distilling illegal in the US?

Liquor distilling can go very wrong if you do not know what you are doing. Home distilling is illegal in the United States because the government has an interest in protecting its citizens. There is a high risk of heavy metal contaminants or methanol. These present significant health risks. 

How long does it take to distill whiskey?

How long it takes to distill whiskey will depend on the system used, the distillation temperature, and the amount of whiskey being distilled. However, it typically takes several hours. 

Learn about American craft distilling from the best distilleries by finding tastings through Distillery Nearby.