Veteran moonshiners Mark and Digger recently faced a unique challenge when a longstanding client requested 100 gallons of 140-proof corn liquor. Understanding that standard production methods wouldn’t suffice, the duo set out to develop a system capable of producing high-proof alcohol while preserving the rich corn flavor their client loved.
A Custom Solution for a High-Stakes Order
The client, concerned that lower-proof liquor would dilute when soaking cherries, insisted on the 140-proof benchmark. Mark and Digger immediately recognized the difficulties this presented. Traditional column stills could achieve the desired proof, but at the cost of stripping away essential flavors. Determined to meet the challenge, they devised an alternative approach by modifying their existing equipment.
Their solution involved adjusting the mash composition, increasing both grain content and sugar to boost alcohol by volume (ABV). They also enhanced their thump keg setup, designing a system that passed alcohol vapor through a series of cooling pipes, allowing for a double-thumping effect that concentrated the proof while retaining the distinct corn notes.
Crafting a Superior Mash
To optimize fermentation, the team increased the sugar content from the usual six pounds per 50-weight to nine pounds, raising the potential ABV to around 18-19%. By carefully controlling the yeast levels, they ensured maximum conversion of starches into alcohol. The process required precision and patience, as any misstep could compromise the final product.
Building a Revolutionary Thump Keg System
Meanwhile, Kelly and Mark took on the task of engineering a double-chambered thump keg fitted with eight cold-water pipes. This innovation allowed the alcohol vapor to condense in multiple stages, effectively increasing its potency. However, the added complexity raised concerns about back pressure potentially blowing the cap off the still. To counter this risk, they incorporated a drainage system, ensuring that excess liquid could be released to prevent dangerous buildup.
The Moment of Truth
As the first batch of liquor made its way through the newly designed system, anticipation was high. Digger performed the traditional “shake test,” analyzing the size and behavior of bubbles in the jar. Initial impressions were promising, but the final test would be the proof measurement.
When the hydrometer settled, the reading was an impressive 168 proof—exceeding expectations. More importantly, the flavor profile remained intact, delivering the robust corn notes the client demanded.
