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Showing posts with label Course. Show all posts

Tasmanian Whisky Academy Intro to Distilling – Part Three

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Tasmanian Whisky Academy Intro to Distilling – Part Three


After leaving Moo Brew Brewery, the Intro to Distilling course enjoyed a lunch of beautiful local Tasmanian produce at Frogmore Creek Winery in the Coal River Valley. Just beyond the manicured gardens and fields of grapes sits an unassuming tin shed; many a tourist would sip their wine admiring the view without realising the tin shed is where Bill Lark’s famous award-winning Lark whisky is aged.

It was only a short trip from Frogmore Creek to the Cambridge-based Sullivans Cove Distillery. We were greeted at the distillery by Sullivans Cove Head Distillery, Pat Maguire, who wasted no time showing us where the whisky wash (from either Moo Brew or Cascade breweries in Sullivans Cove’s case) is pumped into the distillery. Sullivans Cove is set up to receive 12,000L of whisky wash at a time, although the distillery only operates a single 2,400L pot still. The whisky wash is transferred to a storage tank on the outside of the distillery to be pumped, when required, to the pot still inside. The distillery is open to the public for tours and cellar door sales throughout the business week and has a viewing platform overlooking the copper pot still, tucked away in a corner of the bond store. From 1996 – 2003, Sullivans Cove distillery occupied the old gas works site in Hobart and employed two people; the distillery was then sold and moved to Cambridge in 2004 where it now employs 12 people.


The distilling setup at Sullivans cove consists of a single 2,400L French designed (originally for brandy distillation) copper pot still, connected to a condenser via a lyne arm with a swan’s neck kink at the still end and six spirit collection tanks. The first step in the distilling process is to create 'low wine', which is what you are left with after the wash run or initial pass through the still. Whisky wash is pumped into the pot still from the wash receiving tank outside. Since Sullivans Cove start with 12,000L of whisky wash and only have a 2,400L still, they need to do five wash runs to process all the whisky wash. The still is filled and heated to 81˚C causing the alcohol to boil off but leaving most of the water behind. The vapour rises up the still and into the lyne arm where it partially condenses. So much of the distilling equipment is made of copper because copper chemically reacts with the condensing vapour. This property of copper was a serendipitous discovery, much like the effects of ageing spirit in wooden barrels. The copper reacts with sulphur in the vapour to form copper sulphate and draws unpleasant compounds and oils out of the spirit.

Next the spirit reaches the vertical column shaped condenser, where as the name suggests, the vapour is cooled and condensed into a liquid. The low wine is collected in the various storage tanks until all the whisky wash has gone through the pot still. At this point, the low wine is at about 25% ABV and is ready for the first of two spirit runs which will eventually become Sullivans Cove’s double-distilled newmake spirit. After the first spirit run, the spirit is transfer back into the still and the process begins again. This time the liquid that leaves the condenser is of a much higher alcohol concentration (around 71% ABV) and the copper strips away more unwanted compounds.

It is not a simple matter of just collecting all the liquid that comes out of the condenser however; more than one type of alcohol is distilled and not all alcohol is safe to consume. The first liquid distilled in a spirit run is mostly methanol, a strong smelling and poisonous alcohol. The distiller must separate this and other unwanted components in order to capture the ‘heart’ of the spirit run which is mostly ethanol. To achieve this, the distilled spirit is diverted at the beginning and end of each spirit run into a separate storage tank. The point when the spirit is diverted is called a cut and the first portion of cut spirit the ‘foreshots’ and the last portion the ‘faints’. The ‘fores & faints’ are not wasted, but rather added to the next spirit run since they still contain a portion of usable alcohol. Cutting the spirit can be an automated process or done manually as is the case at Sullivans Cove. You can smell, taste and sometimes see when the spirit run changes from mostly methanol to ethanol and a distiller uses all these indicators and their own experience to decide when to cut the spirit.

During those two or more years, the spirit and wood undergo an almost magical metamorphosis where the wood releases organic chemical compounds into the spirit that introduce new colour, flavours and aromas. 

The spirit that is produced from the distillation process is not yet whisky. In order to be legally labelled as Whisky, the freshly distilled newmake, must be aged in wooden barrels for a minimum of two years (in Tasmania) or three years (in Scotland). During those two or more years, the spirit and wood undergo an almost magical metamorphosis where the wood releases organic chemical compounds into the spirit that introduce new colour, flavours and aromas. Sullivans Cove do not print age statements on their bottles, but they do list the distillation and bottling dates so you can work out the age of the whisky for yourself; often around 10 years which makes it some of the oldest Tasmanian whisky available.

