Behind the allure of copper stills and the aroma of spirits lies the less glamorous, yet equally critical world of maintenance. Valves, tools, grease. Forgive the pun, but it’s literally the nuts and bolts of your operation…
This article delves into what distillers need to grasp about maintenance. We cover the various approaches and systems, as well as the essential tasks and considerations for both processes and equipment.
We will also touch on how to develop a maintenance strategy that aligns with the unique needs of a craft distillery, ensuring that your operation runs smoothly, and your spirits retain their intended character.
Understanding the role of maintenance in distilling
Maintenance in the distillery is the silent guardian of your craft. It is what stands between a flawless operation and a costly breakdown.
Not only does a well-maintained still ensure consistency in your spirits, but neglected equipment can also lead to contamination, or even dangerous malfunctions.
Embracing it is not just about fixing what’s broken. It’s about preventing issues, preserving your environment (and the Environment), and protecting the integrity of your product.
Approaches to maintenance
Choosing the right maintenance approach for your distillery is akin to selecting the right cask for ageing your spirit; you need to find a harmony to get the desired the end product. There are several maintenance strategies to consider. A distillery must weigh the costs, risks, and benefits of each approach and find a blend that suits their operation best.
No maintenance: This laissez-faire approach is a gamble, suited only for non-critical, inexpensive equipment where downtime does not disrupt production. It’s usually for the type of equipment that can be delivered new within 48h or where you are almost always going to have a spare part to replace immediately. “Out with the old and broken – in with the new”.
Good for hose connections and minor tools.
Run to failure: Different to no maintenance – this approach is about letting equipment run until it fails, then fixing it at that point rather than replacing it. It can be quite cost-effective given some items last significantly long time in less than ideal condition. That said, it can lead to unpredictable production halts and higher costs in emergency repairs, and be a drain on efficiency and staff morale depending on how irritating it is.
Good for transport equipment like pallet trucks, cleaning equipment etc.
Preventative maintenance: A scheduled approach, based on manufacturer recommendations or past experience, can reduce the risk of unexpected failures. It’s ideal for ensuring critical equipment is always operational.
Good for pumps, tanks, boilers, filters etc.
Predictive maintenance: The most advanced approach, employing data analysis and sensors to anticipate failures, can optimise tasks and costs. This approach is best for distilleries where uptime is critical, and budget allows for an upfront investment in technology. For those who can’t afford this, it’s possible to do predictive maintenance based on expected life cycles.
Implementing maintenance systems
Embrace the digital age we live in! Investing in a Computerised Maintenance Management System (CMMS) can become the backbone of an efficient maintenance program.
A CMMS can streamline your maintenance operations with its ability to schedule tasks, issue work orders, track equipment history, and manage inventory. It acts as a central repository for all maintenance-related information, ensuring nothing falls through the cracks.
The use of a CMMS also brings a layer of accountability. “Didn’t we just get a new one of those?” is a conversation of the past. CMMS aids in forecasting future maintenance needs and budgeting.
Undeniably, they are an extra layer of admin to set up. However, for a craft distillery that’s making whisky or operating 7 days a week with multiple ferments on the go in a sequence, a CMMS can be a valuable tool for maximising equipment uptime and minimising costs.
Routine tasks
Routine maintenance is the daily discipline of the distillery. Each distillery should have daily or weekly lists to complete. It includes tasks such as:
Cleaning: Removing residue and contaminants to prevent off-flavours and ensure sanitary conditions.
Lubrication: Reducing friction in moving parts to prevent wear and extend equipment life.
Safety checks: Ensuring all safety valves, pressure gauges, and emergency stops are functioning properly to protect both staff and operations. A lot of the time, it’s about ensuring they do not get blocked off with clutter, equipment and other items that should be stored elsewhere.
Inspection and calibration: Regular checks on measuring devices to ensure accuracy.
Often simple but critical tasks like this can be the unsung heroes for smooth operations. They help spot potential issues before they escalate into costly repairs, keeping the distillery safe and the spirits flowing.
Performance improvement
Improving performance in a distillery can be done by embracing maintenance methodologies that enhance equipment reliability and efficiency. Pick one of these and build it into your operations:
Total Productive Maintenance (TPM) is a proactive approach that involves everyone from operators to management in maintenance activities, fostering a sense of ownership and awareness. This collective effort aims to reduce breakdowns, slow-running equipment, and defects.
Reliability Centred Maintenance (RCM) goes deeper by analysing potential failure modes and their consequences, creating a tailored plan that ensures each piece of equipment receives attention based on its importance and risk. This method can significantly improve a distillery’s operational reliability.
Lastly, the 6S methodology (Sort, Set in Order, Shine, Standardise, Sustain, and Safety) provides a systematic framework for organising and maintaining the workplace. It not only improves maintenance efficiency but also enhances safety and productivity by reducing time spent on searching for tools and parts.
Crafting a maintenance strategy for distilleries
Creating a maintenance strategy for a craft distillery requires a bespoke approach. It’s about understanding the specific needs of your process and equipment and balancing different maintenance approaches.
For example, a micro distillery might employ predictive maintenance for their stills while using a run-to-failure approach for less critical equipment. A bigger distillery may need to go further than a simple either or and write a Total Productive Maintenance plane and implement it.
Any strategy should consider the distillery’s scale, production schedule, and the expertise of the staff. A good maintenance strategy will be comprehensive, covering everything from daily cleaning routines to annual overhauls, and it should be reviewed regularly to ensure it evolves with the distillery’s growth and equipment upgrades.
Whichever scale you are – make a note of these four things as your takeaways:
Invest in training for a skilled maintenance team is crucial; knowledgeable staff can detect and address issues before they escalate. Secondly, maintain a stockpile of essential spare parts for critical equipment can prevent prolonged downtime.
Third, re-centre your mindset around costs. Yes, it will cost you time and money to implement maintenance programmes. But look at it this way, you are saving money. There is a cost implication to downtime and equipment replacement, which outweighs regular maintenance. Don’t think of it as how much it is costing you to get right, think about how much you are saving by not getting it wrong and being at a standstill.
Fourth and finally, consider the value it has in reducing environmental impact (a well-maintained distillery not only runs more efficiently but also has a smaller environmental footprint)
Maintaining the plan (and implement it)
A distillery’s maintenance plan is a living document that requires regular scrutiny and adjustment to reflect the evolving landscape of the distillery’s operations. You’ve got to implement it daily and then adapt it based on what it’s like in real life.
By integrating maintenance into the daily rhythm of the distillery, you ensure the longevity of your equipment, the quality of your spirits, and the safety of your operations.
Maintenance, in essence, is part of the distiller’s craft—integral to creating spirits that resonate with character and quality.
Through adapting the strategies and practices outlined in this article, distillers and new distillery start-ups can equip themselves to navigate the complexities of maintenance with confidence and foresight, ensuring their craft thrives for years to come.
