Swede

Built by MB, nice setup... I remember seeing the build posted on another forum. First class craftsmanship and very functional, If I had a distillery I would purchase this as a startup unit or a small test batch unit. Not sure about the cap type, but a work of art no doubt. If I recall correctly it's a standard bubble cap column with a jacketed boiler that has an engine turned stainless jacket. Good luck with the sale mb6388

Wow, That's got to be the worst customer relations situation I've ever heard of. If you need elements you should look to your local hardware store for water heater elements (ULWD rated) Hope that this will help others avoid similar problems...

If you were using a similar style still for the larger production batches then I'd say you'll be able to translate very well to larger batches. If you use a different style still (column) then you won't get the same results without some serious playing around.

It sounds like you need to either reduce your heat/btu input, or increase your reflux. You should have no trouble achieving 95% with a setup like that if run properly. What's your heat source for the boiler? How do you manage the reflux?

I'm sure the finished product will look fantastic, is there going to be a stainless liner in it, or will you be using just the wood for the vessel Paul?

Currently, the maximum wattage available for the control kit's offered at Swede's Custom Control Systems is 13.5kw. This wattage rating is more than sufficient to run small capacity low production rate stills with column sizes up to 8", however, lower wattage ratings on the control kit's can lead to impractical heat up times on the boiler. Additionally, some distilleries run larger boilers on columns this size, and this can result in further wait times during the pre-heat stage. To address this issue, SCCS has developed a Distillery Control Center Extender kit (DCCExt16.5k) that is compatible with all semi automated and integrated control kit's that have been sold so far, and is available as an add on to any upcoming kits sold. This kit will require additional element installation into the boiler, or tandem elements installed in current ports (3 phase elements can be sourced if additional element ports are unavailable) It supports an additional 16.5kW heat input into the boiler (example, 3 more 5500watt elements.) This comes in a simple wall mountable enclosure as a stand alone unit. It includes panel mounted control switching with element control selector (auto preheat/off/on) and dedicated E-Stop and Power inputs with an auxiliary element status pilot light. The kit works like this; During the ramp and hold phase of the preheat stage, the DCCExt16.5k runs up to an additional 3 elements (max power rating 16.5kW). Upon reaching the hold temp, your column ready alarm sounds on your current panel. This is also the trip threshold for the DCCExt16.5k panel. Once the system is preheated, the DCCExt16.5k automatically shuts down power to the auxiliary elements and remains off for the rest of the run, leaving the main panel to handle all controls for the system (heat/auto tails runout and shutdown, and auto reflux control on integrated systems) Optionally, you can select manual 100% (on) control of the elements to control heat manually. This new kit will include the panel, prewired to accept the trip input from your main panel, it will require it's own GFCI protected power source and associated wiring. It will be available in single and three phase configurations (240/1 and 208/3) With this add on module, the distiller will be able cut down on extended run times due to pre-heat wait times on smaller test stills and production stills using our control systems. Please contact us for pricing and lead times swede@distillerycontrols.com Email for pictures of the front panel layout...

Depending on the dephlegmator control setup you've got, an independant feed is not needed. You can source the water off the product condenser to feed the dephlegmator. This allows for preheated water that limits thermal shock and instability when using an automated flow control system that cycles water flow to the dephleg via PID logic controlled water valves. This works great in the systems that I produce, and I believe that Sherman also uses this logic in his fully automated distillery control solutions.

Chris, The bubble caps and downcomers you're planning to use should work great, just remember to put all the downcomers on one side of each plate and stagger the location of the downcomer cluster (IE, put them on opposite sides of the column for each plate) For your plate disablers, I'd advise against automated valves, you'll find with experience that it's really not necessary, and a pain to fine valve diaphragms that are ethanol safe over long periods of time. There are motorized ball valves that would do that job and are ethanol safe, but they would be cost prohibitive to control for the small ease of use benefit that they'd offer. Regarding dephlegmator control as porter has commented, some distillers use simple ball or needle valves to regulate water flow to the dephleg, and others use automated solutions. There are various ways of doing this, and the system that I build has simple solenoid operated diaphragm valves managing water flow to the dephleg. This allows you to manage reflux and thereby abv/product profile by controlling the amount of distillate that is returned to the plates as reflux, and the amount of distillate that is allowed to continue to the product condenser as takeoff. Regarding your plan on securing the plates in the column, you'll want to solder them in, not simply rest them on pegs in the column as it seems that you're planning. The silver solder you're talking about will work fine, as would standard lead free plumbing solder. The only problem with using low temp plumbing solder is that if you plan on attaching your ferules after you've soldered in the plates you'll have issues with the plates becoming desoldered. For this reason I'd suggest you solder the plates in with the silver solder you've got, and then useing a lower melting point solder to secure the flanges that you'll be using. If you're using stainless ferrules to secure the column sections together then you might consider a copper/stainless TIG joint... This could be done by a competent TIG welder that's familiar with fusing dissimilar metals. Either way, best bet is to consider order of operation regarding assembly, and use the highest melting point solder you've got available to assemble the first parts of the build, and use lower melting point solder for the subsequent portions (or use localized heat/welding methods such as TIG for all parts)

Welcome, while I'm not a commercial distiller I have close ties to small startups such as you envision. Control is key to a fine distilled product and small startup distilleries and developmental scale stills are where I target the control systems that I've developed. When you get to the stage that you're thinking of securing equipment, there are several suppliers of small scale distillation and mashing equipment including artisanstilldesign.com (they offer commercial scale equipment too), confederate stills, and several others. Depending on your proposed size and product line you might wish to contact one of these guys for the hardware once you've sorted out a location. Once you've figured out heat source and power availabilities in your new facility, feel free to drop me a line. Cheers

There's a small startup in Falbygdens Sweden you might look up called Falbygdens Branneri. I've sent him some control panels for his stills. He may not be up and running yet but PM me for his email if you want to look him up.

This would make your work much easier... An electric powered hydraulic pump to run your press piston. http://www.harborfreight.com/1-hp-electric-hydraulic-pressure-pump-46169.html

Hi, I'm considering adding 1/3ph input, 3ph output VFD's (variable frequency drives) as an add on to the control kit's that are currently offered at www.distillerycontrols.com These VFD's could be offered as an add on to simple single phase power for distillers that only have 1ph power available in their facility, and if ordered with an integrated distillery control center or dephlegmator control kit would offer control of functions such as variable agitator control speed, and 3 phase CIP pump control. Some European and Asian MFG's offer CIP and Agitator drive motors inclusive with their equipment, but often these are 50 or 60Hz 3 phase motors with single speed capability. With a VFD there is no need to change out motors to meet local power supply needs or motor speed requirements. I'm proposing economical stand alone, self installed VFD's for basic control as well as integrated VFD control right into the panels that Swede's Custom Control Systems already offers. This is not an option that is currently available on our panels/control kits but if there is a need then I'd be happy to look at implementing this functionality into our systems. Please, let me know what you think. Would you like to have variable speed agitator control built right into your panel? Would you like to have the ability to run 3ph motors (CIP or Agitator) on the 1ph power you have available in your distillery? Thanks Oli

If they were three phase motors on the agitators it may be possible to increase the speed by utilizing a VFD and running them >60Hz. Depending on how much more speed you need this might be more cost effective than replacing the motors.

Stainless will be more forgiving than plastics, so based on Panoscape's advice I'd go for it provided the price was right and the tanks are actually useful in a distillery environment. Plenty of distillers store their new make spirits in HDPE white plastic drums until ready for use. This may be a more cost effective solution for a new startup.