How to Distill - 101

This blog provides information for educational purposes only. Read our complete summary for more info.

Although our stainless steel distillers and copper still parts kits can be used for many things (water, essential oils, fuel alcohol, spirits, etc.) we've had a ton of requests for a simple tutorial on how to distill alcohol. Before we answer that question, we need to tell you this: Distilling alcohol is illegal without a federal fuel alcohol or distilled spirit plant permit as well as relevant state permits. Our distillation equipment is designed for legal uses only and the information in this article is for educational purposes only. Please read our complete legal summary for more information on the legalities of distillation.

Next, we recommend beginners (and even experienced distillers) buy a good book on the topic of distilling because we'll never be able to explain everything there is to know about distilling in a blog article. Also, we don not claim to be experts and this information is for entertainment and educational purposes only. It is not intended to be relied upon by anyone for any act or decision whatsoever.

Anyone who follows the process outlined below should either a) reside in a place where brewing and distilling is legal, b) have a fuel alcohol permit and use the final product for fuel, or c) have a commercial distillers permit.

That said, here's a simple outline of the distillation process:

  • Make a mash
    • This can be accomplished by either using cereal grains such as corn, barley, and rye, or it can be made using granulated sugar.
  • Ferment the mash
    • After a mash is made, cool it to 70F and pitch yeast. Cover with a lid and add an airlock. Leave it sit for 7-10 days at room temperature. During this time, yeast will convert almost all of the sugar into alcohol. What will be left is called a "wash."
  • Distill the wash
    • Siphon the fermented wash into a still and heat to approximately 175 degrees Fahrenheit. Methanol starts to boil in the high 140's and ethanol will start to boil at about 174F. Anything produced by the still while liquid temp is under 174 can be assumed to be methanol (which is poisonous) and should not be consumed.
    • As ethanol starts to boil out of solution and the concentration of ethanol in the wash contained within the still starts to decrease, still temperature will need to be increased for the still to continue to produce. What this means is that boiler temp will be roughly 175F at the start of the distillation process but will need to slowly rise to approximately 210 by the end of the process.

Under no circumstances should an individual ever distill or sell alcohol without a permit. If an individual chooses to distill alcohol, make sure to obtain all applicable fuel or spirit permits (explained in the distillation law summary, mentioned above).

Portrait of Kyle Brown

Kyle Brown is the owner of Clawhammer Supply, a small scale distillation and brewing equipment company which he founded in 2009. His passion is teaching people about the many uses of distillation equipment as well as how to make beer at home. When he isn't brewing beer or writing about it, you can find him at his local gym or on the running trail.

Leave a comment

Please note, comments need to be approved before they are published.

59 Comments

  • R
    Comment Author: Random

    To the person with the 50 gallons of mash and 5 gallon still the rule of thumb is that there 1oz methanol to every gallon of mash you run. If you run 5 gallons you trow out the 1st 5 ozs. If you empty out your still and refill it with 5 more gallons you’ll have to throw out the first 5 it’s again. You just started the distilling process over again with new mash which the new Mash still Contsjns methanol. If you’re run 50 gallons of mash at 5 gallons a time that’s 50 ozs of methanol (1st 5 oz with each 5 gallon run) 1o runs. I hope this helps.

  • MP
    Comment Author: Michael Pena

    Hi there I was wondering after I distill my corn whiskey do I need to dilute it before it can be consumed. Or is what comes out of the distiller ok to consume?

  • M
    Comment Author: Michelle

    My electric element went bad on my heater band while running the still can I just run it another day on gas or is this batch a failure? I have to order a propane stove

  • JB
    Comment Author: John Beck

    My question is about rerunning tails and adding flavor in the thumper, I get so many different answers its confusing.I’m just starting out and pretty much what I’ve made so far isn’t that tasty so NY queastionis can I put all I’ve made so far together with water and redistil it for a better strength and taste? And if I’m adding stuuf to thumper gor taste with what (later or alcohol) do input with it and how much? Hope you can help, thanks John

  • B
    Comment Author: Bruce

    You guys need to chill, you use malted barley to turn the starches into formentable sugar if you don’t have barley you have to use amylase. You guys ask the stupidest questions.if your fire keeps going out yes you have to throw away the first out of the still. You start getting alcohol at 175 degrees the fist will start vomming out at 134 degrees thats acetone.