The final process is to bottle the aged whisky, but once again it is not as simple as syphoning the whisky straight from the barrel and into a bottle. The compounds released by the wood that impart so much flavour and aromas to the whisky have varying solubility depending on alcohol concentration and temperature. This means, that they will tend to solidify and clump together over time. There is nothing wrong with this other than the cosmetic effect of having a cloudy whisky or seeing sediment in the bottom of your bottle. For this reason, most whisky bottled under 46% ABV has undergone some form of filtration. Chill-filtration is a fast, industrialised process where the whisky is chilled to force the wood compounds to solidify so they can be removed from the whisky. This will produce the clearest whisky and is common where whisky is produced on a massive scale. The other method is called flocking. Flock is the name given to the solidified wood compounds that accumulate over time and Sullivans Cove employ the flocking method since they bottle their whisky at 40% ABV and in relatively small quantities; flocking requires a lot of time and space.

The barrelled whisky is poured into plastic containers and filtered water is added to bring the alcohol concentration down to a bottling level of 40% ABV. The diluted whisky is then left to sit for months at a time. As the whisky rests, the heaviest and least soluble wood compounds clump together and settle on the bottom of the containers. The whisky above the flock, is drawn off and placed into another plastic container so that the process can be repeated and the whisky drawn off again. I have been told that the whisky flock is quite delicious and is highly sought after for culinary purposes. Once the distiller is happy with the clarity of the whisky, it is bottled, labelled and ready for sale.

Having followed the whisky making process from malt to bottle, the Intro to Distilling course returned to Hobart. A lucky few who did not have to dash away, were met at Hadley’s Orient Hotel by none other than Bill and Lyn Lark and shared a dram or two with the first-family of Tasmania Whisky.

This concludes the three-part feature on the Introduction to Distilling Course but check back soon for an interview with Anne Gigney, Director of the Tasmanian Whisky Academy.
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Tasmanian Whisky Academy Intro to Distilling – Part Two

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Tasmanian Whisky Academy Intro to Distilling – Part Two


The first excursion on our Introduction to Distilling course, is to Moo Brew Brewery, owned by David Walsh of the Museum of Old and New Art (MONA) fame. Moo Brew plays an integral part in many of Tasmania’s distilleries but what does a brewery have to do with a distillery? Quite a bit actually. Let’s start with a quick lesson on the whisky making process, which can be broken down into five distinct parts: Malting, Fermenting, Distilling, Ageing and Bottling.

Malting is the process of taking raw grain (barley in this case) and turning it into a product that can be easily fermented called Malt. Barley is harvested and cleaned, then steeped in water to cause the grain to germinate or sprout. Germination is a biological process where the grain prepares itself to grow into a new plant. Inside the grain, hard starches are unlocked and converted into soft starches to become an initial food source for the plant. These soft starches can be converted to sugars by plant enzymes within the grain. 

These sugars are important, because we want to use them to feed Yeast, a micro-organism that converts sugars to carbon dioxide and alcohol. The germination process must be interrupted at the ideal time in order to maximise sugar yields. This is done by heating and drying the malt in a kiln, also referred to a Kilning. This is also the time when a smoky character can be imparted onto the malt by burning aromatic fuel sources such as Peat, to introduce smoke into the kiln. Once dried, the malt is ground into pieces about one third the size of a full grain. The grain needs to be cracked open to access the sugars within, but not milled too much as to clog the machines in the following processes.


The next step is Fermentation, which is what Moo Brew Brewery does and why we visited the brewery. We were greeted at Moo Brew by Head Brewer, Dave Magil who took us into the delivery area first. The smell of cereal hits your nose as soon as you walk in like steam rising from a fresh bowl of warm porridge. Unmalted barley is hard and chewy and has a mild neutral flavour. Malted barley on the other hand is fragrant and crunchy with a sweet cereal flavour; quite tasty really, even in its natural state.

Malted barley is delivered to Moo Brew whole and is milled on site. The milled malt is then passed through into the brewery floor where it enters the Mash Tun and is mixed with hot (76˚C) water. The Mash Tun is simply a large mixer and this is when the plant enzymes convert the remaining soft starches to sugars. The Mash Tun’s job is to turn the milled barley into a sugar solution and the most important factor Dave tells us is to ensure all the malt gets wet.

You know how when you mix Milo with milk and you get those big clumps? If you bite into one, it’s full of dry powdered Milo. Well malt does the same thing and clumps together. Any malt that doesn’t get wet is wasted sugars so it’s important that the malt is mixed well in the Mash Tun to ensure it all comes into contact with the hot water and there are no clumps. 

