TOTEM 

Operating Principle and Design Advantages of Our Double-Walled Pálinka Distilling Kettle

Safe and Scorch-Proof

• The double-walled, water-jacketed kettle is considered one of the best methods for preventing mash from scorching during pálinka production.

• The pressure inside the water jacket can be increased to a maximum of 0.5 bar using a spring-loaded safety and pressure-regulating valve.

• At a pressure of 0.5 bar, the boiling point of water reaches approximately 110°C. Consequently, the temperature of the inner kettle wall in contact with the mash can also reach a maximum of approximately 110°C.

• At this temperature, fruit mash cannot scorch inside the kettle. The mash temperature can rise to approximately 100°C. Heat transfer is gentle and indirect.

• Even thick, Szatmár-style plum preserve will not scorch inside the kettle.

Fast and Versatile

• For optimal column operation, the double-walled distilling kettle features a reduced water volume and a short response time, enabling precise control of the heat input.

• The reduced water volume has low thermal inertia and responds quickly to changes in heating output.

• Thanks to its versatility, the kettle is also suitable for brewing beer, preparing grain mash and cooking jam.

Structurally Robust and Scorch-Proof

• To ensure that the bottom of the kettle—the area subject to the greatest structural stress—reliably withstands the pressure inside the water jacket, we use a shallow-domed kettle bottom with a central drain. This prevents deformation and twisting that could not be fully eliminated over the long term in a flat-bottomed design, even with additional reinforcement, due to the pressure acting from within. A distinctive feature of the kettle is its TÜV-certified safety relief valve, which reliably releases excess pressure from the water jacket without manual intervention, in accordance with applicable standards and regulations.

• Since the temperature of the water and the equilibrium steam above it inside the water jacket cannot exceed approximately 110°C at a pressure of 0.5 bar, products such as fruit mash, jam ingredients and grain mash will not scorch, even under intensive heating.

Kettle Specifications

Material: AISI 304 / KO33 / W. Nr. 1.4301, high-alloy chromium-nickel steel, food-grade stainless steel

Material composition:

So-called 10/18 stainless steel derives its name from its high chromium and nickel content. These high levels of chromium and nickel give the material its distinctive properties: it resists acids found in food, is corrosion-resistant and can be polished to a mirror finish. Stainless steel is exceptionally robust but requires extensive processing and specialised welding techniques.

Sheet thickness: Inner kettle: 2 mm; outer kettle: 1.5 mm; bottom plates: 2 mm

Gross capacity: 95 litres

Filling capacity: 80 litres

Scorch protection: Double-walled kettle operating at low pressure (0.5 bar)

Heat-transfer medium inside the water jacket: Water; during operation: water and water vapour

Reduced-volume water jacket:

The design prioritises rapid heating of the distilling kettle and optimal configuration of the heat-transfer surfaces. This enables dynamic heat transfer even at high heating outputs. The kettle can be vented through the pressure relief valve, allowing even more efficient heat transfer similar to steam heating.

Spring-loaded safety pressure valve:

A TÜV-certified, German-made spring-loaded pressure valve limits the maximum pressure inside the water jacket to 0.5 bar. If excessive heat is supplied during heating or heat transfer deteriorates—for example, because the mash is very thick or no agitator is present—the spring-loaded valve releases excess pressure from the water jacket and restores the pressure to 0.5 bar.

Angled vent valve:

This high-flow safety valve, commonly used in heating systems, serves as an additional, secondary safety device. The valve can be opened easily using a rotary knob to vent the kettle. This allows the distilling kettle to heat up faster and increases the available heating output when using combined heating methods, such as gas and electricity.

Vacuum relief valve:

After heating and distillation have finished, the hot kettle begins to cool down. As the temperature inside the water jacket decreases, a vacuum may develop, potentially causing mechanical damage or deformation of the kettle. The vacuum relief valve equalises the pressure. As the kettle cools, air enters through the valve to compensate for the pressure difference.

Water jacket pressure gauge:

Analogue pressure gauge, 0–1 bar. It is important for operators to be able to monitor the current operating conditions of the distilling equipment at all times using the available instruments. The gauge displays the low pressure inside the water jacket, which must not exceed 0.5 bar. Rated for temperatures between 0 and 120°C, it has a significantly longer service life than models that are not designed to withstand high temperatures.

