ALERT! This content material is for excessive tequila geeks solely! You may have been warned.
One of the best ways to be taught is by doing, proper? That’s the gist behind our “Lotecito” (small batch) destilado de agave mission, which was born amid Covid quarantine however continues on to this present day.
As aficionados know, tequila is an extremely complicated spirit, with a myriad of manufacturing steps alongside the way in which. Every one is able to altering the ultimate product. So to unravel the thriller of precisely how these adjustments create the aromas and flavors we generally discover in tequila, we bought a tiny (20 liter) copper pot nonetheless and made our personal small batch distillate, utilizing cooked agave direct from the ovens of our beneficiant tequila-making pals.
Along with being an effective way to find out about tequila manufacturing, this mission additionally turned out to be loads of enjoyable. A lot that we determined to transform our storage at dwelling right into a mini distillery. We now have 2 copper pot stills, quite a lot of fermentation and extraction strategies, skilled measuring instruments, a cooling system for the pot nonetheless condenser, and a bottling space.
With this mission, we’re studying priceless classes that solely deepen our love of tequila and respect for individuals who make it. The intent of this manufacturing log is to share these classes with you.
After all, this mission wanted a reputation, so we got here up with “Lotecito”, which suggests “tiny batch” in Spanish. We labored with proficient designer Eduardo Mejia to craft the brand and bottle design.
(Disclaimer: Though we discuss in regards to the course of of constructing tequila, our Lotecitos are technically agave distillates since they don’t seem to be made below the supervision of the CRT, subsequently they can not legally be labelled as “tequila.”)
Fast Hyperlinks:
– Lotecito 001
– Lotecito 002
– Lotecito 003
Lotecito 001
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Agave Supply: Ixtlan Del Rio, Nayarit
Age: 6 years
ART (sugar content material): 22.12
Weight: 50.7 kilos (1 single agave)
Cooking: Brick Oven (3 days) (Tequila Fortaleza)
Yeast: Champagne
Extraction: By hand, wooden submit
Fermentation:
– 1. Stainless Metal tanks (2), open air, with out fibers
– 2. Glass carboy w/air lock, with out fibers (2)
Brix of Mosto: 12
Fermentation time: 8 days
Quantity of Mosto: 83 liters
Distillation: 2x, copper pot
– 1st Distillation: 11 liters @ 23.4% abv
– 2nd Distillation: 4.9 liters @ 47.1% abv
Bottled ABV: 44.4%
We wrote about our first batch in an earlier submit, and it features a video of all the course of.
Some background: We had no thought what to anticipate going into this. Would we even be capable to create one thing drinkable or wouldn’t it be some sort of poisonous moonshine? Fortunately now we have many tequila {industry} pals who gave us recommendation alongside the way in which.
The consequence was positively drinkable, and unhazardous. (We had it examined for parts like methanol and different superior alcohols and all the ranges have been inside the industry-standard vary.) If something we thought it is perhaps a bit too clear. We determined that we in all probability minimize too deep into the heads and tails, so subsequent time we might widen the minimize.
After speaking to a few of our {industry} pals in regards to the brix stage of our mosto, we began to assume that fermenting at 12 brix was too excessive. (In lots of tequila distilleries, fermentation occurs anyplace from 8-10 brix.)
The opposite problem we confronted was yield. Hand-crushing the agaves might be the least environment friendly option to extract the sugars from the fibers. With tahona-produced tequilas (the closest comparability) yield is sometimes 10 kilos of agave per liter. Our yield was greater than that. Maybe fermenting with fibers might assist enhance that?
By the way in which, we did this complete experiment on the roof of our workplace, and the expertise was a lot enjoyable that we determined to transform a storage right into a tiny distillery. After a number of months we had that distillery prepared for the subsequent batch.
Lotecito 002
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Agave Supply: Arandas, Jalisco
Age: 6 years
ART: 25.3
Weight: 50 kilos (1 single agave)
Cooking: Brick Oven (22 hours) (El Pandillo)
Yeast: Champagne
Extraction: By hand, wooden submit
Fermentation: Stainless Metal tanks (3), with and with out fibers
Brix of Mosto: 10
Fermentation time: 9 days
Quantity of Mosto: 108.5 liters
Distillation: 2x, copper pot
– 1st Distillation: 15 liters @ 16% abv
– 2nd Distillation: 4.1 liters @ 41.9% abv
Bottled ABV: 41.9%
The purpose was to get extra complexity, so we made some adjustments to the method to hopefully obtain it. The adjustments have been:
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– Ferment at 10 brix as an alternative of 12.
– Fermentation totally in 40 liter stainless-steel tanks (3), open air
– Fermentation with fibers in one of many tanks
– Distilled to proof (no water added for dilution later)
– Wider cuts on the heads and tails
After making the primary batch we realized that our distillation cuts have been very protected and slender, so our purpose this time was to create extra complicated aromas and flavors by making small changes to the way in which that we fermented and distilled. (We determined to stay with champagne yeast so we might evaluate the 2 batches with out yeast being an element.)
