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March 30, 2013

Distillation Column Packing - For Higher Proof

Increase Final Proof by Packing Still Column

Copper Mesh, Raschig Rings, and Glass Beads

distillation column packing - how to increase final proof

Packing a distillation column with copper scrubbers, raschig rings, or glass distilling beads is the easiest way to increase the final proof of moonshine whiskey while making it taste better. The packing material increases final proof by causing a slight natural reflux action in the column. If copper packing material is used, it simultaneously removes sulfur compounds from the vapor, producing a better tasting final product.

As vapor moves up through the column it migrates through network of material that is a slightly lower temperature than the boiler, etc. For example copper mesh forms a thermal bridge between the cooler edges of the column and the center of the column (because it's super conductive). It creates an abundance of surface area that is just slightly below the condensing temperature of water (but ideally above the condensing temp of alcohol), providing opportunity for water vapor to turn back into a liquid while allowing the alcohol vapor to move on.  

As water comes into contact with the packing / mesh material, some of it condenses and drips back down through the column. However, alcohol vapor moves onward due to its lower boiling temperature and ends up making its way all the way to your mason jar. As a result, final proof is much higher than it would have been without the use of packing.

Pot Still vs. Pot With Thumper vs. Packed Column vs. Reflux

Thre are a lot of different still designs out there. Clawhammer stills are essentially simple pot stills with the addition of a column to make the design more versatile. If nothing is done to the column, the our stills will operate just like a pot still and first run proof will start in the range of 100-110 proof and drop from there. If the column is packed, our stills will operate like pot stills with a thumper and first run proof will start as high as 130-150 depending on starting ABV.

We intentionally left the reflux coil out of our design because our stills are made for making sipping whiskey, not fuel alcohol. At a minimum a true reflux still would have a reflux coil at the top of the column. As vapor comes into contact with the coil, much of it condenses and drips back down through the column. Kind of like our moonshine stilldesign...on steroids. Some even have advanced features such as perforated plates for fractioning, needle valves for reflux control and controlled output, etc. This stuff is used to maximize single run proof while simultaneously stripping nearly all of the flavor from the end product, creating a "neutral grain spirit." Again, we don't offer this stuff because we think it simply isn't necessary for making good whiskey. If making high octane racing fuel is the goal, then one should consider a true reflux still. (Warning: shameless self-promotion ahead). Though, if making smooth, flavorful sippin whiskey is the goal, Clawhammer stills are optimal.

Although we don't endorse true reflux technology for the production of traditional whiskey, we wholeheartedly endorse the use of column packing to induce a very slight, natural reflux in the column during distillation runs. This allows the still to work a bit faster, first run proof to be a bit higher, and does all of this without stripping the final product of it's flavor. There's also an added advantage if copper packing is used (described below).

Copper: The Best Column Packing Material

An added advantage of using scrubbers is that they remove sulfides from the distillate. Sulfides are found in some fruits and are a natural byproduct of the fermentation process. They tend to get concentrated when products are distilled. This will show up as off flavors and smells in the final product. The best way to get rid of them is to add as much copper to the still as possible.

Sulfur compunds react with copper, precipitating them out of the mixure. This is good, because sulfur tastes and smells bad. There's no place for it in good whiskey. It's likely that this is why commercial distilleries still use copper in their distiller designs. For example, Downslope Distilling in Denver, Colorado uses a 240 gallon, 100% copper still with two large diamond shaped chambers in a column formation made by Col. Vaughn Wilson of Arkansas. The chambers contain trays that are loaded with copper mesh. Downslope's head distiller insists that this is one of the reasons that their whiskey is so good (and they have the medals to prove it). So, even if your still isn't a column still, it's not a bad idea to add as much copper to it as possible. Accordingly, we believe that using copper mesh or copper scrubbers is the best way to pack a column. 

Here's how to pack the column on Clawhammer's Copper Stills:

  • Add 1-2 scrubbers to column of a 1 gallon still.
  • Add 4-8 scrubbers to the column of a 5 gallon still.
  • Add 5-10 scrubbers to the column of an 8 gallon still.
  • Add 7-13 scrubbers to the column of a 10 gallon still.

    Note: you MUST make sure that packing material is 99.9% copper - which can be hard to find. To make it easy on you we've sourced pure copper scrubbers and have them available here for purchase. DO NOT buy copper mesh or scrubbers if the product does not explicitly state, or if you cannot verify, that they are pure copper. Some of copper mesh / scrubbers contain other metals while other products are copper coated steel. Also, if copper scrubbers are purchased, remove steel clasp in center of scrubber.

    Other Packing Material: Glass Beads and Raschig Rings

    Packing a column with glass beads or raschig rings is not optimal for several reasons. First, they don't remove sulfides. This is actually a big strike against both of the materials. Removing sulfides is critically important for crafting top notch spirits. Second, they're difficult to install and secure in the column. Third, (this applies to glass beads only) actual scientific glass distillers beads are significantly more expensive than the other materials. The cost alone makes this option a no-go.

