1. WHISKEY BEVERAGE TECHNOLOGY SUBMITTED TO: Mr. MANOJ KUMAR.
SUBMITTED BY:
UZMA SIDDIQUI, ROLL No- 29,
M.Sc. (3RD SEM)

3. DISTILLED BEVERAGES
A term which includes all potable alcoholic liquors obtained by the process of distillation,(such as whisky, brandy, rum. and gin) but excludes fermented and malt liquors, such as wine and beer. All alcoholic drinks are fermented, but distilled beverages go through additional processing to purify the product. Distilled beverages are basically the same in the beginning. Plant material with sugars gets fermented by yeast. Then, the distillation begins.

4. GENERAL PROCESS OF DISTILLATION
Distillation takes advantage of the fact that different substances boil at different temperatures. Thus, the constituent components of a liquid solution can be extracted separately Distilled spirits (or, simply, spirits or liquors) are the Alcohol-containing fluids (ethanol, also called ethyl alcohol) obtained via Distillation of fermented juices from plants. These juices include wines, distillates of which are termed brandies. The most commonly used plants are sugarcane, potatoes, sugar beets, corn, rye, rice, and barley; various fruits such as grapes, peaches, and apples are also used. Flavours may be added to provide distinctive character.
GENERAL PROCESS OF DISTILLATION

5. All distilled spirits begin as a colourless liquid, pure ethyl alcohol (as it was called by 1869)—C2H6O. This had been called aqua vitae (Latin, water of life) by medieval alchemists; today it is often called grain alcohol, and the amount contained in distilled spirits ranges from 30 to 100 percent (60 to 200 proof)—the rest being mainly water.
Examples of distilled spirits include brandy, whiskey, rum, gin, and vodka.

6. WHISKEY
Whisky or whiskey is a type of distilled alcoholic beverage made from fermented grain mash. Various grains (which may be malted) are used for different varieties, including barley, corn (maize), rye, and wheat. Whisky is typically aged in wooden casks, generally made of charred white oak.
Whisky is a strictly regulated spirit worldwide with many classes and types. The typical unifying characteristics of the different classes and types are the fermentation of grains, distillation, and aging in wooden barrels.
Whiskey is classified as a spirit made from cereal starch, the manufacture of which involves hydrolytic breakdown of the starch into fermentable sugars, followed by fermentation, distillation, and maturation.

8. CLASSIFICATION On the basis of cereal used- wheat, barley, corn, rye
On the degree of blending
On the country of origin- Scotland, Ireland, United States, etc

9. PROCESS OF MANUFACTURE
FROM BARLEY TO WHISKEY.…

10. 1- [A] MALTING AND KILNING (for malt whiskey)

11. FLOW DIAGRAM OF MALTING AND KILNING
BARLEY
CLEANING
STEEPING
(cold water/ 2-3 days)
DRAINING

12. SPRERAD ON MALTING FLOORS
GERMINATION
SPRERAD ON MALTING FLOORS
(2-3 feet depth, temp-24°C, 8-10 days)
GERMINATION
(increase in the levels of activities of α-amylases and β-amylases.)
KILNING
KILNING
(Temp- 52°C stops germination but do not destroy enzymes.
Moisture content reduced to 5%.
Malting conditions favour Maillard reaction- contribute to browning and flavour development.)

13. [B] COOKING AND COOLING (for grain whiskey)
In the production of grain whiskey, an initial cooking stage at 120°C for 1.5 hour is required in order to gelatinize the starch of cereals other than barley. The resulting mash is cooled to 60-65°C before the addition of 10-15% of freshly malted barley, which provides the amylase activity for hydrolysis of the gelatinized starch.

14. 2- MASHING

15. The dried malt is cleaned and then milled to form the grist
The dried malt is cleaned and then milled to form the grist. The grist is mixed with water at approximately 68°C in mash tanks for hr. During mashing, the milled malt and water are subjected to continuous agitation; and, in addition, four batches of water, each hotter than the preceding batch, are used to attain maximum extraction of soluble compounds
from the malt. The process of mashing is
characterized chemically by the continuing
Hydrolysis of starch by amylase activity into
fermentable sugars, chiefly maltose, with
smaller amounts of sucrose, glucose,
and fructose. The other principal purpose
of mashing is to bring into solution not only
the sugars but also the amino acids, resulting
from protease activity, where are to be a nitrogen
source for yeast growth during fermentation. At the end of the mashing period, the resulting liquor (wort) is recovered by filtration, while the remaining residue (draff) is used as cattle feed.

16. 3- FERMENTATION
The wort is cooled to 20-25°C and then inoculated with yeast (Saccharomyces cerevisiae). Fermentation, in wooden vessels of diameter 4 m and height 5 m, and a capacity of 7500 to 45,000 litters, requires 2 to 3 days and is principally characterized by growth of the yeast and the fermentation (through the Embden-Myherof-Parnas, or glycolytic, metabolic pathway) of the wort sugars to ethanol. The pH of the fermenting medium may decrease from to due to the production of organic acids, especially acetic, succinic, and pyruvic acids.