Silicone water-level indicator and filling/drain valve:

A robust, thick-walled silicone hose indicates the liquid level inside the water jacket, allowing the correct filling level to be checked. The filling and drain valve serves both functions and plays an important role, among other things, in protecting the water jacket against frost.

Fully drainable, domed inner bottom:

A common weak point in double-walled kettles is the inner jacket and bottom. Even relatively low pressure can deform large surfaces, potentially leading to cracks and structural damage over time. To prevent this, we manufacture the inner kettle from 2 mm-thick sheet metal and use a shallow-domed, pressure-resistant design. In addition, an 8 mm solid square-steel reinforcing ring is fitted around the kettle neck.

The edge of the shallow-domed bottom plate is flanged, allowing it to be joined to the kettle wall using an optimal butt weld. In accordance with stainless steel fabrication requirements, the weld is ground smooth and fully penetrated from the root side, without black burn-through marks. A fillet weld at the joint between the wall and the bottom is structurally less advantageous.

Drain pipe:

76 mm drain pipe with a ball valve for emptying the mash.

Drain ball valve:

2.5 inches, with an enlarged flow cross-section and minimal internal restriction.

Welded tubular handles:

For easy and safe transport and repositioning of the kettle, welded handles are fitted around the kettle neck. Their ergonomic design prevents them from cutting into the hands when lifting the kettle. After installation, the handles can also serve as supports for the alcoholmeter cylinder and the mash thermometer.

Brass swing bolts:

The copper dome is secured using four individually manufactured M12 bolts. The advantage of brass is that the threads are resistant to seizing, even over long periods, and are less prone to damage from repeated tightening and loosening.

Bakelite hand nuts with brass inserts:

The hand nuts press the copper dome against the gasket on the kettle neck. The Bakelite remains cool to the touch, protecting the operator from burns caused by accidental contact. The brass inserts prevent the threads from wearing out or seizing, even with frequent opening and closing.

Secure connection between the copper dome and the kettle:

The hand nuts and swing bolts allow the dome to be securely sealed with minimal effort. The number and arrangement of the fastening points are precisely designed, with the required spacing between individual pressure points carefully calculated. This ensures that dangerous overpressure cannot build up inside the kettle. Instead, only the pressure required for the correct operation of the column is generated.

Removable copper dome:

By releasing the fastening points, the copper dome and column can be removed from the kettle. This removable design is particularly practical for annual maintenance and essential when the kettle is to be used for other purposes, such as cooking jam.

3 M14 HEIGHT-ADJUSTMENT SCREWS

The levelling screws are used to align the neck of the kettle horizontally. This ensures that the distilling still stands vertically once the copper dome has been fitted, which is essential for maintaining even liquid levels in the column.

FLOOR-MOUNTABLE FOOTPLATES

The overall height of the distilling still is 237 cm. The footplates must therefore be secured to the floor during installation to ensure that the distilling still stands securely.

REMOVABLE LEG

The kettle legs are attached to the distilling kettle with bolted connections and can be removed when necessary.

HEAVY-DUTY TRIPOD CONSTRUCTION

Welded stainless steel legs made from solid, closed-section profiles and solid round steel bars ensure that the distilling still stands securely.

EQUIPOTENTIAL BONDING CONNECTION POINT

Allows connection to the equipotential bonding system and provides electrical grounding and protection against electric shock. All related work must be carried out by a qualified electrician.

SHORTENING THE LEGS WHEN CEILING HEIGHT IS LIMITED

The overall height of the distilling still is 237 cm. If the room intended for installation does not have sufficient ceiling clearance, we recommend ordering the unit with shortened legs.

FUNCTION DURING HEATING

Heat is transferred rapidly from the water jacket through the inner kettle wall because metals are good conductors of heat. However, without stirring, the heat transferred through the inner kettle wall spreads through the mash only slowly. Heat gradually moves from the kettle wall towards the centre of the mash (core temperature). Due to the resulting temperature differences within the kettle and the lack of agitation, heat accumulates near the walls, slowing down the heating process. The additional heat supplied cannot be absorbed by the mash sufficiently efficiently.

