Consistent spirits production is a discipline that commands intricate craftsmanship and nuanced artistry. It demands discipline. Perhaps no where more so that for gin, where every single flavour you taste is the direct result of human process and decisions. There’s no alchemy of time, no ageing, no showcasing a base material. It’s grams, timing, cuts, measurements and human creativity.
Distilling a brilliant gin once is tough. But because of all of the above, making the same liquid identically twice much harder than you think. Making it month after month at a consistent elite level is exceptionally difficult.
However, it’s in consistency that great brands are built. It’s where trust is created. Here are a few key areas for gin makers to monitor to ensure product consistency in their distillation, with an emphasis on process controls, checkpoints, and safeguards to ensure each batch of gin you make is nothing short of world-class.
Setting up process controls – consistency is key
No matter how excellent a single batch might be, your reputation as a distiller depends on the consistent quality you can maintain.
From the precise weighing of botanicals to methodical placement in the stills, each step in the process plays a critical role in the overall product quality.
Each distillery should have a policy and system in place to ensure each is being delivered to perfection each and every time.
Distilling time and ABV
Start by accurately recording your distilling time and the alcohol by volume (ABV) that flows at at any given point for each batch. You should have a chart with time as the horizontal axis, and ABV as the vertical.
The distillation time impacts the extraction of flavours from the botanicals. Distilling for too long or too short a period can result in a gin that is wildly different to previous batches even if the hearts cut is the same volume.
Your chart should have notes for power input on the side and any corrective action taken.
Hearts cut measurements
The “hearts” of the distillation run are the ideal balance of flavours and aromas. Regular measurement of the hearts cut – and, indeed, the heads and tails – ensures a consistent flavour profile batch after batch.
As making cuts is almost always lead by the distiller, it’s worth ensuring that sensitivity to the timing isn’t lost nor something that becomes a run of the mill decision. Respect the moment and find ways to keep the focus.
Have early warning systems in place to let you know it’s approaching. ABV, overall volume that’s flowed from the still are good visual indications you are approaching a moment where you need to start sensory assessments.
Every so often, capture the first litre of the tails cut, and take a moment later in the day to really nose it and memorise the notes. A lot of making the right cuts is training a memory muscle (your nose) into picking up smells and automatically following through with the correct action.
Botanicals: Precision and balance
Carefully weigh each botanical to maintain a consistent flavour profile across all batches. Take detailed notes of your botanical blend, noting any changes in source or quality. Keep in mind that even subtle variations can cause a significant change in the final product.
Stills: Consistent placement
For the likes of a vapour chamber, consistent placement of botanicals within the stills is crucial to achieving a uniform extraction. Some botanicals release their essential oils quickly, while others need more time, and the placement can affect this process.
If you stack them in a certain way, always stack them in that exact way. Believe it or not, but sometimes, the way they are stacked is the reason why it tastes wrong, not the grams! Just ask any distiller whose worked with oyster shells…
Maceration: consistent conditions
It goes without saying, but for those macerating ahead of time, the conditions in which botanicals are infused must be replicated each and every time. Time, temperature and ABV all matter.
Make a ritual of it. Literally as if it were a spiritual ritual and actions, sequences etc. are repeated over and again, identically. Take solace in that moment as a maker.
Consistent botanical supply
One of the main challenges distillers face is the consistent sourcing of quality botanicals. The quality of botanicals can vary seasonally or even batch-to-batch from the same supplier. To help mitigate this, consider purchasing in reasonable bulk when your botanicals are at their peak quality.
Bulk buying comes with its own challenges, such as storage conditions and the potential for spoilage. Keep your botanicals in a cool, dark, and dry place to preserve their quality. You could even consider vacuum-sealing and freezing them to extend their shelf life. Aim to have a six months of supply, dwindling down to three months, topped up quarterly.
Instituting safeguards
Establishing maximum allowable variables for your process parameters can protect the quality and consistency of your gin. These could include limits on the ABV range, distillation time, or temperature during distillation.
If a batch falls outside of those parameters, it should be quarantined and put through sensory evaluation to judge if it can go forward with proofing / bottling etc.
Develop a sensory evaluation protocol to consistently assess the aroma, flavour, and mouthfeel of your gin. Having a standard tasting panel – whether in-house or external – can provide valuable feedback on the consistency and quality of your batches.
See our articles on Sensory Assessment, Process Control, Quality Control for more on this.
Holistic process management and regular evaluations
Embrace taking a comprehensive overview of your gin production process. By considering each section of the production not in isolation but as part of an interconnected whole, you can gain a more profound understanding of how changes in one area can influence outcomes in another.
For this reason, it’s crucial to document each part of your process meticulously. Set up an umbrella review system specifying that amalgamates all the inputs from all the different areas of your process.
Once you have this system in place, monthly evaluations become an indispensable tool in maintaining and improving the consistency and quality of your gin. Weaponise the data.
Review any fluctuations or patterns in your data, and assess them against measurable criteria such as flavour consistency, yield, energy consumption, and so forth.
For instance, you might find that minor variations and minor snags didn’t make much difference batch to batch but viewed over a month – have had a much bigger cumulative effect. Maybe, it didn’t affect the flavour, but it’s cost you 10% more in energy…
With this insight, you can proactively fine-tune your process, addressing potential issues before they escalate.
This practice of holistic process management and regular evaluations, therefore, enables you to have a deeper understanding and control over your gin production, improving not just the consistency, but also the efficiency and sustainability of your process.
Consistency wins the race
When it comes to building consistency, none of it is much fun. None of it is particularly glamorous nor what most distillers get into the job for. It’s repetitive. It demands attention to detail and self discipline. But it’s what separates elite level producers and the rest.
Make a ritual of it. Obsess over it. Consider it the distilling equivalent of omnipresent parenting – and take immense pride the reliability you provide.
Adherence to consistent procedures, careful monitoring of variables, and regular maintenance are your allies in creating a truly world-class gin. In the medium to long run, that creates immeasurable value.