17. Many other compounds, such as higher alcohols, carboxylic acids, esters, aldehydes, and ketones, are formed at this time: these compounds are sufficiently volatile to carry over into distillate and therefore to make a major contribution to the final flavour of the whiskey. Glycerol, also formed during fermentation, is non-volatile (b.p. 290°C) and therefore is non-distillable organic material that might otherwise have contributed to whiskey flavour. The yeast, in addition, has the ability to convert sulphur-containing amino acids into volatile sulphur-containing flavour compounds such as dimethyl disulphide( CH3-S-S-CH3).
In whiskey an important component in terms of contribution to flavour is a small optimal amount of the fusel oil fraction, which consists of n-amyl alcohol, isoamyl alcohol, butanol, isobutanol, and propanol. The principal components of the fusel oil fraction are the two amyl alcohols that originate during fermentation as a result of deamination of leucine and isoleucine. These amino acids in turn arise from the hydrolysis of grain proteins and of autolyzed yeast protein.
The product is a liquid (the wash) that contains about 10% ethanol. The carbon dioxide produced during fermentation is recovered and used, for instance, in the manufacture of soft drinks.

18. FERMENTATION OF MSALTOSE TO ETHANOL & CO2
MALTOSE
maltase
water
GLUCOSE
Glycolytic (EMP) pathway
PYRUVIC ACID CH3COCOOH
Pyruvic decarboxylase
CO2
ACETALDEHYDE CH3CHO
+2H+
Alcohol dehydrogenase
ETHANOL CH3CH2OH

19. 4- DISTILLATION

20. [A] FOR MALT WHISKEY
The production of malt whiskey involves batch-distillation of fermented liquid in two copper pot stills, namely the wash still and the spirit still.
The contents of the fermentation vat are transferred to a large wash still, of capacity 15,000 to 30,000 litres, and boiled to produce a distillate (the low wines) that contains 20-25% ethanol (35-45° proof British). The low wines are distilled in the spirit still to produce the following three fractions:
Foreshots
Whiskey (potable spirit containing 63-71% ethanol: ° proof British)
Feints (approximately 25% ethanol).
The distillate is run through a spirit safe, prior to maturation, in order to determine the quality of the spirit. The ethanol content is determined by hydrometry because ethanol possesses a specific gravity lower than that of water.

21. The careful selection of cut points during this distillation procedure greatly influences the flavour of the final product. The first cut from foreshots to spirit governs the level of aldehydes and short-chain esters; the second cut (spirit to feints) determines the concentrations of higher alcohols and acids. The foreshots and feints are returned to the process, being redistilled in the spirit still with the next batch of low wines. The conditions of distillation also enable further reactions to occur with respect to whisky flavour development:
Containing ester formation
Maillard reaction and the accompanying Strecker degradation to produce aldehydes (especially acetaldehyde, 2-furaldehyde, 5-hydroxymethyl-2-furaldehyde)
Continuing formation of volatile sulphur-containing compounds from corresponding non-volatile precursors
4. The conversion of β-hydroxypropionaldehyde to acrolein:
HOCH2CH2CHO >CH2=CHCHO
-H2O
5. The oxidation of unsaturated fatty acids (derived from barley malt) to carbonyl compounds.

22. [B] FOR GRAIN WHISKEY
Grain whiskey is normally produced by continuous distillation in a Coffey (patent) still, which consists of an analyser column and a rectifier column.
In distillation system, the incoming material is cold wash of 10% ethanol content, and the products from this process are as follows:
A low-boiling-point fraction (the heads)
rich in aldehydes and esters, from which any
ethanol present can be recovered.
Raw spirit (main fraction) containing
ethanol, approximately 95% by volume.
A higher-boiling fraction that is rich
in fusel oil components.
The distillation of aqueous ethanolic mixtures is governed by specific physical properties of water and ethanol, most notably that an aqueous ethanolic mixture cannot be separated into ethanol and water.

23. These are liquids that are completely miscible with each other and, therefore, out of all possible ethanol-water mixture compositions, there is one particular mixture (96% ethanol and 4% water) that has a maximum vapor pressure and that therefore boils at a lower temperature than any other mixture of these two liquids. This mixture is an azeotropic (constant boiling) mixture that is able to distil without changing its composition; that is, the distillate has the same composition as the original liquid.
In this case it is a minimum boiling mixture (a particular kind of azeotropic mixture) because the boiling point is lower than for any other mixture of ethanol and water.
In Coffey still, the wash is steam-distilled and the resulting vapor is richer in ethanol than the original wash. However, in the rectifier column, the principal distillate fraction recovered is the azeotropic ethanol-water mixture (raw spirit) containing approximately 95% ethanol.
After distillation, the spirit is diluted with distilled water: the ethanol content (percent by volume) of malt whiskey is reduced to 63.5%, while that of grain whiskey is reduced to 55% before being placed into oak barrels for maturation.