When the product inside the inner kettle is mechanically stirred, the resulting heat mixing and heat transfer (convection) ensure rapid and dynamic heating of the mash. Stirring largely equalises the temperature differences between the kettle wall and the mash.

DURING DISTILLATION

At the beginning of distillation, temperature differences develop inside the inner kettle when the mash is not stirred. The mash is hotter near the kettle wall, while the core temperature remains lower. As a result, boiling begins first directly along the kettle wall. The central part of the mash (the core) begins to boil later and less vigorously than the area near the side wall, which is partially heated by steam.

This phenomenon negatively affects the distillation process because the same compounds (e.g. heads components) are released from different areas of the mash at different times due to temperature differences. As a result, the separation points between the heads, hearts and tails become distorted, overlap and extend over a longer period. Without stirring, valuable aromatic compounds may be lost during the heads fraction, while there is also a risk that acidic tails components will enter the distillate earlier. In addition, the distillation rate is higher when the mash is mixed evenly.

The agitator can be removed by loosening a single screw, allowing it to be taken out of the kettle when necessary, for example when pasteurising jam. When the agitator is in use, the temperature distribution throughout the mash is homogeneous, and the vapour flow generated during distillation is uniform.

AGITATOR GEARMOTOR

Stirring is carried out by a suitably sized, high-torque geared motor (230 V, 20–25 Nm) and a robust stirring blade.

STIRRING BLADE

A generously sized stirring blade, mounted at the appropriate angle, ensures optimal mixing and movement of the mash inside the kettle.

REMOVABLE STIRRING BLADE

The stirring blade shaft is connected to the motor drive shaft by a heavy-duty M16 bolt. This allows the blade to be detached and removed from the kettle when required.

STUFFING BOX

Rotating components are critical areas of any machine. In our design, the motor drive shaft must transmit torque through the kettle wall without allowing steam or liquid to escape while the shaft is rotating.

In addition to providing a reliable seal, the sealing material must meet food industry requirements. The rotating motor shaft is sealed using a specialised braided packing impregnated with food-grade lubricating and sealing oil.

Application:

Since the probe extends directly into the mash inside the inner kettle, the rise in mash temperature can be monitored throughout the heating phase. This makes it possible to determine when the mash is approaching its boiling point.

Current Boiling Point:

The current boiling temperature of the mash can be used to estimate how much alcohol remains in the mash, which stage of distillation has been reached, and when distillation can be stopped.

Audible Alarm:

A minimum/maximum temperature alarm can be configured. The audible signal warns when the mash approaches its boiling point (from 90°C onwards). The boiling temperature is displayed on the thermometer and can be used to estimate the alcohol content of the mash (e.g. a boiling point of 95°C at an alcohol content of 5%). When the mash temperature approaches the boiling point of water, distillation can be stopped because the remaining alcohol content is then minimal.

Beer Brewing and Grain Mash Production:

The mash thermometer can also be used to manually monitor the required temperature ranges and rest times during beer brewing and starch conversion.

Accuracy and Resolution:

The typical accuracy of the mash thermometer is ±0.5°C within the temperature range relevant to our applications. The display resolution is 0.1°C, allowing temperatures above 99°C to be read easily. In pálinka production, such temperatures indicate that distillation is nearing completion.

Update Rate:

Rapid measurement updates are also particularly important. Both the head thermometer reading and the mash thermometer reading are updated once per second.

Mounting:

The probe is mounted in the vapour space at the upper end of the column using a specially designed packing gland. The stainless steel probe can be secured by hand by tightening the knurled screw. A food-grade silicone seal ensures reliable sealing. This prevents steam from escaping during pálinka production. At the same time, the probe can be fixed precisely at the position where the temperature relevant to the process needs to be measured.

Minimum Kettle Fill Level:

25 litres (this quantity is already sufficient to reach the height of the mash thermometer probe).

Purpose: The final step of a distillation cycle is to drain the spent mash remaining in the kettle, which contains only a minimal amount of alcohol.

Safe Draining: The drain elbow, angled at 90 degrees, serves an important safety function by preventing hot spent mash from discharging in a horizontal jet when the ball valve is opened.

Connection to a Drain: For convenient operation, we recommend connecting the drain elbow directly to a drain.

