1.

PURPOSE
1.1. This work instruction describes the flow of fermented beer to fine and heads &
tail alcohol.
1.2. The purpose of this procedure is to distill the fermented beer and produce best
quality of alcohol product. This procedure provides for the communication
between the operators of the equipment in this section.

2. SCOPE
2.1. Includes distillation and stoppage.

3. RECORDS
3.1. Record column operation which includes time and respective temperatures of
the columns.

4. ASSOCIATED DOCUMENTS
4.1.
5. DEFINITIONS
5.1. Distillation - is the process of separating the constituents of a liquid mixture by
virtue of the difference of their boiling points.
5.2. Beer – the feremented alcoholic liquid.
5.3. Heads - distillate containing a higher percentage of low boiling constituents
such as aldehyde.
5.4. Proof - a measurement of alcohol strength, which is derived by multiplying the
percent alcohol by volume by 2.
5.5. Rectified Alcohol - fine alcohol (or product) that usually contains 95% alcohol.
5.6. Slops - the residue after complete extraction and distillation of alcohol from
beer.
5.7. Tails - distillate containing a higher percentage of fusel oil.

6. RESPONSIBILITY
6.1. The department supervisor shall maintain this instruction.
 6.2. The Distillation Man shall maintain and ensure the operating standards of each
coulmn, communicate the fermentation man, maintenance mechanic and to
follow this procedure.
6.3. The Maintenance Mechanic and Senior Aide shall ensure the level of beer in
beer supply tank, communicate the distillation man, follow this procedure and
not move on to another section without inspection.

7. TOOLS, GAUGES, FIXTURES

8. SAFETY REQUIREMENTS

9. INSTRUCTIONS
9.1. Distillation Section
9.1.1. Before start-up, the Distillation man checks and ensures that steam valves
for all Beer stills, Aldehyde and Rectifier columns are fully closed. Drain
valves of beer stills going to the slops level controller should also be
closed. Most importantly, the outlet valve of the Beer Supply Tank going
to the Constant Level Tanks should be closed.
9.1.2. The Distillation man switches ON Cooling Water pumps 1 and 2, ensuring
that all valves going to the condensers are opened. After few minutes, the
Distillation man checks if the water from the condensers, and Water
Supply Tank 1 and 2 already overflows. In addition, cooling water from
the DCT basin should still be at proper level. Note: Throughout the whole
operation, the Distillation man decides whether both pumps are to be
operated or alternately used depending on the level of water at the Water
Supply Tanks.
9.1.3. The Distillation man then signals the Fermentation man that beer is ready
for transfer. Afterwards, the Fermentation man in turn, signals the
Distillation personnel that beer has already been transferred to the Beer
Supply Tank.
9.1.4. AAP Maintenance Mechanic and Senior Aide open the output valve of the
Beer Supply Tank going to the Constant Level Tank/s as instructed by the
Distillation man.
9.1.5. The Distillation man starts to gradually open the steam main valve and
the steam valves going to the beer still columns. The Pressure Regulating
valve is adjusted to meet the standard pressure of the incoming steam.
Note: Beer still’s steam valve opening must be estimated by the
Distillation man for the hourly data recording.
9.1.6. Steaming of beer stills take about 15-30 minutes and is monitored
through the Temperature Flow recorder, under the ‘TPH’ section, in
degrees Celsius. Note: Temperature readings must be recorded by the
Distillation man every hour on the Column Operation Logsheet provided.
9.1.7. By the time the beer still attained its standard temperature, the beer feed
valve is gradually opened ensuring balance between the incoming steam.
(Refer to the Alcohol Plant Monitoring System for the corresponding
standard temperature and beer flow rates per column) When the
temperature observed under the ‘TPH’ section seems to stabilize upon
addition of beer, the auxiliary and controller valve located at the bottom
section of the beer still is opened.
9.1.8. To ensure that the process is operating well, the Distillation man checks if
the sight glass at the Primary Beer Heater produces a clear liquid. Note: If
the liquid observed at the sight glass is brownish in color, the Distillation
man should either lessen the beer feed flow rate or increase the incoming
steam at the beer still if possible.
9.1.9. After about 45 minutes, the distillation man checks the liquid level at the
base of the Aldehyde through the sight glass. If the level is about 3/4 of
the sight glass, steaming of the Aldehyde column is to be done next.
9.1.10. The steam valve going to the Aldehyde column is gradually opened by the
distillation man and at the same time ‘BALD’ section at the Temperature
Flow Recorder is monitored. It will take a few minutes for the Distillation
man to stabilize and achieve the standard required temperature of the
Aldehyde column. Note: Steam valve opening should be monitored for
data recording as well as the Temperature reading from the base and top
of the Aldehyde column.
9.1.11. At this time, the Alcohol percentage leaving the Aldehyde column is at
50% and ready to undergo the next and final stage of distillation. Similar
 to the process of steaming the Aldehyde column, liquid level at the base of
the Rectifier is to be checked first. After which, the Reboiler pump is
switched ON and steaming may now take place.
9.1.12. The Distillation man opens the Steam valve going to the Rectifier column
while ensuring balance on all other Temperature readings. To monitor the
temperature reading inside the Rectifier, the ‘MRT’ section in the
Temperature Flow Recorder which stands for Middle Rectifier aids the
Distillation man in the operation. Note: All temperature reading is
recorded by the Distillation man every hour in the provided Column
Operation Logsheet for further reference.
9.1.13. It is an unending responsibility of the Distillation man to maintain and
ensure that the temperature readings within the whole process starting
from the Beer still up to the Rectifier are within their corresponding range.
The Distillation man may either control the steam input or the beer feed
and even decide to order cleaning of the condensers and coolers. Note:
Alcohol condensers and coolers are cleaned every start of a shift by the
AAP Maintenance Mechanic and Sr. Aide.
9.1.14. After 4-5 hours, it is expected that production of the final product will be
seen at the Alcohol tailbox. The valve then going to the reprocess/bad
alcohol tank is opened as laboratory’s Alcohol Jr. Technician checks for the
alcohol’s proof.
9.1.15. By the time the laboratory signals the Distillation man that the alcohol’s
proof reached the standard, the valve going to the bad alcohol tank is
closed and the valve going to the Heads and Tails is opened instead.
Quality is monitored closely by the AP & AP Laboratory until some time
that they will signal the Distillation man that production may then be sent
to the Fine Alcohol Production tank.

9.2. Stoppage
9.2.1. If for instance, power interruption, or steam/water insufficiency happens,
or even unexpected equipment failure/maintenance is to be done, the
following are the standard procedures in terminating Distillery operations
9.2.1.1. The output valve of the Beer Supply tank and the Constant
Level tank/s should be closed by AAP Maintenance Mechanic
and Sr. Aide.
9.2.1.2. The beer feed valve followed by the steam valve directed to
the Aldehyde and Rectifier columns is to be fully closed.
9.2.1.3. In addition, the drain valves located at the bottom of the
Beer still column must be closed.