The quality of a spirit is only as good as the cleanliness of the process that creates it. Therefore, cleaning is a key part of daily operations and it’s not something you can outsource via regular cleaning services! Just like a bartender takes care of their station – distillers take care of their environment.
From the gleaming copper stills to the fermentation tanks, every surface that comes into contact with the product must be pristine. Or at least consistent in how it’s not so…
This article delves into the essential considerations and practices for maintaining optimal cleanliness and hygiene in a distillery, offering guidance for both seasoned distillers and newcomers to the field. Time to scrub up on your knowledge!
Understanding the importance of cleanliness in distilling
Cleanliness is probably not what we all aspire to doing when we picture craft distilling, nor what motives anyone choosing it as a career path. But it’s a big part of the job for anyone involved in operations.
A relentless attention to detail ensures that every drop of spirit produced is not only safe to consume, but also meets the high-quality standards.
Cleanliness is non-negotiable in the distilling process for several reasons –
Impact on product quality
Distillation is a delicate dance of chemistry and physics. Even the smallest impurity can mar the entire batch. Especially when it comes to fermentations. Residues from previous runs, microbial contamination, or even the natural build-up of organic material can lead to off-flavours, cloudiness, and spoilage. Beyond reducing yield these impurities can mask the subtle nuances of flavour that distillers work so hard to create.
Compliance with regulations:
Cleanliness in a distillery isn’t just a matter of quality; it’s also a legal requirement. Regulatory bodies around the world impose various standards to ensure that alcoholic beverages are produced in a way that makes them safe for public consumption. Your bottling line will have to adhere to stringent standards in particular. Often, you’ll be audited on it too.
Failure to adhere to these standards can result in hefty fines, disruptive recalls and loss of certificates that some wholesalers and national retailers insist on.
Extending equipment life and efficiency
Distillery equipment represents a significant investment, and its lifespan is directly tied to how well it is maintained. The build-up of sediment deposits and scaling can cause corrosion, wear, and inefficiency, leading to costly repairs and downtime.
Regular and thorough cleaning prevents such issues, ensuring that equipment runs at peak efficiency. This not only prolongs the life of the equipment but also maintains the consistency of production runs.
The safety of staff and consumers
Beyond the product, the well-being of the people involved in the production and consumption of spirits is paramount. Proper cleaning reduces the risk of accidents caused by slippery surfaces or the build-up of hazardous fumes, dust and more.
The process: Cleaning and sanitation
A comprehensive cleaning regimen is essential to ensure that each batch of spirit is as pure and flavourful as intended. Let’s break down the key components of an effective cleaning and sanitation process in the distillery.
The fundamentals of CIP systems
Cleaning-in-Place (CIP) systems are at the heart of modern sanitation processes in distilleries. These automated systems are engineered to clean the interior surfaces of tanks, pipes, and vessels without the need to disassemble the equipment. This not only saves time but also minimises the risk of contamination from human contact.
A well-designed CIP system uses a series of steps to ensure that every surface is reached and that no residue remains. The choice of a CIP system should be made with consideration to the size and complexity of the distillery operations.
The sinner’s circle
The efficiency of a CIP system is governed by the principles of the Sinner’s Circle. The concept of the circle is to outline four key factors: time, temperature, chemical action, and mechanical action.
Each factor is interdependent; a change in one requires an adjustment in others to maintain the balance. For instance, if you decrease the temperature, you may need to increase the time or the strength of the cleaning agents to achieve the same level of cleanliness. Understanding this balance is crucial for distillers to optimise their cleaning process.
Selection and use of detergents
Choosing the right detergent is obviously a big part of the cleaning process. The nature of the soils – organic or inorganic – determine whether you need an alkaline or an acid detergent.
Organic soils, such as residual sugars and proteins, are best tackled with alkaline detergents like caustic soda etc. Inorganic soils like water scale and mineral deposits require acid detergents.
It is essential to use detergents that are effective yet do not harm the equipment or leave unwanted residues that could taint the spirits. Think about what each removes (the cleaning properties), what it comes in contact with (the equipment) and the risk of what happens downstream (risk of contamination) before finalising any decision.
Water quality and treatment
The quality of water used in the cleaning process is just as important as the quality of water used in distillation. Water should be free of impurities that could lead to scaling or corrosion. In areas with hard water, treatment systems may be necessary to soften the water before use in cleaning. See our article on Water for more on this.
Validation and verification
The efficacy of the cleaning and sanitation process must be validated and verified regularly. This involves testing surfaces for microbial activity or residue and adjusting the process as needed to ensure standards are met.
This might include swab tests, ATP monitoring, and other methods that provide objective evidence that the cleaning process is effective. See our article on Hygiene for more on this.
Equipment: Design and operation for optimal cleanliness
Let’s focus on the technical aspects of the equipment used in distilleries, guiding through the choice and maintenance of cleaning systems, and how these decisions impact the overall hygiene and efficiency of the distillation process.