    How to Install Copper Scrubbers / Mesh

    Installing copper packing material in the column is very easy. First, the material goes in the column (not the boiler, not the condenser, etc.). If you're using scrubbers (after removing steel clasp that holds scrubber together) simply push the scrubbers up into the column. The more the better, but do not use force to install them. They should fit in the column loosely and there may even be a tiny bit of space between them. Scrubbers will need to be unraveled before being installed in a 1 gallon kit. Though, they fit very nicely in the 5 and 10 gallon columns.

    Where to Buy Copper Scrubbers / Mesh for Columns

    Pure copper scrubbers are available on our website. Click on the picture BELOW to  purchase. Note: we do NOT recommend, nor do we have a good source for raschig rings or glass beads. 

     

              

     
     
    • I’m finishing up a 4" reflux still, all copper construction. I was told SS packing holds up better than copper. With all the copper I have in the system do I still need to consider using copper packing?

      Posted by Jim Curtis on August 30, 2014
    • I am wanting a column that is 2" and will atach to a keg use ing tri-clamps. Thanks

      Posted by James e Woolery on August 10, 2014
    • how tall should your column be? can it be to tall or to short

      Posted by garnett hedrick on May 10, 2014
    • how tall should your column? can it be to tall or to short

      Posted by garnett hedrick on May 10, 2014
    • Okay so, packing the column raises proof. What if you pack the column then make a mason jar thump keg between the column and condenser, then stuff it with copper mesh or scrubbers as well. Would that raise the proof more?

      Posted by michael on May 05, 2014
    • Why is my buddy proof dropping from 100 to 80 in same run. 3 gallon batch into it 4 to 4.5 pint jars full now and dropped after 2 nd one.??? Ty in advance

      Posted by Woody on February 18, 2014
    • how much could you sell a gallon of sugar shine for at 90 proof

      Posted by New shiner on February 01, 2014
    • I’ve been using the 5 gal. still for a while now so, if y’all don’t mind, I’ll answer a few questions. I use Chore Boy copper scrubbers. They’re held in the column by their own tension. Wjen making brandy or rum, I leave them in the column for a few runs before removing and cleaning them. When making a barley wiskey, they often foam over before settling down, I remove them immediately after cooling down and thoroughly clean them. I remove them with a wire coat hanget straightened out with a small hook bent into the end.
      Jimbob, the amount of distillate you get from a run depends on the original amount of alcohol in your wash and how efficient your rig is. When I make brandy in my 5 gal. rig, four 4 liter jugs of wine at 12.5% alc. gives me just shy of 4 liters of brandy at around 90 to 94 proof. That’s a good balance because it lets through some good flavor.

      Posted by rudraigh on December 15, 2013
    • Okay so, packing the column raises proof. What if you pack the column then make a mason jar thump keg between the column and condenser, then stuff it with copper mesh or scrubbers as well. Would that raise the proof more?

      Posted by Mike on November 22, 2013
    • If using your kit should you install the copper scrubbers/mesh prior to soldering the cap and column together or am I missing something?

      Posted by Chris on November 15, 2013
    • WHEN IT COMES TO COLUMN PACKING WHAT ARE PERFURATED PLATES FOR? IS THAT TO HOLD THE PACKING IN? IF NOT WHAT HOLDS THE PACKING IN THE COLUMN. ALSO HOW OFTEN SHOULD THE SCRUBERS BE CHANGED? IM STILL NEW TO MOONSHINING AND AM JUST TRYING TO GET ALL MY RESEARCH DONE.

      THANKS

      Posted by KRIS LAMBERT on October 29, 2013
    • how much shine do u get off a 10 gallon run?

      Posted by jimbob on October 15, 2013
    • this is a new world and it is all over the map. some say reflux columns others not what is one to think having just found this island of interesting people and ideas.

      Posted by john youngblood on September 30, 2013
    • How many runs should I use the same scrubbers for? Replace each time?

      Posted by Shane on September 25, 2013
    • How tall should a 2 inch copper column be for a 5 gal stainless still ?

      Posted by Marty Boder on September 24, 2013
    • Do you clean the scrubbers each time you use them and how do you clean them. Thank you

      Posted by Tom McCabe on August 31, 2013
    • do the scrubbers need to be changed each run?

      Posted by josh on June 11, 2013
    • What are your thoughts about using quarter inch soft copper tubing cut into half inch lengths in place of ceramic rashing rings, glass beads or marbles ?

      Posted by Richard Pedrotti on April 01, 2013
    • The copper mesh shown above available from Amazon has this comment in the product description on Amazon: "30 foot roll of Stuf-fit Copper Mesh … This is a mesh blend it is not 100 % copper like some seller say. "
      Not sure if that means it is not made of 100% copper, or that is is a mesh and not solid copper???

      Posted by Rila on March 15, 2013
    • Libman pure copper scrubbers can be purchased locally at the Giant Eagle Grocery stores if you live in the Pittsburgh, PA area.

      Posted by JJ Chubbs on March 14, 2013


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