Stillage dewatering
in the beverage industry

Sustainable and efficient dewatering of stillage from distilled spirits production

Industrial centrifuges for stillage processing

In the manufacture of distilled spirits, stillage refers to the residue remaining after fermentation and distillation of mash or other substances. The stillage usually contains water, solids, unfermented residues and other organic components. These solids can be separated using mechanical separation technology, concentrated and thus optimally pre-dewatered before thermal drying.

In addition, separation technology can be used to recover the solids content, but the volume can also be drastically reduced, so that costs for transport and, if necessary, disposal are significantly reduced.

Optimize the dewatering of stillage in the liquor industry with Flottweg

How does the stillage dewatering process work in the alcoholic industry?

The process of dewatering stillage after the distillation process is complex and poses various challenges. Flottweg specializes in the processing and dewatering of stillage in the alcoholic beverage industry and offers solutions for efficient stillage separation. 

Mezcal – Tequila stillage processing

Mezcal is distilled from fermented agave, which is why any agave-based liquor is referred to as Mezcal. A special form is tequila, which is made exclusively from blue agave. The agave are usually cooked or roasted in order to obtain the juice for further fermentation. The manufacturing process is characterized by fermentation of the pure agave juice and the separation of the plant fibers and pulp. This waste is also called bagasse. The vinasse, as the stillage from Mezcal production is called, remains after distillation. Due to the increased production and vinasse volumes, a reduction in disposal volumes is an important issue in the industry. 

Flottweg uses Sedicanters^®, or separators as required to achieve the best possible purification even with fine solid sediment. 

On an industrial scale, pure agave juice is also used as a starting product. Flottweg can also assist with the purification of the agave juice, thus improving the quality and process stability in the further fermentation and distillation process. 

Example of a production process for the production of tequila

Processing of Rum stillage

In industrial-scale Rum production, fermented sugar - typically molasses or sugar cane juice - is fermented and distilled. The characteristic rum taste is created by adding a part of the stillage to the wash – also known as dunder. Here, Flottweg can achieve great results in the handling of the dunder after the fermenter. 

With the help of a Flotttweg decanter, Sedicanter^® or separators, the quality and yield of the fermented wash can be improved and the solids load of the wastewater can be significantly reduced. 

Pure molasses is also used as a primary product in large-scale industrial production. Flottweg can also assist with the purification of raw molasses, thus improving quality and process stability in the subsequent fermentation and distillation process. 

Example of a production process for making rum

Processing of Whiskey stillage

The amber-colored liquor made from fermented grain is matured in wooden barrels and is given its own character by the type of barrel, maturing time, and the distillation process used.  

A Flottweg decanter can be used to process thick stillage and thus produce a wet cake of 34-42 percent solids (by weight). In a second, optional step, the thin stillage can be purified using a Flottweg Sedicanter® or separator to significantly remove any remaining fine solids. The solids are thus prepared for further utilization (animal feed, protein, nutrient source, fuel), and the water content is drastically reduced. Depending on the type of whiskey, raw material and mash recipe, Flottweg can draw on extensive process knowledge and select the optimum centrifuge set-up for the respective requirements of the distillery. 

Sustainable process efficiency with the goal of zero emissions is becoming increasingly important in the whiskey industry and will be the goal for the coming years.  

Value-added products created through upcycling represent further opportunities to increase the profitability of distilleries, solve environmental problems, and reduce the CO₂ footprint. 

Grain whiskey, for example, which is mostly made from corn, provides corn oil as a valuable by-product in addition to the classic stillage. The Flottweg Tricanter^® enables a continuous three-phase separation, in which corn oil is extracted from the concentrated thin stillage (CDS). 

Example of a production process for making whiskey