Backflushing Function: Rinsing and cooling water can be connected to the drain elbow via a ½-inch ball valve.

Alcohol Content Measurement: During pálinka production, we measure the alcohol content of the distillate flowing out of the still for reference. The simplest way to measure alcohol content is to continuously direct the distillate from the outlet into an alcoholmeter cylinder.

Operating Principle: The distillate leaving the product condenser flows vertically into the tube containing the alcoholmeter. This vertical feed prevents the flow of the distillate from carrying the alcoholmeter along and lifting it significantly, which would result in a measurement error.

Alcoholmeter Supplied as an Accessory and Replacement: The alcoholmeter cylinder is supplied with a technical alcoholmeter featuring a scale from 0 to 100. An additional spare alcoholmeter is also provided.

COPPER DOME

Material Quality: Oxygen-free red copper with a copper content exceeding 99.90%.

Removable Copper Dome: By loosening the brass swing bolts attached to the upper part of the kettle, the copper dome can be completely removed, making it a separate component. On most pálinka stills, the dome is permanently attached to the kettle by welding or other means. The removable dome offers a significant advantage, as the entire inner surface of the kettle remains accessible during routine maintenance and can be cleaned easily.

Seal Between the Copper Dome and Kettle: A food-grade silicone profile is fitted around the specially manufactured rim, which matches the profile of the kettle neck. It provides a perfect seal between the nearly horizontal edge of the dome and the kettle neck.

Material Thickness: 2 mm — particularly robust for this product category.

Aroma Catalysis: Red copper contributes to the formation of new aromatic compounds during distillation. A sufficiently large copper surface area and adequate contact between the copper and the vapour are essential for obtaining an aromatic distillate.

Adsorption by Red Copper: Thanks to its surface-binding properties, red copper can bind harmful compounds present in the vapour generated during pálinka production, such as sulphur compounds and hydrocyanic acid, resulting in a purer distillate.

Robust Construction: The domed shape provides high mechanical stability. The rim is bent into an L-shaped profile and reinforced with an 8 mm-thick edge.

Structural Strength: Red copper is a soft metal, but a specialised forming process strengthens its structure, ensuring the required mechanical stability.

Clamping Ring: The rim is fitted with a clamping ring made from solid stainless steel flat bar, with welded clamping tabs. The ring is removable, and its surface is easy to clean.

Reinforcement and Column Connection Flange: A specially welded 5 mm-thick stainless steel flange is fitted around the reinforced neck section, providing additional rigidity to the red copper dome. The flange also serves as the connection point for the column.

LOADING DOOR

Purpose: Cleaning the kettle, filling it with mash and visually monitoring the process through the viewing window.

Foaming: A typical issue in pálinka production is that the mash can sometimes foam excessively. Cherry, sweet cherry and grape pomace mashes, as well as wine yeast, are particularly prone to foaming. The viewing window allows foam formation to be detected early so that the distillation process can be adjusted accordingly.

Usable Filling Hatch Diameter: 120 mm

Flanged Hatch Opening: The dome features a custom-made, flanged filling opening that is easy to clean. An 8 mm-thick stainless steel ring is welded to the flanged, ground-flat opening using a combined copper-to-stainless-steel joint. The clamping screws are secured to this ring.

Viewing Window Integrated into the Hatch: A viewing window with a clear viewing diameter of 76 mm allows visual monitoring of the boiling process inside the kettle.

Brass Swing Bolts: The hatch cover is secured with two individually manufactured M10 bolts. The advantage of brass threads is that they resist seizing over time and are less likely to be damaged by repeated tightening and loosening.

Silicone Gasket: A D-profile silicone ring fitted into a groove ensures a reliable steam-tight seal.

Ergonomic Bakelite Hand Nut with Brass Threaded Insert: The hand nuts press the hatch cover against the gasket on the kettle neck via the swing bolts. The Bakelite remains cool to the touch, protecting the operator from burns caused by accidental contact. The brass insert prevents the thread from wearing out or seizing, even after numerous opening and closing cycles.

Handle: A handle secured with a bolted connection allows the hatch to be removed safely.

The funnel is secured to the filling opening of the copper dome using the hand nuts.

