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Modern regulated dynamic way of obtaining vodka

"SILVER FILTRATION®" is an ideal tool in modern conditions.

 

LLC  "Technofilter" offers to the enterprises of the alcohol industry an innovative technology for producing vodkas without coal columns - the technology "Silver filtration®". The technology is patented by Technofilter. Patent No. 2 222 586 "Method" silver filtration "of vodka sorting and vodka and cartridge filter".

 

 

Main advantages

 

the absence of an increase in the content of aldehydes both during the processing of sortings and vodkas, and at long stops, make it possible to work periodically;

 

high speed processing of sortings and vodkas;

 

large service life of EPSP.UAg0.4 filter elements;

 

compactness of the equipment, in comparison with bulky coal columns, allows to use the minimal quantity of the areas;

 

ease and ease of operation of filter elements will save a lot of time and effort, which are required to replace coal in a classic coal column;

 

as a result of the high hardness of the coal, the costs of control filtration are minimized, especially compared to the "Supplier" system and starch technologies, when the costs of subsequent multi-stage filtration are enormous.

 

The main problem of distilleries is the impossibility of periodic work. In addition, the used coal columns require considerable labor for their maintenance, use of night shifts, experienced personnel. For enterprises that increase production volumes, considerable areas are needed for expansion, and newly constructed ones require large construction costs.

 

 

The processing of sorting in the suspended layer of coal and the "Poltovchanka" system make it possible to work periodically, but they require considerable expenditures for subsequent filtration, and, most importantly, do not allow for flexible control over the contact time of the sorting with coal.

 

A prerequisite of the proposed Technofilter production facility for processing sortings and vodkas Silver Filtration® was a known fact of increasing the efficiency of active coal by applying a small amount of colloidally dispersed silver to its surface.

 

Specialists of Technofilter Ltd. realized the task of creating a new sorting and vodka sorting method combining the effectiveness of modern active coconut coals impregnated with silver with the advantages of cartridge cartridge elements and microfiltration equipment that have proven themselves in the filtration of liquids.

 

As a result of the tests that began at the enterprise back in 1998, active coal from special coconut shell varieties of hard rocks impregnated with silver was chosen as a silver-containing coal. These coals are characterized by high hardness (> 97%), large surface area (> 1000 m2 / g), low ash content with minimal water soluble ash content, excluding high aldehyde-forming capacity, practically no migration of silver to the filtrate (after washing 140 liters of water, residual quantity silver in the filtrate is 5 μg / l at the maximum permissible norm of 100 μg / l). As shown by the studies carried out at VNIIPBT, active coals from the coconut shell are more efficient than BAU-A for a number of technical characteristics. Their mechanical strength is more than 1.5 times higher, the ash content is 3-5 times less with a minimum content of water-soluble ash, the specific surface is twice as high.

 

The basis for the new technology is the developed and patented original design of HYPERLINK cartridge filtering element EPSF.U Ag0.4.

 

In this case, the design of the filter element takes into account the ability of active coal to change the volume (swell) during operation and excludes the possibility of "channeling" even at high filtration rates.

 

When this element is operating, the water-alcohol mixture passes through a coal "minicolumn" filled with silver-containing coal and longitudinal movement of the liquid.

 

By joining elements of 250 mm height by heat sealing, elements of 500,750 and 1000 mm in height are produced.

 

 

 

     
Unique patented design of EPSP.UAg0.4 
Installing USDF.2 (8x750 / 24x1000) -5 manufactured by Technofilter
the filter elements EPSP.UAg 0.4 with a height of 250, 500, 750, 1000mm

 


The unique patented design of EPSP.UAg0.4 filter element and high-efficiency coconut coal impregnated with silver allowed to increase the speed of sorting, which means to reduce the amount of coal and reduce the amount of sorting in contact with coal (for more details see the article  Silver filtration® "- HYPERLINK" http://technofilter.ru/use/food/vodka/serebryanaya_filtraciya/ "Your quality management tool" in the Information Bulletin "Distillery production and winemaking" No. 1, 2008). This allowed to switch to a periodic mode of operation, to work in one shift, to produce the quantity of products that is necessary without overloading warehouses, which is especially important for young enterprises entering the market with a new product.

 

Based on experience and conducted studies, the recommended filtration rate through one "mini-coal column" (ESPF.UAg0.4 filter element 250 mm high) is 3-6 dal / hr when processing sortings and 8-12 dal / h with additional filtration of vodkas. Depending on the initial quality of water and alcohol, the resource of one miniliter works by sorting is 3500-5000 dal. The resource of work of an element on vodka 7000-9000 was given.