To state the obvious, but all cleaning should be as efficient as possible to minimise downtime while ensuring thoroughness. To do this, don’t just leave it to chance or reverse engineer it into operations. It requires careful planning and scheduling of cleaning cycles in harmony with distillation runs.
Choosing the right cleaning heads for your CIP
The selection of cleaning heads is critical for an effective CIP system. When choosing what’s right, consider that the design must accommodate the vessel’s shape, size, and purpose. Fixed spray balls are economical options that provide a simple, static cleaning solution, suitable for smaller or less complex systems.
Rotary cleaning heads, on the other hand, offer dynamic coverage, moving to reach all parts of the vessel, making them ideal for larger and more complex systems. The choice between the two should be based on the specific needs of the distillery and the type of residues typically encountered.
CIP system design
Taylor the CIP system to the distillery’s scale and complexity. A single-use system, where the cleaning solution is used once and then discarded, is straightforward and ensures a fresh solution for each cycle. However, it can be wasteful and less environmentally friendly.
Recovery systems, which reclaim and reuse cleaning solutions, are more sustainable and cost-effective in the long run but require more sophisticated design and control systems to ensure the cleaning solution remains effective over multiple uses.
Figure out if you can pay more upfront, to save costs and environmental impact down the line.
Maintenance of cleaning equipment
Regular maintenance of cleaning equipment is as vital as the cleaning of the distillation equipment itself. Worn seals, nozzles, and pumps can reduce the effectiveness of the CIP system, leading to subpar cleaning and potential contamination.
A maintenance schedule should include regular inspections, testing, and replacement of parts as necessary to maintain the integrity of the cleaning system.
Piping and flow considerations
The configuration of pipes and the flow of cleaning solutions through them is an integral part of equipment design. If you are designing your distillery, or overseeing new pipes being installed – slope pipes appropriately to avoid pooling of liquids, which can become breeding grounds for bacteria.
Design valves, bends, and other fittings to minimise crevices where residues could accumulate. The flow rates and pressures should be calibrated to ensure adequate mechanical action without damaging the equipment.
A note on material selection: The materials used in distillery equipment must not only withstand the rigours of distillation but also the chemicals and temperatures of the cleaning process. Stainless steel is a standard in the industry for its durability and resistance to corrosion. However, the quality and grade of stainless steel can vary so pick wisely.
Automated vs. manual systems
While automated CIP systems offer consistency and safety, manual cleaning still has a place in certain areas of a distillery, particularly for equipment that is difficult to clean in place or for small-scale operations.
Manual cleaning requires careful training to ensure thoroughness and safety. It also provides an opportunity for staff to inspect equipment closely, potentially identifying issues before they become significant problems.
Operating the CIP system effectively
An effective Cleaning-in-Place (CIP) system is central to maintaining the highest standards of cleanliness in a distillery. However, the mere presence of a CIP system does not guarantee cleanliness; it must be operated effectively to be of any benefit.
By thoroughly understanding and adhering to the following operational principles, distilleries can ensure that their CIP systems work effectively, maintaining the cleanliness essential for producing high-quality spirits.
Pre-rinse, wash, and post-rinse cycles
The CIP process typically includes several stages. The pre-rinse cycle involves flushing the system with water to remove loose debris and residues, preparing the equipment for the main cleaning phase. The wash cycle then circulates the cleaning solution through the system, employing the appropriate temperature, concentration, and contact time to remove soils.
Finally, the post-rinse cycle removes any traces of the cleaning agents, ensuring that the system is not only clean but also free from potential contaminants that could affect the next batch of spirit.
Monitoring and controlling parameters
Effective CIP operation relies on careful control of various parameters. Temperature, flow rate, and concentration of cleaning solutions must be monitored and adjusted to match the specific requirements of each cleaning session.
Modern CIP systems may include sensors and automation to maintain these parameters within the desired range. Train operators / distillers to understand the significance of each parameter and how to respond if readings deviate from the expected values.
Documentation and trouble-shooting
Detail when the cleaning was performed, the parameters used, and any issues or deviations encountered during the process. This documentation provides a valuable reference for troubleshooting, process optimisation, and evidence of compliance during audits.
Even with a well-operated CIP system, issues can arise.
Train operators to recognise common problems, such as uneven spray patterns or insufficient cleaning action, and know how to troubleshoot them. This might involve inspecting and cleaning the CIP spray heads, checking for clogs in the system, or recalibrating sensors and pumps.
Chemical handling and storage:
The chemicals used in the CIP process must be handled and stored with care to ensure safety and maintain their efficacy. This includes storing chemicals in a cool, dry place away from direct sunlight and ensuring they are clearly labelled and accompanied by Material Safety Data Sheets (MSDS).
Proper training in chemical handling prevents accidents and means that cleaning agents are used effectively.
Promoting better distillery cleanliness
Promoting better cleanliness involves a comprehensive approach, combining design, procedure, and people.