The support tab rests on the flange of the filling opening and holds the funnel securely in place. This allows a bucket or barrel to rest on the designated curved section, making it easy to pour the mash into the kettle.

Material: Stainless steel

Upper Diameter: 350 mm

Lower Diameter: 92 mm

Height: 252 mm

COLUMN DIAMETER: 114 mm

MATERIAL: Food-grade stainless steel

DISMANTLABLE COLUMN SECTIONS: The entire column can be dismantled for cleaning. This is an important feature, as the distilling equipment must be cleaned regularly. Following certain distillation problems, such as excessive foaming of the mash, the internal components must be thoroughly rinsed. Greasy and oily distillation residues can accumulate inside the column. Thorough cleaning is practically impossible with tray columns whose sections cannot be dismantled (welded column sections).

MODULAR FLANGED CONNECTIONS: The individual column sections are connected by rings (flanges) secured with bolts. The flanges are 5 mm thick.

SILICONE GASKET: A food-grade silicone gasket with a sealing lip is fitted between the flanges. The sealing lip and the appropriate material hardness ensure a perfect, leak-proof seal.

SPLASH GUARD SECTION: Prevents solid particles carried upwards by the boiling mash from entering the first tray.

SIEVE TRAY COLUMN SECTION: The design consists of a perforated plate with appropriately sized and spaced holes and an overflow. The overflow determines the maximum liquid level on the tray. For the production of fruit brandies and pálinka, we recommend tray columns exclusively. Fact(!): Virtually all professional producers of fruit brandies, pálinka and other aromatic spirits use tray columns.

Some advantages of tray columns:

• Stable liquid levels

• Fast and efficient mass transfer through forced flow

• Adjustable liquid levels

• Correct operation can be monitored through the viewing windows

• Problems with distillation control can also be identified through the viewing windows

• Control can be adjusted to suit each distillation fraction

• Individual trays can be deactivated

• Continuously adjustable liquid levels

FLANGED VIEWING WINDOWS: The 76 mm viewing windows, featuring a T-piece-style design, provide a hygienic and aesthetically pleasing solution. Without viewing windows, meaningful monitoring and appropriate control of the distillation process are not possible. Food-grade, heat-resistant glass and a silicone gasket matched to the profile ensure reliable sealing at the flange connections.

What can be observed through the viewing windows:

• Vapour formation at the start of distillation

• Column equilibrium

• Reflux rate

• Liquid levels

• Foam formation

• Distillation vapour velocity and bubble formation

• Impressive backlighting

The liquid level adjustment mechanism with a wooden handle serves the following functions during distillation:

• It allows us to actively adjust the operation of the column during distillation.

• The higher the liquid levels, the more strongly the column rectifies the vapour.

• During heads separation: At maximum liquid levels, a small quantity of highly concentrated heads can be separated. This prevents valuable aromatic compounds from being lost due to an unnecessarily prolonged heads phase.

• During the hearts phase: When collecting the first third of the hearts fraction, we can observe that, for most fruits, the majority of the valuable aromatic compounds carry over during this stage. By lowering the liquid levels or deactivating one or two trays, heavier flavour-contributing aromatic compounds can pass through into the distillate.

• Before the tails phase: Towards the end of distillation, the remaining alcohol and aromatic compounds recoverable from the mash can be concentrated more effectively.

Function: The correct operation of the distillation process inside the column can be monitored through the viewing windows when the interior of the column is illuminated. An RGB LED mounted on the rear of the column illuminates the interior through viewing windows with a diameter of 25 mm. The lighting is not merely decorative. Without additional illumination, it is considerably more difficult to monitor the distillation process inside the column.

Striking Backlighting Effect: Three LEDs are positioned behind each viewing window. The central LED illuminates the interior of the column, while the light from the upper and lower LEDs is diffused by the polished surfaces of the column. This impressive lighting effect is a real eye-catcher in any distillery.

Robust Stainless Steel Cover: The custom-bent cover, attached to the column, blends harmoniously with the design of the equipment while providing reliable protection for the electronic components.

Customisable RGB LED Colour: The colour of the LED lighting can be changed across the full RGB colour spectrum.