The contents of the Mash Tun really is like a grainy and cloudy sweet hot porridge, but at this stage that is all it is, a grainy sugar solution. Next, the contents of the Mash Tun are pumped into a Lauder Tun, otherwise known as a Separation Tank. The purpose of this step is to separate the grain husks or Grist, from the sugar solution.


Inside the Lauder Tun, explains Dave, the grist floats on the surface and forms a natural filter bed. A hot water spray or Sparg, runs through the barley grist bed to separate the sugar solution from the grist. If the barley was not milled to the correct size, this natural filtering process would not work properly. 

The hot sugar solution, called Wort, collects inside the Fermenting Tank and must be cooled to 20˚C before it is ready to become a meal for yeast and undergo fermentation. Yeast is added to the wort and fermentation can take around a week for all the sugars to be converted. The final product after fermentation is a milky solution called Whisky Wash. Beer is made in a similar way, but whisky wash is un-hopped for example. The whisky wash is around 7% ABV and tastes different depending to what malt and yeast is used, but the Moo Brew whisky wash tasted a lot like a wheat beer such as Hoegaarden, although very cloudy in comparison. The finished whisky wash is pumped into large plastic containers ready for pickup by the customer distilleries.

Join me again for Part Three of this Introduction to Distilling feature when we follow the whisky wash to Sullivans Cove Distillery to be taken through the distilling, ageing and bottling processes by non-other than Sullivan’s Cove Head Distiller, Pat Maguire.
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Tasmanian Whisky Academy Intro to Distilling – Part One

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Tasmanian Whisky Academy Intro to Distilling – Part One

Introduction and Whisky Basics


My day begins at the historic Hadley’s Orient Hotel in the heart of Hobart, Tasmania. Commuters pass by the hotel bar windows on their way to work while faint piano music floats through the air inside. The smell of freshly brewed coffee catches my attention as I walk in, so I pour myself a cup and join half a dozen other students. We are seated beneath ornate chandeliers, beside a bar whose shelves are stocked with a selection of the best whisky Tasmania has to offer. We have a long day ahead of us but will return to the Orient Bar later in the afternoon.

We are here for the Introduction to Distilling course, the first time such a course has been run by the Tasmanian Whisky Academy. Although small in number, we are a diverse group from many walks of life. From both Tasmania and interstate, some like Wes and Damien are interested in starting their own craft distilleries. Wes is from Sydney and Damien wants to start Flinders Island’s first distillery; he has big plans to turn Flinders into Tasmania’s very own Islay. Martin joins us from Brand Tasmania, a government funded organisation which aims to promote Tasmania on the world stage as a location for quality products and services. Others like myself, are just interested in learning more about our favourite brown spirit, whisky. 

The course is designed to be suitable for a wide variety of students and gives unique access to the whisky making process. In Tasmania, Moo Brew Brewery provides whisky wash to seven of the state’s distilleries, including Sullivan’s Cove. This means that Moo Brew takes delivery of malt earmarked for whisky, mills it, turns it into a sugar solution, ferments it and provides the fermented 'whisky wash' directly to distilleries. Distilleries do this for a few reasons; it saves them a lot of money by removing the requirement for expensive brewing equipment and processes and by leveraging the expertise of a professional brewery, it allows the distillery to focus only on distilling the spirit, ageing and bottling it.

Our host for the day is Anne Gigney, Director of the Tasmanian Whisky Academy and after a brief rundown of the day's planned actives, she introduces us to Todd Morrison, owner of Destinations Cellars and our first presenter. I know Todd, as does anyone wanting the best range and advice about whisky in Tasmania. I have attended a number of whisky tasting events hosted by Todd, which you can read about here and here. Todd took us through a brief history of Tasmanian whisky and the whisky basics, to ensure everyone was at least at a base level of knowledge before departing for our first hands-on experience.

Did you know that distilling was first made legal in Tasmania in 1821 but was later made illegal in 1838 under the belief that drinking whisky encouraged immoral behaviour! It wasn’t until 1991 that whisky distilling returned to Tasmania with Bill Lark lobbying for the first Tasmanian Distiller’s Licence to be issued in over 150 years. In the 25 years since, the Tasmanian whisky industry has thrived, winning some of the biggest and most prestigious awards in the world of whisky and now includes over 25 distilleries, with new distilleries appearing all the time; making many types of spirits such as vodka, gin and of course whisky.

If you are new to whisky or would like to test your own knowledge, you can do so by viewing my new Whisky Basics page, otherwise, join me again soon for Part Two of this Introduction to Distilling feature when the course travels to Moo Brew Brewery to learn how malt is turned into whisky wash, ready for distilling.
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