As a distiller or someone venturing into this exciting industry, hygiene, bacteria and contamination may not be your first thoughts when it comes to spirits production. Or even second or third to be honest…
That said, you’ll need to think about it as maintaining good distillery hygiene is the only way to produce exceptional spirits.
This article aims to shed light on the importance of maintaining a hygienic environment in your distillery, the various elements that need monitoring, and effective strategies for dealing with potential hygiene-related challenges.
The importance of distillery hygiene
Distilling spirits is a science that demands a certain level of hygiene to deliver optimum results. This is especially true with mashing, fermentation and any post-distillation infusion that needs to be carried out.
So much of it is easy. So much of it is common sense. Regular monitoring and a proactive approach to cleanliness can significantly reduce the risk of contamination. These two simple acts ensure that the spirits produced are not only of the highest quality, but also safe for consumers to enjoy.
It’s worth remembering that at a product level microbial contamination can significantly alter the flavour profile of spirits, leading to off-flavours and spoilage. Meanwhile, contaminants such as bacteria and fungi pose health risks, potentially causing illness. Just look at the Legionnaires outbreak in Edinburgh, which was well into the craft distilling movement by the time in happened in 2012… Or in the allergy suits being filled all over the world for mis-labelled products or trace contaminants.
Protect yourself by protecting consumers.
Identifying key microbiological threats
Fungi: While some fungi like yeast are essential in alcohol fermentation, others like moulds (or molds for Americans reading!) can produce harmful toxins. Moulds on raw materials, such as grains, berries and barks, can create aflatoxins, known carcinogens.
Bacteria: There are beneficial bacteria that contribute to fermentation and harmful types like Escherichia and Enterobacter. These harmful bacteria can come from a contaminated water supply and affect both the flavour and safety of the final product.
Unfortunately, certain bacteria in contaminated products can cause short term but unfortunate health issues like vomiting and diarrhoea. Neither is something you want to happen to anyone, let alone to be associated with your product.
Strategies for microbiological control
Creating a hygiene-conscious distillery is the best way to avoid undesirable outcomes. Equipment and facilities should be designed with hygiene in mind. For example, smooth, non-porous surfaces and easy access for cleaning help prevent microbial build-up.
Implementing rigorous cleaning protocols is also essential. This includes regular sanitisation of all equipment, especially those in direct contact with the product. Meanwhile employing rapid detection methods like ATP bioluminescence and PCR can help identify contaminants quickly too.
Monitoring and control of ingredients and environment
A lot of good distillery hygiene starts with ensuring high-quality inputs. Regular inspection of raw materials helps greatly with this (and has other benefits too – the quality of the ingredients directly impacts the final product, so it pays to be paying particular attention to what’s coming in). It’s wise for distillers to inspect grains, fruits, and other raw materials for signs of mould or bacterial growth.
Yeast is often a key focus point, and an ingredient prone to contamination.
Yeast cultures must be handled with care to prevent contamination from harmful fungi and bacteria. This includes measures like sterilising equipment and using purified water.
Proper storage conditions, such as controlled temperature and humidity, can prevent the growth of unwanted microorganisms. Maintaining an environment with unsuitable temperatures, humidity or pH levels for microbial growth is ideal. Battling fungi and bacteria is the only time creating hostile conditions is a good thing!
Airborne contaminants can also affect the quality of the spirits. Installing filters and maintaining clean air (and good ventilation) in the distillery can significantly mitigate growth.
A note on water quality
Water is a crucial component in the distilling process. Its quality can affect everything from fermentation to the final flavour profile. Ensuring that the water used is monitored and treated is a big area of good distillery hygiene. See our detailed article on Water here.
In the specific and quick context of this article however, it’s worth noting that hot water and steam are particularly useful in maintaining clean environments. High temperatures achieved through hot water or steam are a very effective means of killing bacteria and other microorganisms. This method is often used for sanitising tanks, pipelines, and other equipment in the distillery.
Choosing sanitisers and training teams
Common sanitisers in distilleries include peroxyacetic acid, which is effective and leaves no residue, and chlorine-based sanitisers, known for their broad-spectrum efficacy. The choice depends on various factors, including the type of equipment in comes into contact with (and is being cleaned), the specific microorganisms present, and environmental considerations.
The five key factors in selecting a sanitiser are obvious. However, it’s worth pointing them out and doing a quick five point check when picking.
Consider effectiveness against specific microorganisms, its safety profile (both for users and the environment). Then consider its compatibility with distillery equipment, and if it’s ever going to come in contact with product. Then check the legal regulations concerning its use.
Once the right sanitiser has been selected, applying it correctly is the next hurdle.
This involves adhering to recommended concentrations, contact times, and methods of application. Most of all, it involves training employees, keeping records and reading Material Safety Data Sheets (MSDS) alongside wearing appropriate personal protective equipment (PPE).
Often, building collective responsibility is the best approach to staying one step ahead of any build ups or hazards. Encouraging staff to take an active role in maintaining hygiene standards helps in early identification of potential issues and fosters a sense of responsibility towards the overall quality of the product being made.
Prioritising equipment for long-term hygiene
Quality over cost: While budget constraints are a reality, investing in high-quality, durable equipment pays off in the long run. Such equipment is often easier to clean and maintain, reducing the risk of contamination and equipment failure.
Design matters: Equipment designed with hygiene in mind features smooth, non-porous surfaces, and minimal crevices where microbes can hide. Stainless steel, for example, is a popular choice in the industry due to its resistance to corrosion and ease of cleaning.
Regularly upgrading equipment and keeping up with maintenance schedules prevent hygiene issues that can arise from wear and tear. This includes replacing parts like seals and filters that can harbour bacteria over time.
Regular audits and assessments
Regularly scheduled audits are essential. These audits should comprehensively assess all aspects of the distillery’s operations, from raw material storage to final product packaging.
That said, audits should not just be about identifying shortcomings; they’re an opportunity for continuous improvement. Implementing the learnings from each audit helps in refining processes and raising the overall hygiene standard.
Sometimes, an external perspective is invaluable. Engaging with third-party auditors who specialise in distillery hygiene can provide new insights and help ensure compliance with industry standards and regulations. As we mentioned in our article on Health & Safety and Insurance – sometimes they can also provide certificates that will help too.
Incorporating these all of these elements into a distillery’s hygiene strategy will significantly enhance the quality and safety of the spirits produced. It will also contribute to the longevity and efficiency of the distillery’s operations too.