Remote Control: The lighting can be operated using a dedicated remote control. Key functions include switching the lights on and off, adjusting brightness, custom colour mixing, and selecting the primary colours blue, green and red.

Power Supply: A 12 V power adapter is included and powers the LED panel from a 220 V mains supply. A 220 V power outlet should be provided behind the equipment for connecting the adapter.

Red copper catalyst and packing material for aroma development and adsorption (for details, see the section on the copper dome). The packing chamber contains 330 copper rings with a total surface area of nearly 1 m². One advantage is that, thanks to the column still distillation process (reflux formation: vapour–liquid–vapour), the distillate components come into contact with the red copper surface multiple times. The copper binds unwanted compounds and contributes to the formation of new flavour compounds during distillation.

Copper, in appropriate quantities, is an indispensable component of distilling and pálinka stills. In addition to the quantity of copper, it is crucial to ensure the highest possible degree of contact between the copper and the distillation vapour. One of the most effective ways to achieve this is by using red copper packing.

Shell-and-Tube Dephlegmator: An active (water-cooled) partial condenser that ensures a sufficient proportion of the vapour rising through the column condenses and returns to the liquid state. The vapour condensed in the dephlegmator flows back into the column. This returning condensate is known as reflux. The correct reflux rate and temperature activate the column trays and enable column-still distillation. For the dephlegmator to operate optimally, the following criteria must be met:

• Correct Sizing: The cooling surface must be sized according to the volume of vapour flowing through the column. Undersized dephlegmators consume large amounts of water and allow too many components to pass through.

• Mechanically Enforced Flow Path: The components of the distillation vapour must not be able to bypass the cooling surfaces of the dephlegmator.

• Problems Caused by Oversizing: An oversized dephlegmator can cause valuable distillate components to be lost.

• Precise Control Required: Even a well-engineered, high-quality dephlegmator cannot operate optimally if the coolant flow cannot be controlled precisely and there is no clear feedback on the process.

• Gravity-Operated Dephlegmator: Components that cannot pass through the dephlegmator under the prevailing cooling conditions due to their physical properties are condensed. Dephlegmators positioned beside the column operate with forced reflux. The operator uses a valve to determine the proportion and quantity of distillate returned to the column. These side-mounted dephlegmators are designed for industrial rectification processes and are not recommended for the production of fruit brandies.

Operating Principle: The high-alcohol-content vapour leaving the top of the column enters the product condenser through a 1-inch union fitting. The distillate vapour condenses in the upper third of the product condenser (transitioning from vapour to liquid) and is then cooled further across the surface of the tube bundle.

Functional Objectives:

• Complete condensation of the distillation vapour, without losing aromas or other components.

• Cooling the condensed distillate to below 30°C to minimise evaporation losses.

Average Cooling Water Requirement: 100–150 litres per distillation, with an inlet cooling water temperature of 15–20°C.

Large-Surface-Area Tube Bundle: Ensures that the distillate is fully condensed and cooled across the surface of the tube bundle.

Energy-Efficient Countercurrent Operation: The cooling water flows countercurrent to the distillate vapour. This allows the product condenser to operate with low water consumption. Countercurrent flow is the most efficient method of heat transfer.

Sufficient Length: The product condenser has an overall length of almost 1 metre. This provides sufficient time for the condensed distillate film to cool as it flows down over the tube bundle.

Design Advantages: The large heat-transfer surface, countercurrent operation and exceptional length for this product category are key design advantages. Together, they enable low cooling water consumption while maintaining optimal cooling performance.

Complete Condensation: A disadvantage of short product condensers with small cooling surfaces is that valuable aromatic compounds may escape. We use a product condenser measuring almost 1 metre in length to achieve complete condensation, adequate distillate cooling and low water consumption.

Prevention of Copper Oxide Contamination: The condenser is made of food-grade stainless steel. Once the distillation vapour has condensed in the product condenser, contact with red copper surfaces would be undesirable, as copper contamination could enter the distillate. In larger quantities, this can cause a bluish-green discolouration known as copper break.

Analogue Thermometer for Cooling Water Outlet Temperature: The thermometer is located in the upper quarter of the product condenser and displays the temperature of the heated cooling water leaving the condenser. If the temperature is too low (below 50°C), the cooling water flow rate can be reduced using the rotameter. If the temperature is too high (above 70°C), the cooling water flow rate is insufficient. In this case, the flow rate must be increased to ensure that the distillate is adequately cooled.