 

During the work on the introduction and improvement of new technology, specialists of  Technofilter developed a series of filtration Silver filtration" of the type of USF with a capacity of up to 1000 dal / h by sorting and up to 2000 dal / h on vodka. The units are compact, mounted on a single frame and consist of an explosion-proof pump unit, a main filter holder (a coal treatment unit) of stainless steel for various amounts and height of filter elements, a prefilter for protecting coal elements from mechanical impurities, a rotameter, and shut-off valves. The SFM can be equipped with a control panel with an automatic switch and a frequency converter for smooth adjustment of the pump.

 

All the installations of the "Silver filtration" are equipped with cartridge sorption-filtering elements of ESPF.UAg0.4 brand with a height from 500 to 1000mm (certificate of compliance No. ROSS RUJA 56. 099444 dated 20.10.2004, sanitary and epidemiological certificate No. ЗЗ.ВЛ.09.515.П. 991372.08.04. Of August 24, 2004).

 

An important advantage of "Silver filtration ®" is the absence of a period of entering into the regime, and, consequently, the absence of an unrecoverable marriage, the amount of which can reach up to several tons when working on coal columns. The installation of "Silver filtration ®" produces vodka of high quality from the first minutes of operation and without an unrecoverable marriage, and a high organoleptic evaluation of vodka is confirmed by numerous awards at exhibitions and specialized tastings.

 

One of the most important indicators of the effectiveness of the "Silver Filtration®" technology, along with the convenience and good quality indicators of the product, is a large resource of filter elements. For example, an installation with a capacity of 400-500 dal / hr has an average service life of a filter element set to 500 thousand dal (24 elements with a height of 1000 mm or 96 "mini-columns"), which determines the low cost of using the technology.

 

The "Silver Filtration®" units are easy to maintain and do not cause difficulties in mastering the technology, which increases the reliability in operation.

 

At the same time, the technologist has a convenient tool that allows to receive products corresponding to various tastes of the consumer. Changing the speed can vary the softness of vodka, making either very soft, with a delicate aroma, or more burning, warming - for those who love "hot". It became possible with minimal losses to receive vodka from small amounts of sorting with a special formulation, for example, purified milk.

 

 

   


Installations of "Silver filtration" with filter elements EPSF.U Ag0.4 from 2005. are recommended for use instead of coal columns ("Production technological regulations for the production of vodkas and alcoholic beverages". Amendment No. 1 to MF 10-12292-99 of 07.11.2005 8.5.9 and Changing No. 2 to MFR 10-12292-99 from 12.03 8.5.9) for small-scale production plants, in factories with long filter stops on coal batteries, as an additional purification of water-alcohol solutions after coal columns and as a control filtration before bottling in order to increase organoleptic parameters (Izme ix №1 to the PTR 10-12292-99 of 07.11.2005 r.8.5.10 and Change №2 to the PTR 10-12292-99 from 12.03.2008r. 8.5.10).

 

 

We draw your attention to the fact that in Amendment No. 2 to the APR 10-12292-99 dated March 15, 2008, section 8.5.9. (Preparation of vodkas using "mini coal spikes" (elements) filled with carbon impregnated with silver EPSF. U Ag 0.4 "Silver filtration") was revised as amended:

 

 

 


Change №2 to the PTR 10-12292-99 from March 15, 2008.

 

p.8.5.9. (Preparation of vodkas using "mini coal spikes" (elements) filled with carbon impregnated with silver EPSP.UAg 0,4 "Silver filtration").

 

 

 

The rectified high purification alcohol, Extra, or Lux is diluted with the corrected water to the required strength in a sorting vat or mixer of a different design.

 

The supply of rectified alcohol and water is maintained at the desired level by means of rotameters or an automatic control system for the supply of alcohol and water, while maintaining the density of the mixture at the outlet. The resulting homogenized water-alcohol mixture of the required strength is sent by a centrifugal pump to a storage tank of stainless steel or an enameled container.

 

To improve the organoleptic properties, the water-alcohol mixture is treated with granulated de-gelled silver-containing coconut activated carbon. Coal adsorbs impurities and catalyzes oxidative processes that favorably affect the quality of vodka.

 

Sorting is carried out under dynamic conditions, filtering it in "mini coal columns", sorting is carried out under the pressure of the sorting itself or by means of a centrifugal pump.

 

To clean the water-alcohol mixture on the sorting feed line, filter holders or filtration units of USF (TU 5131-009-10471723-2004) consisting of a pump unit, filter holder, rotameter and stop valves with "mini-coal columns" (elements) made in the form of standard filter elements of the brand  EPSF.UAg0,4 produced by LLC NPP "Technofilter", filled with granulated dezolized erebrosoderzhaschim coconut activated carbon impregnated with 0.4% silver. The impregnation method used to produce this coal ensures that there is no migration of silver to the filtrate.

