Troubleshooting

KL04640 Gen2 - Alcoengine - Copper reflux Still | Troubleshooting

Please see below for a list of the most common distillation issues

NEVER REMOVE THE MESH FROM THE COLUMN!

If the temperature is not stabilising below 80°C

If the temperature does not drop below 80°C within 10 minutes something may be wrong. Check that the column is level, and check that the packing is all in one place. Check that no vapour is escaping from anywhere, particularly the top of the column. Check that the valve is closed. Check that the wash you are boiling contains at least 10% alcohol — sometimes the wash will get ‘stuck’ and not ferment properly, particularly if it is cold. If none of these fix it, then try pushing mesh further into the column about 2cm. DON’T REMOVE THE MESH. If this doesn’t work, consult your dealer for advice.

If you are not getting at least 90% alcohol

Is the temperature staying below 80°C? If not see above. Make sure you finish collecting the spirit before the temperature rises above 82°C. Measure how fast the alcohol is coming out of the still. If it is still coming out faster than 1.5L per hour, then it will need to be repaired — contact your dealer.

If you are not getting as much alcohol as expected

You should get over 3L of 92% alcohol from a 25L wash if you are using 6Kg of sugar, or over 3.8L if you are using 8Kg. This can be used as a rough guide; however, ideally the amount of ethanol in the wash should be determined using a hydrometer. This will give you a good idea how much alcohol you can expect to recover from distillation.

If you are not getting this, make sure that there is no steam coming out anywhere — check carefully at the top column, as it can be hard to see. You will need to increase the water flow if there is steam at the top of the column. Check that there is no steam leaking around the lid of the boiler or anywhere else. A VERY small amount of vapour leaking anywhere will result in a LOT of alcohol loss. You should be able to smell it. Measure how fast the alcohol is coming out of the still. If it is coming out faster than 1.5L per hour, then it will need to be repaired — contact your dealer. Make sure that before distilling the wash, that it has completely stopped bubbling, and use a hydrometer to check that it is between 0.980 and 0.990. If not, the wash has not produced the correct amount of alcohol. If none of these fix it, then try pushing the mesh further into the column about 2cm. DON’T REMOVE THE MESH. If this doesn’t work, consult your dealer for advice.

If there is steam or vapour coming out of the top of the still

This generally indicates that the cooling water flow is too slow - increase the flow until the steam stops. If you are using a water pump, it may not be powerful enough. A constant Pressure pump capable of maintaining 8L/minute through the condenser is required. Most submersible pumps (for example) are not powerful enough.

If the product still comes out hot

This is not normal for this type of still. Slightly warm is fine - this helps to evaporate any light volatiles that can cause smells and tastes.

If the product is coming out very slow

This still should run around 1.2L per hour with the 1mm Outlet. After you have opened the tap, you would expect it to take around 40 minutes to get to 800mL from a 5L boiler, or about 3 hours to get 3.8L from a 25L boiler. Measure the output by placing a 1 cup measure (250mL) under the output with it still running. Time how long it takes to fill - it should take about 12 minutes. If it takes longer than this, then you may need to clean the orifice.

Very carefully clean out the tiny hole with a needle. DO NOT MAKE IT BIGGER, just gently clean it.

Small yield

No alcohol is created during distillation - it is (as the name suggests) distilled from the wash. Therefore, in order to understand the expected yield, you must know the batch size and ABV. An alcometer cannot measure ABV of a wash - this must be derived.

To calculate wash ABV, ensure you take an SG (Starting Gravity) and FG (Final Gravity) reading using a hydrometer. Use these figures in an online ABV calculator to estimate the ABV of the wash. This will give an idea of yield. For example, in a 25L wash at 10% ABV there is a total of 2.5L alcohol, thus the yield will be around 2.5L

Distillate (vapour or liquid) is coming out the top of the still

If spirit is coming out the top of your still, this is known as puking. There are several reasons this can occur. Please see the separate troubleshooting section below. Puking is the most common issue faced when distilling.

'Puking' Troubleshooting

'Puking' is the term used in distillation when vapour or liquid escapes from the still, typically from the top of the still. NOTE: The AlcoEngine Stills are not sealed so it is normal for liquid to escape when cleaning etc. However, there should be no loss of product through vapour or liquid during a distillation run. The possible causes of puking and the solutions are listed below.

1: Insufficient Coolant Flow

The AlcoEngine Still range are Liquid Management Stills. This means the distillate is controlled by the speed at which the actual liquid distillate is allowed to exit. Thus, the AlcoEngine range is extremely easy to setup and run as there is no real need for management (such as controlling coolant flow or temperature etc) during a run. However, it is important to have a minimum flow rate through the condenser.

The recommended minimum flow rate through the coils is 8L/minute. This generally requires mains pressure water or a constant pressure pump with sufficient pressure

The water temperature is not as critical as the flow rate. However, a water temperature of over 30°C may not suffice

Insufficient coolant flow is the main reason for puking issues. Mains pressure water or a powerful pump are required to provide enough pressure to provide adequate flow.

2: Boiler power is too high

The temperature at which the wash boils cannot be changed as the boiling point of a wash is determined by the ABV and other factors. However, the rate of the boil can be controlled by changing the power input (where possible).

Enough power to maintain a boil but not so much power that the condenser cannot overcome it is required. A boiler with switchable elements (such as a Digiboil or BrewZilla) or using a Power Controller is recommended. For example, when using a 35L Digiboil, it is quite common to bring the wash to a boil with both elements but switch off the 500W element once the boil has started.

3: Packing too tight

The stills are packed correctly from the factory. However, on rare occasions or if the packing has been removed and re-inserted, it may be too tight which will affect the operation of the still. Remove and repack carefully.

4: Conditioner not used in the wash/wash not clean

If the wash is not 'clean' or has a lot of matter or protein, this can cause boilovers into the column which can cause puking. Try to only transfer clear wash to the boiler. Use of a distillation conditioner or fining agents can also help if the wash is foaming up too much in the boiler.

5: Boiler is overfilled

Sufficient headspace must be left in the boilover to prevent boilovers into the column. 25L in a 35L boiler is generally a good volume that will allow adequate headspace. Use of a Distillation Lid with a sight glass can help diagnose this

6: Packing needs cleaning

If the still has not been cleaned or if there has been a boilover etc, the packing may not be clean. This can lead to puking or blockages. Clean the inside of the still thoroughly, or remove and soak the packing in a cleaner such as PBW

7: Packing not evenly distributed

The packing may not be evenly distributed in the column. Remove the packing and make sure it’s distributed evenly in the column.

Troubleshooting Checklist

Running through this troubleshooting checklist will assist us with troubleshooting any issues if lodging a warranty claim. Please ensure you have thoroughly checked through this list prior to lodging a claim.

1. What pump or water source are you using?

2. What is the coolant water temperature before and after running through the condenser coil in the still?

3. What is the cooling water flow rate after running through the condenser coil in the still?

4. What temperature is the still set to and how much power is the boiler set to?

5. Which Flow Control Outlet is being used and is it clear from blockages?

6. What was the recipe used to make the wash?

7. What was the ABV of the wash as determined by hydrometer readings before and after fermentation?

8. What is the purity of your distillate?

9. Has the still been cleaned recently?

10. Is the copper packing evenly distributed throughout the still, packed not too tight and with no blockages?

11. How much wash is in the boiler and has distilling conditioner been used?