Function and Operating Principle: In its standard position, the valve directs the distillate towards the outlet pipe. When the valve is turned clockwise as far as it will go, the flow path to the outlet pipe is closed. At the same time, water from the water inlet manifold enters the system and flows through the column in the opposite direction to the normal flow, fills the condenser and then enters the column via the swan neck.

Column Flushing: Drinking water of suitable quality is required to flush the column. The flushing water removes residues from the previous distillation from the inside of the column, preventing them from mixing with the first fraction of the next distillation.

CONTROL VALVES: HERZ manual straight valves allow the water flow to the dephlegmator, Pistorius tray and product condenser to be regulated. The metal conical seal and fine-thread adjustment mechanism allow precise control of the water flow rate.

FLOAT-TYPE FLOW METERS (ROTAMETERS): Precise control of the water flow rate is one of the most important requirements for correct column operation. The metal float inside each rotameter rises when the valve is opened and falls when it is closed. The current water flow rate can be read from the scale in litres per hour. Without feedback on the cooling water flow rate from rotameters or an equivalent system, neither column equilibrium nor the optimal water flow rate for the product condenser can be set. This makes proper manual control of the equipment impossible.

The pálinka still is equipped with 3 rotameters:

• Dephlegmator rotameter: Essential for setting the correct reflux rate, head temperature and column equilibrium.

• Product condenser rotameter: Ensures that the product condenser can achieve the functional objectives described above.

State-of-the-Art Technology: Most of the leading commercial pálinka distilleries use column still distillation. This is no coincidence. Column stills offer outstanding advantages in terms of energy efficiency, process control, alcohol yield, maximum aroma extraction and the preservation of primary fruit aromas.

Fast Distillation: Since the distillation only needs to be carried out once to achieve the desired technical objectives, considerable time can be saved compared with traditional double distillation. With sufficient heating power, distillation of an average mash (e.g. apple or pear) typically takes around 2 hours: approximately one hour for heating and one hour for distillation.

Higher Technical and Design Requirements:

If a distilling still equipped with a rectification column does not have the control valves and components required to regulate the distillation process, the desired distillation results cannot be fully achieved.

Over-Rectification: A column still used for pálinka production must be regulated differently depending on the stage of distillation. If the equipment cannot be adjusted to suit the current stage, maximum aroma extraction becomes more difficult to achieve, and valuable aromatic compounds may be missing from the finished pálinka. Most column stills are suitable only for concentrating alcohol and, due to design and control limitations, cannot fully achieve the goal of maximum aroma extraction. We therefore strongly recommend a tray column (sieve-tray or bubble-cap tray column) with an adjustable liquid level and a suitably sized, adjustable dephlegmator.

Aroma Loss: This can occur when a column still is poorly designed, as described above. A well-designed column still, correctly operated by the user, can produce distillates of exceptionally high quality.

Minimal Aroma Losses: Since the mash only needs to be heated once during column still distillation, fewer delicate aromatic compounds are affected by thermal degradation or lost during the process. This contributes to the growing popularity of aromatic column-still distillates rich in primary fruit aromas.

Higher Initial Investment: A well-designed distilling still with suitable control technology and a comprehensive range of functions is generally more expensive than a comparable traditional copper pot still intended for double distillation. However, it is important to compare the technical specifications of the equipment directly. Traditional double distillation ideally requires two kettles: one for the first distillation (stripping run) and another for the second distillation (spirit run). Each must be designed for its respective distillation process. Under these circumstances, a column still can already offer a price advantage.

Ease of Use and Operation: This applies only to column stills that have been designed appropriately.

Several distillation techniques can be explored. The distillation method can be tailored to the specific fruit, allowing different approaches to pálinka production to be tested.

Column Still Distillation: One charge, one heating cycle and one distillation run.

First Run of Double Distillation (Mash Distillation): The first distillation follows the traditional copper pot still method, with the dephlegmator not in use, until low wines (raw distillate) are obtained.

Traditional Second Distillation: The low wines obtained can be distilled using the traditional copper pot still method, with the dephlegmator and trays deactivated.