As soon as we had our plan and mini distillery prepared, we organized to get a cooked agave from Felipe Camerena’s distillery, El Pandillo, the place the prepare dinner time is simply 22 hours. The colour of the agave was a lot lighter than that earlier batch from Fortaleza, the place the cooking course of lasts for 3 days.
Grover took these 2 halves of an agave straight from the brick oven on the El Pandillo distillery.
One large lesson realized on this batch: It’s an excessive amount of work for 1 particular person. Our “crush match” pals, Andres and Karla, weren’t obtainable to assist out, so I (Grover) single-handedly did each step within the course of. Crushing the agave took me 3 days, which is totally too lengthy. The longer the agave is uncovered to air, the extra likelihood undesirable airborne yeasts and bacterias can begin feasting on these valuable sugars.
The primary and second tanks went usually, with no indicators of any undesirable company within the fermentation. However by the third day, the ultimate tank was a special story. This was the tank that included agave fibers, and by the point I pitched the champagne yeast I might already see that it had began wild fermentation. I crossed my fingers and hoped for the perfect, understanding that the outcomes have been going to be random.
We ended up with 108.5 liters of mosto at 10 brix that we put in 3 40-liter stainless-steel fermenters. With the purpose of including complexity, we determined so as to add fibers to one of many tanks. Then we pitched the yeast and allow them to sit for 9 days.
In the course of the course of fermentation the primary 2 tanks smelled like a traditional fermentation, however the third one (with fibers) was simply plain funky, with a tacky/lactic aroma. We positively misplaced management of the fermentation there, however I didn’t know if this was a great or dangerous factor. We hear on a regular basis about manufacturers claiming “wild fermentation, no yeast added”, so I assumed it will simply add aroma and taste complexity.
One of many 3 tanks had fiber included. This tank additionally exhibited some wild yeast fermentation.
When fermentation was full the tanks have been distilled individually. Because the plan was to distill to proof, we knew that we wanted to begin the 2nd distillation with a decrease abv than earlier than, so we stored gathering till we reached roughly 8% abv from the nonetheless, and a mean of 16% abv for the batch.
We mixed the primary distillations collectively and the entire abv was precisely 16% abv, which we hoped can be low sufficient to get us to 42% abv within the second distillation with out having so as to add any water.
The second distillation is the place it actually will get enjoyable since you may expertise the number of aromas popping out of the nonetheless. Each couple of minutes they modify, supplying you with an excellent schooling on how the agave can produce such a posh and compelling spirit.
This step took 4 hours to finish, and sampling from the nonetheless at common intervals we have been getting loads of actually good aromas and flavors. Melon, apple, butter, cinnamon, moist earth, honeysuckle, mint, inexperienced pepper and jicama have been all current at one level.
The good factor about distilling is that sampling what’s coming off of the nonetheless at any given time exhibits you a slender band of aromas and flavors. If the ultimate bottled product is like listening to the music from a full orchestra, sampling from the nonetheless is like listening to a single instrument. It’s positively attention-grabbing as a result of it teaches you what kinds of aromas and flavors are created naturally throughout the distillation course of, nevertheless it’s not a sign of how the ultimate product will come collectively.
One factor we seen instantly was that the yield on this batch was horrible, at 12.2 kilos of agave per liter (in comparison with our goal of 10 kilos/liter.) On reflection, we predict that a number of components contributed to this.
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1. We misplaced loads of liquid as a result of we weren’t capable of squeeze it off of the fibers after fermentation
2. Wild yeast wasn’t as environment friendly as business yeast
3. The crushing and extraction wasn’t thorough sufficient, and a of sugar was left on the discarded fibers
The ultimate product clocked in at 41.9% abv, and it wasn’t dangerous, however you may completely detect the affect of the wild yeast. It has a noticeable sharp citrusy/lactic end that’s generally present in mezcal and raicilla, the place fermentation is actually left to the wild.
Any business tequila producer would take into account this a defect, however for those who’re a fan of funky agave spirits, it is perhaps proper up your alley.
Lesson Discovered: Fermentation is crucial step within the manufacturing course of. Most individuals assume that distillation (and understanding the place to chop the heads and tails) is the half the place you may actually screw issues up, however this batch taught us that the fermentation step could make or break the ultimate product.
The chemical evaluation of this batch was inside the protected/authorized vary, however the lactic “funky stuff” created by the wild yeast exhibits up within the type of elevated esteres at 126.45 (in comparison with 61.9 within the first batch), with an {industry} most of 200.
And since we collected extra tails with the intention to get to a decrease abv, there was a slight improve in methanol. (Methanol spikes dramatically if you hold gathering after 15% abv from the nonetheless.)
I suppose you may say that we achieved our purpose as a result of there’s much more occurring on this batch by way of aroma and taste complexity. The downsides are that we misplaced management of a part of the fermentation, and our yield was tremendous low.