24. 5- MATURATION
The whiskey obtained directly from the distillation step is colourless and has a harsh taste, and therefore a long period of maturation is essential to develop the final flavour, which is a major determinant of whiskey quality. The diluted raw spirit is stored in air-permeable oak barrels (casks) in temperature-controlled government-bonded warehouses for up to 12 or 15 years, sometimes even longer: a minimum maturation period of 3 years in mandatory for Scotch and Canadian whiskies.

25. There are five sizes of oak cask that are used for bulk whiskey.
It is this maturation step that distinguishes whisky from rawer spirits such as gin and vodka.
Maturation, in progress of which is governed by factors of temperature, time, and humidity, is characterized by gradual changes in flavour and colour of the maturing spirit, together with a concurrent decline in both volume and alcoholic content. There is also at this a corresponding decline in the level of volatile sulphur-containing flavour compounds that were generated during the fermentation and distillation stages. The flavour changes occur essentially as a result of reaction among the chemical components both of the barrel wood and of the raw distillate, and continuing interaction between these two sets of chemical components. In chemical terms, the maturation of whiskey is far from being fully understood. However, the degradation of structural components of oak heartwood by heat-charring (a key step in barrel manufacture; done over 200°C) may be outlined as follows:
Lignin to methoxy and dimethoxy phenols, and cresols
Hemicellulose to hexoses and pentoses, which lose molecules of water to become furfural and hydro methyl furfural
Cellulose to D-glucose

26. 4. Maillard reaction with its accompanying Strecker degradation: eventual production of pyrazines, pyrroles, together with direct heat pyrolysis of sugars.
In addition to structural compounds, oak heartwood contains extractives, especially phenolic compounds, fatty acids, and lactones, which become extracted directly into raw spirit during maturation.
All of these low-molecular-weight compounds are highly soluble in aqueous ethanol and such extraction, into the spirit, of these compounds originating from the wood of the barrel is an important part of maturation.
During maturation, the very many chemical reactions, involving both the components of distillate and wood-derived compounds, may be variably described as oxido-reductions, esterifications, Maillard reactions, polymerizations, and polycondensations. The first group of reactions are the most important, especially
since the oak barrels are permeable to oxygen, and may be exemplified by the oxidation of some of the ethanol to acetaldehyde and acetic acid with the subsequent formation of ethyl acetate.
Maturation over a period of several years also in the development of the amber colour, which for the purpose of consumer acceptability may be standardized with added caramel.

27. 6-BLENDING
Malt whiskey by itself has a heavy flavour and is therefore frequently blended with grain whiskey to increase its general acceptability. The most frequent composition of blended whiskey is 60-70% grain whiskey and 30-40% malt whiskey.

28. WHISKEY FLAVOUR COMPONENTS
The ethanol content excepted, the most important property, and hence quality criterion, of whiskey is the flavour, which is governed by the presence and relative concentrations of a large number of organic compounds (congeners), which together are less than 1% of the total whiskey composition. In whiskey, carboxylic acids are present: acetic acid accounts for 50-90% of the total volatile acid fraction. Other acids present are short-chain saturated volatile fatty acids (octanoic (caprylic) acid 8:0, decanoic (capric) acid 10:0, dodecanoic (lauric) acid 12:0), and lactic and succinic acids. The conditions of fermentation, distillation, and maturation favour the interaction of alcohols and organic acids to produce esters, which are volatile and possess distinct aromas. The ethyl esters of the preceding acids are particularly well represented and the most important ester is ethyl acetate (b.p. 77.1°C). Formed by the interaction of ethanol and acetic acid. The predominant aldehyde in whiskey is acetaldehyde, but the other aldehydes are present, especially furfural and hydroxy furfural. Acetals such as 1,1-diethoxyethane also occur in whiskey; they arise, during distillation and maturation, from the interaction of acetaldehyde and ethanol in acid conditions.

29. 7- BOTTLING
The matured spirit is further diluted with water to 40-43% by volume of ethanol before being bottled. Therefore, in terms quantity, the major component of whiskey is actually water (approximately 60% by volume). Once bottled, the whiskey does not undergo subsequent change because oxygen no longer has access to matured spirit. This represents the termination of maturation, but on the other hand there is no decline in whiskey quality due to age.

30. FLOW CHART FOR WHSIKEY MANUFACTURE
Malt whiskey
Grain whiskey
Barley Wheat, corn, rye
Malting Cooking
Kilning Cooling
Mashing
Fermentation
Distillation
Maturation
Blending
Bottling

31. REFERNCE FEDRMENTED BEVERAGE PRODUCTION
Andrew G H Lea
FERMENTED FOODS AND BEVERAGES TECHNOLOGY
Ravindar A.
HANDBOOK OF FOOD AND BEVERAGE FERMENTATION TECHNOLOGY
Y.H.Hui