In the world of gin distillation, ‘heads’ and ‘tails’ are frequently overlooked for what they can do to add to the bottom line. They are often seen as the less desirable by-products of the process and elements, although containing alcohol, that are typically disposed of due to their unappealing flavours.
However, this standard practice may be missing out on a hidden opportunity.
In this article, we’ll explore how these often discarded elements of gin production can be up-cycled into valuable commodities. If you are a gin distiller and send yours to waste – here are ways to waste less, save (or indeed make) money and have fin in the process!
Don’t recycle Heads and Tails into the next batch
When we make Gin, we often regard heads and tails as the unwanted stepchildren of the distillation process. These by-products contain alcohol, but they’re set aside due to their less-than-desirable flavours. Rightly so.
Let’s state this one for the record – there’s no logical way that redistilling your heads and tails in the next batch of gin will result in anything positive. Adding your heads and tails back in with NGS for the next round is a terrible idea, that leads to progressively worse gin.
We accept that some micro-scale producers do it, but no great gin maker does this. Which says everything you need to know.
Yet, by simply casting heads and tails off to the waste you may be neglecting a promising opportunity. You are missing the potential commercial value elsewhere.
Treat them separately and unlock their potential value
These parts can be redistilled separately, and be transformed into a completely different, yet equally useful, spirit.
If you have a small column still or hybrid still with a side-mounted column, you can re-distil the heads and tails into a base vodka of decent merit.
Through re-distilling the liquid, you’ll raise the ABV back up and concentrate the mix into a useful base for a different product. Most gin producers heads and tails collection is around 30-40% abv. Redistilling on a system with a few plates doesn’t just raise the ABV back to over 80%, it will strip out many of the unwanted flavours. It will not be Neutral, but it’ll be quite clean.
This base could be the starting point for an array of seasonal infusions. Imagine an elderflower liqueur on a warm spring day, or a vibrant limoncello lighting up a winter evening…
Alternatively, if you have the stills to do it, you could target your redistilled heads and tails towards a high-proof alcohol suitable for hand sanitisers. As we saw during the pandemic distilleries can play a pivotal role in the community by supplying these essential items. In times of less urgent need – it can be a spin off product sold via the cellar door.
For those operating pot stills, all of the above is still possible but to a lesser degree. You might not be able to rectify up to high 80’s from the typical heads and tails start point. This is fine, you might not need to! Have a look at the tips below for either carbon filtering or pre-flavouring ahead of further infusion.
Tips when up-cycling Heads and Tails
Embarking on the journey of transforming heads and tails into worthwhile by-products is a skilful dance of patience, creativity, and practicality.
Here are some tips to guide you along the way:
Quantity matters: Consider storing the heads and tails from several distilling runs before attempting a re-distillation. The volume matters; a smaller run might not justify the time, energy costs, and resource allocation required for the process. If you have a big pot still, it might take you over a dozen gin runs to build enough volume to run at capacity.
Be patient and collect enough batches to make it worthwhile.
Have an end goal in mind: Once you’re ready to redistill, strategise. Perhaps you’re aiming for a base vodka for your homemade limoncello or a spirit for an elderflower liqueur. Maybe it’s a habañero chili infusion or home made bitters. This end goal can guide your process. For instance, you could incorporate desirable flavours into the re-distillation to prime the spirit ahead of further infusion.
Consider carbon filtration: If you find unwanted flavours persisting even after re-distillation, carbon filtration could be your ally. This process can help to remove impurities and strong flavours, rendering a cleaner, smoother spirit. For those wanting to make an up-cycled vodka from waste by-products, it can be a game changer. However, keep in mind that this additional step will require extra resources.
It’s a balancing act: You need to consider the effort, time, energy and cost involved in the process. There may be instances when the returns are not worth the investments. Conversely, there will be times when this process turns what would have been waste into a valuable commodity.
A note on foreshots: handle with care
As we strive for excellence and safety, knowing what not to use is just as important as knowing what to use.
We differentiate foreshots (the very first liquid that flows out the still) and heads (the first part of the spirit run, that’s subjectively not right for your desired flavour profile). Foreshots are the first few hundred mls to come off, possibly up to half a litre in big stills. They demand a different approach and should be discarded, not up-cycled with the rest.
The reasons are simple. While it’s very unlikely given gin begins from a neutral spirit, these initial distilled spirits can contain the type of higher alcohols you’d rather avoid. It’s very rare, but possible. The main area of concern however, is contamination.
These could include potential residual cleaning fluids from a CIP wash as an example. The remnants of the very end of the previous tails run another. The spirit is typically oily and smells potent too. There’s nothing useful to be gained from them, and several potential pitfalls.
Err on the side of caution. Collect a cup’s worth of these foreshots from what flows off the still and dispose of them responsibly. Then collect the rest (heads and tails) for up-cycle projects.
Waste stillage: An opportunity for up-cycling
Then, there’s the waste stillage – the leftover cocktail of water, low ABV ethanol, and solid botanicals that remains in the still after a batch is distilled. While it may seem like an inconsequential by-product, this waste stillage could serve a purpose beyond the distillery.
The solid botanicals, for instance, can be separated easily and utilised as compost. They could even serve as a creative outlet. If your botanicals come from the vapour chamber, you could explore partnering with artisan makers. They can be made into soaps, candles, cheese, chocolate and other food items quite easily.
Creativity is key here – and there are many examples of craft gin makers doing exceptional things from their botanical waste to draw inspiration from!
The journey of transforming heads and tails into valuable resources is more than just an exercise in sustainability; it’s a testament to innovation in the distilling industry.
As we’ve explored, these by-products can be reinvented into a variety of new products, ranging from artisanal spirits to essential sanitising solutions. They don’t have to become Effluent.
This practice not only reduces waste but also presents an opportunity for distilleries to diversify their offerings, increase their income and engage with the communities around them.