Hygienic design principles:
Good cleaning starts with good design. Design equipment and facilities to minimise areas where dirt and bacteria can accumulate. This includes smooth, cleanable surfaces, self-draining equipment, and the avoidance of dead spaces. Following established design standards such as the European Hygienic Engineering & Design Group (EHEDG) guidelines can significantly ease the cleaning process.
Consider the flow of materials and people to minimise contamination risks, ensuring proper ventilation to avoid condensation and mould growth, and using materials for walls and floors that are easy to clean and resistant to the harsh chemicals used in CIP processes.
Staff training and culture
Even the most sophisticated cleaning protocols are ineffective without buy-in from staff. You need there to be a willingness to do it well and training programs in place. Trainings should not only cover the how of cleaning but also the why, helping staff understand the role cleanliness plays in producing quality spirits.
A culture that values cleanliness will see staff taking initiative to maintain and improve sanitary conditions. A lot of this begins with routine and not just assuming that a cleaning service will take care of it. Establishing and adhering to regular cleaning schedules ensures that cleaning is a continuous process and not just a reaction to visible problems.
These schedules should be clearly posted and enforced, with responsibilities assigned to specific team members.
Inventory and storage practices
Store raw materials and finished products in a way that protects them from contamination. This includes using sealed containers, maintaining a clean storage area, and implementing a first-in, first-out (FIFO) system to prevent old stock from becoming a contamination risk.
A pest control plan is a critical component of distillery cleanliness. Regular inspections, good housekeeping practices, and prompt attention to potential entry points are essential to keep pests at bay. Professional pest control services can provide an additional layer of security if needed.
Advanced cleaning techniques and innovations
As distilleries evolve, so too do the techniques and technologies designed to keep them clean. Advanced cleaning techniques and innovations offer new ways to ensure cleanliness and hygiene, often making the process more efficient and less labour-intensive.
For example, automated systems are becoming increasingly sophisticated, with programmable logic controllers (PLC) and computerised monitoring. These systems can regulate and record the cleaning process, adjust parameters in real-time, and even predict when maintenance is needed. Embrace automation and free up staff for other tasks!
Eco-friendly practices
Sustainability is a growing concern in all industries, including distilling. Eco-friendly cleaning practices focus on reducing water and energy usage and choosing biodegradable or recyclable cleaning agents.
Simple practices like recirculating CIP systems can minimise waste by treating and reusing water and cleaning solutions, while advances in detergent formulations can achieve the same or better cleaning efficacy at lower concentrations or temperatures. Do your research.
Unusual alternatives
Ultrasonic cleaning uses high-frequency sound waves to create cavitation bubbles in a liquid cleaning solution, which then collapse with great force, removing contaminants from surfaces.
This technique is particularly useful for intricate equipment components that are difficult to clean with traditional methods.
Another alternative to traditional cleaning methods is dry ice blasting, which uses solid CO2 pellets. The pellets sublimate upon impact, lifting dirt and residues without water or chemicals. This method is especially valuable for electrical components or where moisture must be avoided.
Distillery manager’s cheat sheet – a checklist for daily, weekly, and monthly cleaning
This checklist is a starting point for those looking for a head start. Each distillery will have unique needs, so adapt cleaning schedules accordingly. Regular review and updates to the cleaning protocol also ensure that it evolves with the distillery’s operations and continues to meet the highest standards.
Daily Cleaning Tasks
- Sweep and mop floors.
- Clean and sanitise all contact surfaces.
- Conduct a pre-rinse and post-rinse CIP cycle on production equipment.
- Empty and clean waste bins and dispose of garbage properly.
- Ensure the processes have been recorded and appropriately documented.
Weekly Cleaning Tasks:
- Perform a detailed and dedicated CIP cycle with detergent on production equipment.
- Deep clean all non-product contact surfaces.
- Inspect and clean difficult-to-reach areas for potential soil build-up.
- Review pest control traps and update logs.
- Inspect and wipe down exterior of equipment.
- Pick one area of the distillery to focus cleaning focused maintenance work.
Monthly Cleaning Tasks:
- Conduct a comprehensive inspection and cleaning of the entire facility.
- Review and restock cleaning supplies and chemicals.
- Clean and organise storage areas, ensuring proper stock rotation.
- Test emergency cleaning equipment and safety showers where possible.
Quarterly Cleaning Tasks:
- Descale boilers and perform preventive maintenance on CIP system components.
- Hold a cleanliness audit and staff review to discuss issues and improvements.
The path to purity
The journey of a distiller is one of constant refinement, both in the crafting of spirits and in the meticulous upkeep of the distillery. The pursuit of purity in distillation is inextricably linked to the rigour of cleaning and sanitation practices.
As we have explored, each element of the distillery’s operation, from the design of the equipment to the culture of the team, contributes to the overall cleanliness that is essential for producing premium spirits. Design things to minimise ongoing work. Automate processes to free up time. Motivate people to get involved.
Cleaning is a big part of the job – so you might as well learn to love it and take pride in it as it’ll have to be done anyway!