So, the plan for the subsequent batch was to work on these 2 points, and we got here up with an formidable plan for tips on how to do it.
Lotecito 003
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Agave Supply: Amatitan, Jalisco
Age: 6 years
ART: 23.04
Weight: 51 kilos
Cooking: Brick Oven (3 days) (Cascahuín)
Yeast: Tequila & Rum
Extraction: By hand (wooden submit) + excessive stress water + sugar cane mill
Fermentation: Glass carboys w/air locks (8), with out fibers
Brix of Mosto: 10
Fermentation time: 7, 8, 9 days
Quantity of Mosto: 120 liters
Distillation: 2x, copper pot
– 1st Distillation (rum yeast): 9.725 liters @ 16.21% abv
– 1st Distillation (tequila yeast): 9.56 liters @ 15.93% abv
– 2nd Distillation (rum yeast): 3.25 liters @ 48.6% abv
– 2nd Distillation (tequila yeast): 3.275 liters @ 48% abv
Bottled ABV: 44.1%
Our targets right here have been to keep up full management of the fermentation, and to enhance our yield.
Fermentation Management:
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– All fermentation would occur in glass carboys with airlocks, stopping any sort of airborne yeast from moving into the method
– The entire agave piñas have been washed down with a excessive stress water sprayer previous to crushing. We did this in order that any airborne yeasts could possibly be washed off earlier than we crammed the fermentation tanks.
– We heated the water used within the fermentation tanks to almost 90 levels C and added the fibers to this to soak for at the least an hour. The concept was like cooking sous vide, any micro organism that could be current wouldn’t be capable to survive that temperature for that time frame.
– Enlist the assistance of Karla and Andres (crush-fit!) in order that we are able to get the extraction course of executed as quick as doable
– And at last, use 2 totally different strains of economic yeast (tequila yeast, and rum yeast). Each of those strains have been designed with effectivity in thoughts, however we have been additionally curious to see what the variations can be between them, when all different circumstances have been an identical.
Bettering Yield:
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– The heated water must also assist to dissolve the sugars on the fibers earlier than we even contact them, so the hand rinsing a part of the method ought to be simpler and extra environment friendly
– Did you discover that we used a excessive stress water sprayer to scrub the agaves? Properly, we thought we must always use it once more later within the course of to blast the final bits of sugar off the fibers that our human arms can’t get to. (Sure, that’s what a diffuser does!)
– We bought a small hand-cranked sugar cane mill to squeeze as a lot of the liquid off of the fibers as doable
– Use extra heads within the course of, and distill to roughly 48% abv, and add dilution water later as wanted
This plan labored! Our yield was wonderful, at 7.82 kilos of agave per liter! We have been shocked at this stage of effectivity, and really nonetheless are. The excessive stress water on the fibers mixed with the sugar cane press was the golden ticket. We have been shocked how a lot sugar got here off the fibers after a double hand rinse.
The cooked agave got here from the Cascahuín distillery, the place they prepare dinner for two days, after which relaxation for twenty-four hours earlier than extraction begins. (We love the slow-and-low method they take, and it makes a giant distinction within the high quality and quantity of sugars you may get from the agaves.)
The consequence was an excellent clear product, probably too clear.The lab report exhibits that the esteres stage was tremendous low, at 8.16 (!) in comparison with Lotecito 002 at 126.45.
The broader minimize on the heads created extra floral notes, and that is evident within the chemical evaluation as properly. Superior alcohols are 427.327, which is excessive (the utmost authorized stage is 500.)
We distilled the totally different yeast varieties after which mixed them later. There have been variations. The tequila yeast had a cleaner aroma that was extra delicate. The rum yeast introduced some complexity, with a slight cinnamon notice on this batch.
Once we first sampled this batch we thought it was overly floral to the purpose of distraction. So we let it relaxation in glass for 3 months earlier than attempting it once more. This did the trick! A resting interval makes a giant distinction within the closing product. Previous to resting it’s frequent for tequila to really feel spiky, nearly as if the microscopic compounds are preventing with one another, resisting.
Ultimately they be taught to play good with one another and mix into one harmonious product, nevertheless it takes time. That is one thing that you just can’t rush!
In the long run we preferred the management we might obtain with the closed glass fermentation, and can proceed to do that with future batches. However we may also place at the least 1 40-liter tank exterior so we are able to mix some open air fermented distillate into the ultimate product.
We additionally assume we have to return to 12 brix for fermenting. This could give us extra alcohol to start with, which ought to give us just a little extra leeway when chopping the heads and tails. When creating tremendous small batches we’ve realized that the cuts is usually a extra important challenge that’s not as distinguished when distilling bigger batches in a business distillery.
Nonetheless, it does really feel like we’re getting near a suitable profile! We’ll make these slight changes for Lotecito 004, and replace this submit.
Might this be the smallest distillery on this planet?