 

Before the beginning of the work, to sort the transportation coal dust into the filter holder with "minicolumns" (elements), sorting is carried out at the rate of 5-10 daltons per one element 250 mm high. Sorting with a suspension of coal dust is placed in a suitable container (collector) to settle the dust for 10-12 hours (correctable marriage). The recommended sorting temperature during processing is 18 ° C + 2 ° C.

 

Filter elements of grade EPSPS.UAg 0,4 must receive sorting, free from foreign inclusions (scale, colloids, sand dust, etc.). Otherwise, it is mandatory to install a pre-filter with a particle retention efficiency of 5-10 μm  EPV- 500 produced by Technofilter LLC).

 

After leaving the filter holder with "minicolumns" (elements), transparent vodka is sent to a collection of filtered vodka or a vat. After full or partial filling of the vodka collection, depending on the required volume, the sorting feed is manually or automatically switched off and the remainder is drained from the filter holder. "Minicolumns" (elements) can remain in the filter holder until the next moment of cooking vodka or taken out of the filter holder and dried in the air. At stops up to 7 days, you need to drain the remaining vodka from the filter holder, you can not remove the filter elements.

 

If you stop for more than 7 days, you need to drain the rest of the vodka from the filter holder, remove the filter elements, allow them to dry at room temperature and seal them tightly to prevent foreign odors.

 

"Mini-Columns" (elements) are not regenerated and must be replaced after processing the work resource.

 

Characteristics of "coal mini-boxes" (elements):

 

The filter element of the brand  EFSP.U  Ag 0, 4 - sorption-filter element cartridge type based on activated de-impregnated coal from the shell of coconut, impregnated with silver. The content of silver impregnated in coal is 0.3-0.5%.

 

Filter element ESPF.Uag 0.4 is a coal mini-column with backfilling with silver-containing coal between the inner and outer bodies and the longitudinal movement of the liquid.

 

These coals are characterized by high hardness (> 97%), large surface area (> 1000 m2 / g), and the impregnation method used for their preparation ensures that silver does not migrate to the filtrate.

 

In the standard base element, a filter element (mini-column) of ESPF.UAg 0,4 with a height of 250 mm, an outer diameter of 70 mm and an inner diameter of 26 mm is placed approximately 330 g of active coal with a density of about 0.5 g / cm3.

 

Depending on the required sorting processing speed, the number and height of the filter elements, as well as the brand of the filter holder or the filtration unit of the USF, are selected.

 

The speed of filtering sorts through one "minicolumn" (element) 250 mm high - from 3 to 6 dal / h.

 

The speed of filtration is controlled by a rotameter or a sorting rate indicator and is set taking into account the mandatory positive effect of the tasting evaluation.

 

The difference in the tasting assessment between vodka and sorting should be not less than 0.2 points, the difference in oxidizability - at least 1.5 minutes on alcohol "Extra" and 0-1.5 minutes - on alcohol "Lux". If there is no improvement in the organoleptic properties, the filtration rate should be reduced, and if the tasting rating does not increase under the influence of coal as the filtering rate decreases, the filter elements must be replaced.

 

8.5.10 Control filtration of vodkas

 

"Minicolumns" (elements) with coconut coal, impregnated with silver of ESPF.UAg 0.4, can be used for additional processing of vodkas.

 

Vodka treated on a coal column, or in another regulated way, is passed through a filtration unit of the  USF (TU 5131-009-10471723-2004) consisting of pump unit, filter holder, rotameter and shut-off valves, with filter elements of ESPF.UAg 0,4 and are sent to a collection of filtered vodka or a vat.

 

At the same time, not only the better transparency of vodkas (with shine) is noted, but also the improvement of organoleptic parameters. The speed of filtering the vodka through one "minicolumn" (element) 250 mm high is 8-12 dal / h. The filtration speed is controlled by a rotameter or a vodka flow indicator and is set taking into account the positive effect of the tasting treatment.

 

The life of the filter element EPSP.UAg 0,4 height of 250 mm in vodka is 7000-9000 dal and depends on the quality of the original vodka.

 

Today the technology "Silver filtration ®" is increasingly used in distilleries. If more recently, vodka producers have seen in technology mainly marketing advantages that use positive associations with silver from the Russian consumer, then the time has also revealed the technological merits, thanks to which, to date, the technology "Silver Filtration®" operates in more than 300 enterprises in 40 countries, and is the main way of processing water-alcohol mixtures in the production of vodkas of Russian brands: Green Mark, Crane, Marusia, Five Lakes, Flagman, Milky Way, White Birch ka "and many other famous brands.


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