Combined Second Distillation: The low wines obtained can also be distilled using the dephlegmator at reduced output.

The foundation of column still distillation is a correctly sized tray and dephlegmator, selected for the intended application, together with precise control over these components. Mass transfer takes place on every tray. Vapour rich in more volatile components (heads, alcohol and aromas) rises upwards, while heavier components (water and tails components) condense and flow back into the lower sections of the column or into the kettle. Each tray effectively represents a separate distillation.

Distillation Cycle: Operating Sequence for Column Still Pálinka Production

1. Filling: Add a maximum of 80 litres of mash and anti-foaming oil.

2. Switching on the Agitator: Ensures rapid heating and uniform distillation.

3. Heating Phase: The mash is typically heated from its initial temperature to 90–95°C at maximum heating output. The end of the heating phase can be monitored using the mash thermometer.

4. Boiling Point: Active boiling is initiated by reducing the heating output.

5. Column Equilibrium: Precise control of the heating output and the dephlegmator rotameter help maintain correct column operation. Electric heating is recommended.

6. Heads Fraction: The cooling water flow rate is gradually reduced using the control valve and rotameter while monitoring the response of the head thermometer.

7. Hearts Fraction: The hearts fraction is collected with consistent dephlegmator cooling and constant heating output.

8. End of Distillation: The tails fraction is generally not collected. The end of distillation is indicated by the precise mash thermometer and changes in the sensory characteristics of the distillate flowing from the outlet.

9. Backflushing: Once distillation is complete, switch off the heating and loosen the filling hatch before beginning to flush the product condenser and the entire column.

10. Diluting and Cooling the Mash: Cooling and dilution water can be added through the filling hatch. The agitator should remain switched on during this stage, as it helps ensure that the kettle can be emptied evenly.

11. Emptying: Open the ball valve to drain the spent mash remaining in the kettle. The kettle can be rinsed with a jet of water through the filling hatch. Wherever possible, the contents should be drained directly into a suitable drain, while using the backflushing function of the drain elbow at the same time.

Operating a column still can be learned within 3–5 distillation runs and is no more complicated than operating a traditional copper pot still.

We support the learning process through all available channels.

Showroom

When collecting the equipment in person, we explain the functions of the individual components.

Operating Manual

We provide a detailed operating manual for the distilling equipment, covering:

1. Installation and assembly of the equipment

2. Cleaning run and thorough cleaning of the components

3. Components and their functions

4. Step-by-step distillation process

Video Materials

Demonstration Distillation

We regularly conduct demonstration distillations using our column still in the spirits production laboratory at the Budapest campus of Szent István University.

On-Site Training

After the purchased pálinka still has been installed, personal on-site training is also available.

Telephone Support

Should any further questions arise during distillation, we are happy to provide assistance through our customer service hotline.

Distillation Demonstration

Using our column still, we regularly conduct demonstration distillations at the spirits production laboratory on the Budapest campus of the Hungarian University of Agriculture and Life Sciences.

Our prospective customers generally fall into two main groups:

• Those who want to familiarise themselves with the operation of the distilling equipment before purchasing, enabling them to make an informed decision.

• Those who have already purchased the equipment and want to take part in a supervised distillation session to learn how to operate it correctly.

On-Site Training

1. The equipment is collected by the owner or delivered by us via courier.

2. Once the connections and installation have been completed, we visit the site at a previously agreed time.

3. At the location provided by the owner, we carry out the first distillation together using their own mash.

4. We explain the theory and practical application of column still distillation.

5. We discuss the correct preparation and handling of the mash.

6. We share technical tips and practical experience to help the owner produce high-quality pálinka easily and efficiently.

7. With the knowledge gained during the first distillation, the owner can immediately begin operating the equipment independently and confidently, with a sound understanding of the key technical principles and processes involved in distillation.

Price: Quotation on request

Essential Design Features of a Professional Column Still:

• A well-controlled kettle with low thermal inertia

• A column section with at least 3 trays

• The ability to adjust liquid levels in the column sections

• A properly sized, water-cooled dephlegmator (air cooling is not sufficient)

• Gravity-driven reflux return (no forced reflux)

Common Design Flaws in Column Stills and Their Consequences: