U.S. patent application number 17/096519 was filed with the patent office on 2021-03-04 for method for rapid maturation of distilled spirits using light and heat processes.
The applicant listed for this patent is LOST SPIRITS TECHNOLOGY LLC. Invention is credited to Bryan Alexander Davis.
Application Number | 20210062123 17/096519 |
Document ID | / |
Family ID | 1000005212152 |
Filed Date | 2021-03-04 |
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United States Patent
Application |
20210062123 |
Kind Code |
A1 |
Davis; Bryan Alexander |
March 4, 2021 |
METHOD FOR RAPID MATURATION OF DISTILLED SPIRITS USING LIGHT AND
HEAT PROCESSES
Abstract
An improved system and process for rapidly producing distilled
spirits having characteristics associated with a much longer
maturation process is provided. The method involves contacting wood
with an unmatured distilled spirit under heated conditions and
contacting the resulting heat-treated spirit with actinic light.
The disclosure provides embodiments where a spirit is sequentially
processed through heat and actinic light treatment. The disclosure
also provides embodiments where a heat-treated spirit is mixed with
a spirit that has been separately treated with light to give
characteristics of a mature spirit. Air may also be percolated
through a mature spirit in a container with a headspace at a gauge
pressure between about -25 inHg and about -30 inHg, until the
alcohol concentration of the mature spirit is reduced by between
about 1% to about 2% by volume, and until the total volume of the
mature spirit is reduced by about 10% or less.
Inventors: |
Davis; Bryan Alexander;
(Vernon, CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
LOST SPIRITS TECHNOLOGY LLC |
Vernon |
CA |
US |
|
|
Family ID: |
1000005212152 |
Appl. No.: |
17/096519 |
Filed: |
November 12, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16715262 |
Dec 16, 2019 |
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17096519 |
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15583993 |
May 1, 2017 |
10508259 |
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16715262 |
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14795841 |
Jul 9, 2015 |
9637713 |
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15583993 |
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14594944 |
Jan 12, 2015 |
9637712 |
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14795841 |
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14152915 |
Jan 10, 2014 |
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14594944 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
C12H 1/22 20130101; C12G
3/07 20190201; C12H 1/18 20130101; C12H 1/165 20130101 |
International
Class: |
C12H 1/16 20060101
C12H001/16; C12H 1/22 20060101 C12H001/22; C12G 3/07 20060101
C12G003/07; C12H 1/18 20060101 C12H001/18 |
Claims
1. A process for producing a mature spirit comprising: (a)
providing heat to a mixture consisting essentially of an unmatured
distilled spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 24 hours to about 336 hours to give a distilled
spirit mixture; (b) contacting the distilled spirit mixture with
wood and actinic light at a wavelength spectrum ranging from about
183 nm to about 1 mm for at least one hour to give an actinic
light-treated distilled spirit mixture; and (c) providing heat to
the actinic light-treated distilled spirit mixture produced in step
(b) to maintain a temperature between about 140.degree. F. and
about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit; wherein
steps (a), (b), and (c) are performed sequentially.
2. The process of claim 1, wherein the wavelength spectrum ranges
from about 183 nm to about 750 nm.
3. The process of claim 1, wherein the wavelength spectrum ranges
from about 200 nm to about 2000 nm.
4. The process of claim 1, wherein the wavelength spectrum ranges
from about 375 nm to about 6000 nm.
5. The process of claim 1, wherein the wavelength spectrum is
within the infrared spectrum, ranging from about 700 nm to about 1
mm.
6. The process of claim 1, wherein the wavelength spectrum is
within the UV spectrum, ranging from about 183 nm to about 400
nm.
7. The process of claim 1, further comprising cooling the distilled
spirit mixture during the actinic light exposure via a cooling
system at a temperature below boiling point, the temperature from
about 174.degree. F. to about 182.degree. F.
8. The process of claim 1, further comprising conducting one or
more of step (a), step (b), and step (c) are under reflux at a
temperature ranging from about 140.degree. F. to about 182.degree.
F.
9. The process of claim 1, further comprising conducting one or
more of step (a), step (b), and step (c) in high pressure vessels
at a temperature ranging from about 140.degree. F. up to about
328.degree. F.
10. The process of claim 1, wherein ultrasonication is used during
step (a) and step (c) to produce heat.
11. The process of claim 1, further comprising introducing oxygen
and/or air to the distilled spirit mixture to autooxidize aldehydes
in the distilled spirit mixture.
12. The process of claim 1, further comprising introducing oxygen
and/or air to the distilled spirit mixture under a vacuum of up to
about -29 inHg to autooxidize aldehydes in the distilled spirit
mixture and remove highly volatile VOCs and ethanol.
13. A process for producing a mature spirit comprising: (a)
providing heat to a mixture consisting essentially of an unmatured
distilled spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 24 hours to about 336 hours to give a distilled
spirit mixture; (b) dividing the distilled spirit mixture into a
first portion and a second portion, contacting the first portion of
the distilled spirit mixture of with wood and actinic light at a
wavelength spectrum ranging from about 183 nm to about 1 mm for at
least one hour to give an actinic light-treated distilled spirit
mixture concentrate; and (c) adding the distilled spirit mixture
concentrate to the second portion of the distilled spirit mixture
and providing heat to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to produce the
mature spirit; wherein steps (a), (b), and (c) are performed
sequentially.
14. The process of claim 13, wherein the first portion of the
distilled spirit mixture is from about 1% to about 99% of the
distilled spirit mixture.
15. The process of claim 13, wherein the wavelength spectrum is
within the infrared spectrum, ranging from about 700 nm to about 1
mm.
16. The process of claim 13, wherein the wavelength spectrum is
within the UV spectrum, ranging from about 183 nm to about 400
nm.
17. The process of claim 13, further comprising cooling the
distilled spirit mixture during the actinic light exposure via a
cooling system at a temperature below boiling point of about
174.degree. F. to about 182.degree. F.
18. A process for producing a mature spirit comprising: (a)
contacting the distilled spirit mixture with wood and actinic light
at a wavelength spectrum ranging from about 183 nm to about 1 mm
for at least one hour to give an actinic light-treated distilled
spirit mixture; and (b) providing heat to the actinic light-treated
distilled spirit mixture to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to produce the
mature spirit; wherein steps (a), and (b), are performed
sequentially.
19. The process of claim 18, further comprising cooling the
distilled spirit mixture during the actinic light exposure via a
cooling system to a temperature below boiling point, the
temperature from about 174.degree. F. to about 182.degree. F.
20. The process of claim 18, further comprising introducing oxygen
and/or air to the distilled spirit mixture to autooxidize aldehydes
in the distilled spirit mixture.
Description
CROSS-REFERENCE TO RELATED APPLICATION
[0001] This application is a continuation-in-part of U.S. Ser. No.
16/715,262, filed Dec. 16, 2019, pending; which is a divisional
application of U.S. Ser. No. 15/583,993, filed May 1, 2017; which
is a continuation-in-part of U.S. Ser. No. 14/795,841, filed Jul.
9, 2015, now U.S. Pat. No. 9,637,713, issued May 2, 2017; which is
a continuation-in-part of U.S. Ser. No. 14/594,944, filed Jan. 12,
2015, now U.S. Pat. No. 9,637,712, issued May 2, 2017, which is a
continuation-in-part of U.S. Ser. No. 14/152,915, filed Jan. 10,
2014, now abandoned. Each of the disclosures of which are hereby
incorporated by reference in their entirety.
TECHNICAL FIELD
[0002] The technical fields are: Food Chemistry and Other Consumer
Goods.
BACKGROUND ART
[0003] By some accounts, human beings have been aging distilled
spirits in wooden containers for almost five hundred years. Despite
billions of person-hours of experience, the myriad of chemical
reactions responsible for the flavor of wood-aged spirits are not
fully understood. Spirits derive their distinct characteristics
over time while stored in wooden containers in part by the
production and presence of esters. Esters are compounds made by
chemically bonding acid molecules and alcohol molecules to form new
compounds, often with pleasant aromas and tastes. This process is
known as "esterification." In addition to esterification, wood-aged
spirits derive additional characteristics through other processes,
including extraction of flavor compounds from the wood container
(e.g., the ubiquitous oak barrel). These processes are not
necessarily separate or distinct, and can interact with and affect
each other.
[0004] Spirits also derive their distinct characteristics over time
while stored in wooden containers in part from the quicker
evaporation of more volatile organic compounds (VOCs) through the
barrel walls, over the slower evaporation of other organic
compounds. The aging process thus eliminates some undesired
compounds, such as methanol, and concentrates and rebalances
others, such as flavorful esters formed from reactions with the
wood barrel.
[0005] Attempts have been made to accelerate maturation of
distilled spirits by cycling or varying pressures over relatively
large ranges (e.g., between -2 and 10 ATM; see U.S. Patent
Publication No. 2013/0149423). These processes generally do not
yield a product close enough to that produced by traditional means.
Other environmental conditions are more important to achieve
characteristics associated with a mature flavor.
[0006] Consumers of distilled spirits are often educated and
discerning. Many will refuse to consume or pay a premium for
non-authentic tasting products. What is needed is a means by which
the quality and complexities associated with traditionally aged
spirits can be achieved in a significantly reduced timeframe,
sometimes with a reduction in the evaporation of finished goods and
a reduction of the build-up of ethyl acetate.
SUMMARY
[0007] The following embodiments and aspects thereof are described
and illustrated in conjunction with systems, tools and methods
which are meant to be exemplary and illustrative, not limiting in
scope. In various embodiments, one or more of the above-described
problems have been reduced or eliminated, while other embodiments
are directed to other improvements.
[0008] One aspect of the present disclosure encompasses a process
for producing a mature spirit. The process comprising (a) providing
heat to a mixture consisting essentially of an unmatured distilled
spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to give a distilled
spirit mixture; then (b) contacting the distilled spirit mixture
with wood and actinic light at a wavelength spectrum ranging from
400 nm to 1 mm for at least one hour to give an actinic
light-treated distilled spirit mixture; and then (c) providing heat
to the actinic light-treated distilled spirit mixture produced in
step (b) to maintain a temperature between about 140.degree. F. and
about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit; and the
wherein steps (a), (b), and (c) are performed sequentially.
[0009] Another aspect of the present disclosure encompasses a
process for producing a mature spirit comprising: (a) providing
heat to a mixture consisting essentially of an unmatured distilled
spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to give a distilled
spirit mixture; then (b) contacting the distilled spirit mixture
with wood and actinic light at a wavelength spectrum ranging from
400 nm to 1 mm for at least one hour to give an actinic
light-treated distilled spirit mixture; then (c) providing heat to
the actinic light-treated distilled spirit mixture produced in step
(b) to maintain a temperature between about 140.degree. F. and
about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit; and then (d)
percolating air through the mature spirit of step (c) in a
container with a headspace at a gauge pressure between about -25
inHg and about -30 inHg until alcohol concentration of the mature
spirit is reduced by between about 1% and about 2% by volume, and
until the total volume of the mature spirit is reduced by about 10%
or less; wherein steps (a), (b), (c), and (d) are performed
sequentially.
[0010] An additional aspect of the present disclosure encompasses a
process for producing a mature spirit comprising: (a) providing
heat to a mixture consisting essentially of an unmatured distilled
spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to give a distilled
spirit mixture; (b) removing an amount of heat-treated distilled
spirit mixture from step (a); (c) contacting the removed amount of
heat-treated distilled spirit mixture with wood and actinic light
at a wavelength spectrum ranging from 400 nm to 1 mm for at least
one hour to yield a heat-treated and actinic light-treated
distilled spirit mixture; (d) transferring the heat-treated and the
actinic light-treated distilled spirit mixture or a portion thereof
to the remaining heat-treated distilled spirit mixture from step
(a) or a portion thereof to yield a combined mixture of
heat-treated and actinic light-treated distilled spirit mixture;
and (e) providing heat to the combined heat-treated and actinic
light-treated distilled spirit mixture from step (d) or portion
thereof to maintain a temperature of between about 140.degree. F.
and about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit.
[0011] Yet another additional aspect of the present disclosure
encompasses a process for producing a mature spirit comprising: (a)
providing heat to a mixture consisting essentially of an unmatured
distilled spirit and wood, to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to give a
heat-treated distilled spirit mixture; (b) removing an amount of
heat-treated distilled spirit mixture from step (a); (c) contacting
the removed amount of heat-treated distilled spirit mixture with
wood and actinic light at a wavelength spectrum ranging from 400 nm
to 1 mm for at least one hour to yield a heat-treated and actinic
light-treated distilled spirit mixture; (d) transferring the
heat-treated and the actinic light-treated distilled spirit mixture
or a portion thereof to the remaining heat-treated distilled spirit
mixture from step (a) or a portion thereof to yield a combined
mixture of heat-treated and actinic light-treated distilled spirit
mixture; (e) providing heat to the combined heat-treated and
actinic light-treated distilled spirit from step (d) or portion
thereof to maintain a temperature of between about 140.degree. F.
and about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit; and (f)
percolating air through the mature spirit of step (e) in a
container with a headspace at a gauge pressure between about -25
inHg and about -30 inHg until the alcohol concentration of the
mature spirit is reduced by between about 1% and about 2% by volume
and until the total volume of the mature spirit is reduced by about
10% or less.
[0012] Yet another additional aspect of the present disclosure
encompasses a process for producing a mature spirit comprising: (a)
providing heat to a mixture consisting essentially of an unmatured
distilled spirit and wood, to maintain a temperature of between
about 140.degree. F. and about 170.degree. F. for about 12 hours to
about 336 hours to give a heat-treated distilled spirit mixture;
(b) removing an amount of heat-treated distilled mixture from step
(a); (c) contacting the removed amount of heat-treated distilled
spirit mixture with wood and actinic light at a wavelength spectrum
ranging from 400 nm to 1 mm for at least one hour to yield a heat
treated and actinic light-treated distilled spirit mixture; (d)
transferring the heat-treated and actinic light-treated distilled
spirit mixture or a portion thereof with an amount of unmatured
distilled spirit to give a combined mixture of unmatured distilled
spirit and heat-treated and actinic light-treated distilled spirit;
and (e) providing heat to the combined mixture of unmatured
distilled spirit and heat-treated and actinic light-treated
distilled spirit from step (d) or portion thereof to maintain a
temperature of between about 140.degree. F. and about 170.degree.
F. for about 12 hours to about 336 hours to produce the mature
spirit.
[0013] The unmature distilled spirit may be selected from the group
consisting of sugar cane spirits, grain spirits, fruit spirits,
and/or agave spirits. The unmature distilled spirit may also be
selected from the group consisting of rum, tequila, mescal,
whiskey, brandy, gin, and vodka.
[0014] The concentration in the mature spirit may be decreased for
one or more chemical markers selected from the group consisting of
methanol, C.sub.2-C.sub.6 fatty acids, and C.sub.2-C.sub.6 fatty
acid esters, such as ethyl acetate. The concentration in the mature
spirit may be increased for one or more chemical markers selected
from the group consisting of vanillin, phenylated esters,
C.sub.7-C.sub.24 fatty acid esters, and phenolic aldehydes. For
example, the mature spirit may characterized by an increase in
concentration of sinapaldehyde, ethyl dodecanoate, and ethyl
decanoate, such as an increase in concentration of sinapaldehyde.
In particular, the mature spirit may be characterized by amounts of
sinapaldehyde, ethyl dodecanoate, and ethyl decanoate that are
substantially similar to the relative proportions shown in FIG. 6,
as measured by GCMS. The mature spirit may have an ethyl acetate
concentration of about 59,000 .mu.g/L.
[0015] Steps (a), (c), and (e) described above are maintained at a
temperature between about 140.degree. F. and about 150.degree. F.
for a period of time ranging from about 168 hours to about 226
hours. Alternatively, steps (a), (c), and (e) are maintained at a
temperature between about 150.degree. F. and about 160.degree. F.
for a period of time ranging from about 24 hours to about 72 hours.
The process may further comprise contacting the mature spirit of
step (c) and/or step (e) with wood and actinic light at a
wavelength spectrum ranging from 400 nm to 1 mm for at least one
hour. The process may also further comprise heating with wood at a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 24 hours to about 336
hours.
[0016] An additional aspect of the present disclosure encompasses a
process for producing a mature spirit. The process comprising (a)
contacting a mixture consisting essentially of a first unmatured
distilled spirit with wood and actinic light at a wavelength
spectrum ranging from 400 nm to 1 mm for at least one hour to yield
a actinic light-treated distilled spirit mixture; (b) transferring
the actinic light-treated distilled spirit mixture or a portion
thereof to a second unmatured distilled spirit or a portion thereof
to yield a combined mixture of heat-treated distilled spirit and
unmatured distilled spirit; and (c) providing heat to the combined
mixture of heat-treated distilled spirit and second unmatured
distilled spirit from step (b) or portion thereof to maintain a
temperature of between about 140.degree. F. and about 170.degree.
F. for about 12 hours to about 336 hours to produce the mature
spirit.
[0017] Yet another aspect of the present disclosure encompasses a
process for producing a mature spirit. The process comprising (a)
contacting a first mixture consisting essentially of an unmatured
distilled spirit with wood and actinic light at a wavelength
spectrum ranging from 400 nm to 1 mm for at least one hour to yield
an actinic light-treated distilled spirit mixture; (b) providing
heat to a second mixture consisting essentially of an unmatured
distilled spirit and wood to maintain a temperature of between
about 140.degree. F. and about 170.degree. F. for about 12 hours to
about 336 hours to yield a heat-treated distilled spirit mixture;
(c) combining the actinic light-treated distilled spirit mixture or
a portion thereof and the heat-treated distilled spirit mixture or
a portion thereof to yield a combined mixture of an actinic
light-treated distilled spirit and heat-treated distilled spirit;
and (d) providing heat to the actinic light-treated distilled
spirit and heat-treated distilled spirit of step (c) or portion
thereof to maintain a temperature of between about 140.degree. F.
and about 170.degree. F. for about 12 hours to about 336 hours to
yield a mature spirit.
[0018] The alcohol concentration of the mature spirit may be
determined during the process using an in-line density meter
connected to the container. The gauge pressure may be between about
-27 inHg and about -28 inHg, such as about -27.75 inHg. The
temperature of the mature spirit may be held constant during step
(d). The mature spirit in step (d) may begin with an alcohol
concentration between about 60% and about 95.5% by volume. The
process may further comprise (g) diluting the mature spirit of step
(d) with water to an alcohol concentration between about 50% and
about 55% by volume, and then (h) percolating air through the
diluted mature spirit in the container with the headspace at a
gauge pressure between about -25 inHg and about -30 inHg until the
alcohol concentration of the diluted mature spirit is reduced by an
additional amount of between about 0.3% and about 1% by volume. The
temperature of the mature spirit may also be held constant during
the step (h).
[0019] In some embodiments, the disclosure provides a process
comprising: (a) contacting an unmature distilled spirit with wood
and actinic light at a wavelength spectrum ranging from 400 nm to 1
mm for at least one hour to give an actinic light-treated distilled
spirit mixture; then (b) providing heat to a mixture consisting
essentially of the actinic light treated spirit mixture and wood,
to maintain a temperature between about 140.degree. F. and about
170.degree. F. for a period of time ranging from about 24 hours to
about 336 hours; and then (c) percolating air through the mature
spirit of step (c) in a container with a headspace at a gauge
pressure between about -25 inHg and about -30 inHg until alcohol
concentration of the mature spirit is reduced by between about 1%
to about 2% by volume, and until the total volume of the mature
spirit is reduced by about 10% or less.
[0020] In other embodiments, the present disclosure provides a
process comprising: (a) contacting an unmature distilled spirit
with wood and actinic light at a wavelength spectrum ranging from
400 nm to 1 mm to give an actinic light-treated distilled spirit
mixture; and then (b) contacting the actinic-light treated spirit
mixture and wood at a temperature between about 140.degree. F. and
about 170.degree. F. for a period of time ranging from about 24
hours to about 336 hours; and then (c) percolating air through the
mature spirit of step (b) in a container with a headspace at a
gauge pressure between about -25 inHg and about -30 inHg until
alcohol concentration of the mature spirit is reduced by between
about 1% to about 2% by volume, and until the total volume of the
mature spirit is reduced by about 10% or less.
[0021] The present disclosure also provides a process for producing
a mature spirit comprising: (a) providing heat to a mixture
consisting essentially of an unmatured distilled spirit and wood,
to maintain a temperature between about 140.degree. F. and about
170.degree. F. for a period of time ranging from about 24 hours to
about 336 hours to give a distilled spirit mixture; (b) contacting
the distilled spirit mixture with wood and actinic light at a
wavelength spectrum ranging from 400 nm to 1 mm for at least one
hour to give an actinic light-treated distilled spirit mixture; (c)
providing heat to the actinic light-treated distilled spirit
mixture produced in step (b) to maintain a temperature between
about 140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to produce the
mature spirit; and (d) percolating air through the mature spirit of
step (c) in a container with a headspace at a gauge pressure
between about -25 inHg and about -30 inHg until alcohol
concentration of the mature spirit is reduced by between about 1%
to about 2% by volume, and until the total volume of the mature
spirit is reduced by about 10% or less; wherein the wood has been
washed with a solution of carboxylic acid in water prior to step
(a), and wherein steps (a), (b), (c), and (d) are separate and
sequential.
[0022] The present disclosure also provides a process comprising:
(a) contacting an unmature distilled spirit with wood and actinic
light at a wavelength spectrum ranging from 400 nm to 1 mm for at
least one hour to give an actinic light-treated distilled spirit
mixture; then (b) providing heat to a mixture consisting
essentially of the actinic light treated spirit mixture and wood to
maintain a temperature between about 140.degree. F. and about
170.degree. F. for a period of time ranging from about 24 hours to
about 336 hours, and then (c) percolating air through the mature
spirit of step (b) in a container with a headspace at a gauge
pressure between about -25 inHg and about -30 inHg until alcohol
concentration of the mature spirit is reduced by between about 1%
to about 2% by volume, and until the total volume of the mature
spirit is reduced by about 10% or less; wherein the wood has been
washed with a solution of carboxylic acid in water prior to step
(a), and wherein steps (a), (b), and (c) are separate and
sequential.
[0023] Moreover, the present disclosure provides a process
comprising: (a) contacting an unmature distilled spirit with wood
at a temperature between about 140.degree. F. and about 170.degree.
F. for a period of time ranging from about 24 hours to about 336
hours to give a distilled spirit mixture; (b) contacting the
distilled spirit mixture with wood and actinic light at a
wavelength spectrum ranging from 400 nm to 1 mm; and (c)
percolating air through the mature spirit of step (b) in a
container with a headspace at a gauge pressure between about -25
inHg and about -30 inHg until alcohol concentration of the mature
spirit is reduced by between about 1% to about 2% by volume, and
until the total volume of the mature spirit is reduced by about 10%
or less; wherein the wood has been washed with a solution of
carboxylic acid in water prior to step (a), and wherein steps (a),
(b), and (c) are separate and sequential.
[0024] Additional embodiments and features are set forth in part in
the description that follows, and will become apparent to those
skilled in the art upon examination of the specification, or may be
learned by the practice of the embodiments discussed herein. A
further understanding of the nature and advantages of certain
embodiments may be realized by reference to the remaining portions
of the specification and the drawings, which forms a part of this
disclosure.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] The disclosure will be readily understood by the following
detailed description in conjunction with the accompanying drawings,
wherein like reference numerals designate like structural elements.
The drawings provide exemplary embodiments or aspects of the
disclosure and do not limit the scope of the disclosure.
[0026] FIG. 1 shows the gas chromatograph mass spectrometry (GCMS)
chromatogram from an unprocessed rum sample.
[0027] FIG. 2 shows the GCMS chromatogram from a sample of a
commercially available rum which has been aged for 33 years by
conventional aging techniques.
[0028] FIG. 3 shows the GCMS chromatogram from a rum sample that
was subjected to heating in accordance with Example 3 but was not
subjected to actinic light.
[0029] FIG. 4 shows the GCMS chromatogram from a rum sample
subjected to actinic light but not to heat in accordance with
Example 4.
[0030] FIG. 5 shows the GCMS chromatogram from a rum sample that is
a mixture of rum subjected to heat and rum subjected to actinic
light in accordance with Example 5.
[0031] FIG. 6 shows the GCMS chromatogram from a rum sample that
has been processed with both heat and light in accordance with
Example 6.
[0032] FIG. 7 depicts a wooden barrel for the heat process with a
cutaway to show the barrel's internals.
[0033] FIG. 8 depicts a sealed vessel for the heat process with a
cutaway to show the vessels internals.
DETAILED DESCRIPTION
[0034] The disclosure pertains to processes for producing a
distilled spirit having characteristics associated with a mature
distilled spirit. The distilled spirit produced in accordance with
the process has many of the characteristics associated with a
matured distilled spirit produced in accordance with industry
standards, but is advantageously produced in a shortened timeframe
while eliminating the evaporation problem and greatly reducing the
"off flavors" associated with excess ethyl acetate. By contacting
an unmatured distilled spirit with wood at increased temperatures
and contacting the spirit with actinic light, the maturation
process can be shortened without reducing the quality of the
spirit. In particular, it has surprisingly been found that the
processes described herein produce a spirit having similar chemical
markers as a 33-year-old spirit in a significantly reduced period
of time.
[0035] This disclosure pertains also to processes for producing a
distilled spirit having characteristics associated with a mature
distilled spirit. The distilled spirit produced in accordance with
the process has many of the characteristics associated with a
matured distilled spirit produced in accordance with industry
standards, but is advantageously produced in a shortened timeframe
while reducing the evaporation problem and greatly reducing the
"off flavors" associated with excess volatile organic compounds
(VOCs), such as methanol and ethyl acetate. By percolating air
through a distilled spirit in a container with a headspace at a
gauge pressure between about -25 inHg and about -30 inHg until the
alcohol concentration of the distilled spirit is reduced by between
about 1% and about 2% by volume, and until the total volume of the
distilled spirit is reduced by about 10% or less, the concentration
of unwanted chemical markers is decreased and the concentration of
desired chemical markers is increased, without the drastic volume
losses associated with traditional aging.
[0036] The distilled spirit in step (a) may begin with an alcohol
concentration greater than 60% by volume, and the process may then
further comprise (b) diluting the distilled spirit of step (a) with
water to an alcohol concentration between about 50% and about 55%
by volume, and then (c) percolating air through the diluted
distilled spirit in the container with the headspace at a gauge
pressure between about -25 inHg and about -30 inHg until the
alcohol concentration of the diluted distilled spirit is reduced by
an additional amount of between about 0.3% and about 1% by
volume.
[0037] Additional embodiments and features are set forth in part in
the description that follows, and in part will become apparent to
those skilled in the art upon examination of the specification, or
may be learned by the practice of the embodiments discussed herein.
A further understanding of the nature and advantages of certain
embodiments may be realized by reference to the remaining portions
of the specification, the drawings, and descriptions, which forms a
part of this disclosure.
[0038] As used herein, a spirit refers to any distilled spirit. In
particular embodiments, the spirit may be a sugar cane-based,
grain-based, fruit-based, or agave-based spirit, such as rum,
tequila, mescal, whiskey, brandy, gin, vodka, or combinations
thereof. The distilled spirit may be a sugar cane-based spirit,
such as rum. The distilled spirit may be a grain-based spirit, such
as whiskey, bourbon, or scotch. The distilled spirit may be a
fruit-based, such as brandy. The distilled spirit may be an
agave-based spirit, such as tequila or mescal. The distilled spirit
may be rum. The distilled spirit may be tequila. The distilled
spirit may be mescal. The distilled spirit may be whiskey. The
distilled spirit may be brandy. The distilled spirit may be gin.
The distilled spirit may be vodka.
[0039] The spirit may be newly distilled or it may have already
undergone a standard or accelerated aging process. For example, a
15-year whiskey may be treated as disclosed herein to produce a
whiskey having a 20-year or 30-year chemical profile. In other
words, when a process disclosed herein is applied to aged spirits,
the ratios of chemical markers are altered and make the distilled
spirit appear much older than it is. The process works on any
spirit, including un-aged spirits such as vodka, gin, un-aged rum,
un-aged tequila, un-aged brandy (eau de vie), and the like. Here,
the process removes the sensation alcohol burn and trace
methanol.
[0040] A distilled spirit having the characteristics associated
with a matured distilled spirit, as used herein, describes a
spirit, which, by one or more chemical markers, has attained
characteristics associated with spirits aged in accordance with
industry standards. Such standards, for example, include aging a
spirit in wood over a period of time greater than 1, 5, 10, 15, 20,
25 or 30 years. The characteristics associated with a matured
distilled spirit may include taste, aroma, and body profiles, such
as smoothness.
[0041] As used herein, lux hours refers to the amount of light
exposure in a given hour. Specifically, cumulative lux hours can be
defined as how much energy from light should be provided over a
specified period of time.
[0042] The disclosed process rapidly removes undesired chemical
markers and concentrates desired chemical markers. A mature
distilled spirit having the characteristics associated with a
matured distilled spirit, as used herein, describes a spirit, which
has attained a flavor and aroma profile organoleptically similar to
spirits aged with wood for many years, and typically showing a
chemical profile containing key chemical markers in particular
proportions.
[0043] Traditionally, producing wood-aged distilled spirits has
included carboxylic acid esterification, phenolic acid
esterification, and the formation of complex esters, including both
phenolic and carboxylic acids. Carboxylic acid esters are
responsible for the fruity aromas and tastes in distilled spirits.
Carboxylic precursor acids are derived from the yeast and bacteria
during fermentation. If organic materials are used for the
container in which these reactions occur, those materials also
influence the process. For example, where a charred or toasted oak
barrel is used, carboxylic precursor acids are also derived from
thermal decomposition of the oak polymer, hemi-cellulose, found in
the inner lining of the barrel.
[0044] Off-flavors are various flavorful or aromatic compounds
present in spirits that are often described by connoisseurs using
colorful terms (e.g., "sulfury," "solventy," "meaty," "acidic,"
"metallic," "vegetal," etc.). Carboxylic precursor acids are
largely responsible for "off-flavors" in distilled spirits. Another
common flaw with a solvent-like "off flavor" is produced by
build-up of ethyl acetate in the maturing spirit. Other compounds,
such as methanol, may not impact flavor but do diminish the
consumers' enjoyment of the distilled spirit.
[0045] The disclosed process favors the removal of methanol above
other compounds present in distilled spirits. Previously known
methods were very costly to remove methanol from distilled spirits.
Methanol is partly responsible for hangovers and its removal is
critical for consumer quality perceptions. Without wishing to be
bound by theory, methanol is removed from the distilled spirit as
its azeotrope or eutectic. When a second sequential negative
pressure treatment is used, the distilled spirits are diluted with
water to bottling strength, thereby changing the azeotropic
distribution within the spirits. The method may also remove the
perception of heat in all types of spirits. This is something
consumers use to perceive quality in distilled spirits.
[0046] Historically, ethyl acetate concentration was used as a
marker for the progress of aging where higher amounts indicate
greater maturation time. But, ethyl acetate is not itself desirable
and adds a flavor and aroma comparable to paint thinners. Moreover,
samples of distilled spirits receiving high reviews, comparable or
in some cases better than an aged spirit, do not always have a high
ethyl acetate concentration. Using modern techniques, highly prized
spirits can be analyzed for their chemical make-up. Using these
data, chemical markers can be selected as a model for a mature
spirit. Surprisingly, these chemical markers provide advantages
over the traditional measurement of ethyl acetate concentration to
determine age. In particular, the chemical markers set forth herein
are desirable for modeling purposes because, unlike ethyl acetate,
the chemical markers contribute to the desired flavor profile. In
one embodiment, ethyl acetate concentrations are reduced to a
concentration less than about 200,000 .mu.g/L. In another
embodiment, the ethyl acetate concentrations range between about
50,000 .mu.g/L and about 170,000 .mu.g/L.
[0047] Fatty acids are structurally simple and even with their
derivatives can be subdivided into well-defined families. Among
straight-chain fatty acids, the simplest are referred to as
saturated fatty acids. They have no unsaturated linkages in the
carbon backbone and cannot be altered during hydrogenation or
halogenation process. Saturated fatty acids tend to be solid at
room temperature and their melting points increase with increasing
chain length.
[0048] The fatty acid chain lengths may range between 2 and 80
carbon atoms, and commonly between 12 and 24 carbons. With a chain
length between 2 and 6 carbon atoms, the fatty acids are called
short-chain fatty acids, or C.sub.2-C.sub.6 acids. Examples of
suitable short-chain fatty acids include, but not limited to,
formic acid, acetic acid, proprionic acid, butyric acid, isobutyric
acid, valeric acid, and isovaleric acid. C.sub.2-C.sub.6 fatty acid
esters include the C.sub.2 fatty acid ester ethyl acetate.
[0049] With a chain length from 6 to 12 carbon atoms, the fatty
acids are called medium-chain fatty acids, or C.sub.6-C.sub.12
fatty acids. A common subgroup of medium-chain fatty acids is
C.sub.8-C.sub.10 fatty acids, having 8 to 10 carbon atoms in the
chain. Examples of suitable medium-chain fatty acids include, but
are not limited to, caproic acid (C.sub.6), enanthic acid
(C.sub.7), caprylic acid (C.sub.8), pelargonic acid (C.sub.9),
capric acid (C.sub.10), undecylic acid (C.sub.11), and lauric acid
(C.sub.12).
[0050] With a chain length between 12 and 24, the fatty acids are
called a long-chain fatty acids, or C.sub.12-C.sub.24 fatty acids.
The same chain length ranges apply to fatty acid derivatives, such
as fatty acid esters. Examples of suitable long-chain fatty acids
include, but are not limited to, tridecylic acid (C.sub.13),
myristic acid (C.sub.14), pentadecanoic acid (C.sub.15), palmitic
acid (C.sub.16), margaric acid (C.sub.17), stearic acid (C.sub.18),
nonadecylic acid (C.sub.19), arachidic acid (C.sub.20), and
heneicosylic acid (C.sub.21).
[0051] The fatty acids may be unsaturated, such as an .omega.-3
unsaturated fatty acid, for example, .alpha.-linolenic acid (18:3),
stearidonic acid (18:4), eicosapentaenoic acid (20:5), and
docosahexaenoic acid (22:6); an .omega.-6 unsaturated fatty acid,
for example, linoleic acid (18:2), .gamma.-linolenic acid (18:3),
dihomo-.gamma.-linolenic acid (20:3), arachidonic acid (20:4), and
adrenic acid (22:4); an .omega.-7 unsaturated fatty acid, for
example, palmitoleic acid (16:1), vaccenic acid (18:1), and
paullinic acid (20:1); or an .omega.-9 unsaturated fatty acid, for
example, oleic acid (18:1), elaidic acid (trans-18:1), gondoic acid
(20:1), erucic acid (22:1), nervonic acid (24:1), and mead acid
(20:3).
[0052] Fischer esterification of fatty acids and alcohol is a
well-understood and commonly practiced chemical reaction. A typical
laboratory process involves heating a solution of fatty acids and
alcohols under reflux in the presence of an acid catalyst. In
laboratory settings, strong acids (e.g., sulfuric acid) are
typically employed as the catalyst, but this can be incompatible
with spirit making where other functional groups are sensitive to
stronger acids and where chemical additives are typically
prohibited. It has long been known that Fischer esterification can
also be completed using weak acid catalysts, but at the expense of
relatively slow reaction rates. Where charred or toasted oak
barrels are used during the maturation of distilled spirits, weak
acids may be gradually extracted from organic material in the walls
of the barrel. It typically takes years for esters to accumulate
using weak acid catalysts derived from the barrel, although it has
been observed that in warmer environments (i.e., modestly heated
within the range of normal atmospheric conditions less than
120.degree. F.) the process can be accelerated significantly (from
decades to years). This early form of accelerated aging comes at
the cost of increased evaporation from the barrel. Often as much as
50% of the product can be lost to evaporation.
[0053] When the alcohol component is glycerol, the fatty acid
esters produced can be monoglycerides, diglycerides, or
triglycerides. Dietary fats are chemically triglycerides. Suitable
examples of fatty acid esters include, but are not limited to,
2-arachidonoylglycerol, ascorbyl palmitate, ascorbyl stearate,
cetyl myristoleate, cetyl palmitate, ethyl decadienoate, ethyl
decanoate, ethyl eicosapentaenoic acid, ethyl macadamiate, ethyl
octanoate, ethyl palmitate, ethylhexyl palmitate, glycerol
monostearate, glyceryl hydroxystearate, glycol distearate, glycol
stearate, isopropyl palmitate, monoctanoin, monolaurin,
2-oleoylglycerol, polyglycerol polyricinoleate, and
virodhamine.
[0054] Phenolic aldehydes also play a major role producing aromas
similar to vanilla, pipe tobacco, and smoke. Phenolic aldehydes are
largely derived from thermally broken down oak polymers found
within the inner lining of the barrel. Complex esters are
responsible for complex honeyed aromas in distilled spirits. The
complex esters are generally produced from the chemical reactions
of both carboxylic and phenolic acids/aldehydes with alcohols
during the time in the barrel or other container. Phenolic
aldehydes are derivatives of phenol. Suitable examples of phenolic
aldehydes include, but are not limited to, hydroxybenzaldehydes,
protocatechuic aldehyde, vanillin, isovanillin, 2,3,4-trihydroxy
benzaldehyde, sinapaldehyde
(3-(4-hydroxy-3,5-dimethoxyphenyl)prop-2-enal), and syringaldehyde
(4-hydroxy-3,5-dimethoxybenzaldehyde).
[0055] Wood extraction is the process that gives distilled spirits
their color and astringent "oaky" and "smoky" taste. Traditionally,
this is attributed to tannins (polyphenols). Interestingly, our
analysis of mature spirits did not find significant evidence of
tannins. But instead found myriad less complex wood derived phenols
such as sinapaldehyde and syringaldehyde. These oak-extracted
compounds proved unexpectedly useful as markers for monitoring the
aging process described below.
[0056] Esterification and the extraction of wood compounds from the
wood container are some of the primary reactions taking place in
the maturation process of distilled spirits. Because these
processes run concurrently, and often interact with or depend on
each other as well as the material and other conditions of their
environment over time, it is very difficult to deviate very far
from traditional methods while still achieving similar results. For
example, rapid oak extraction may not provide enough time for
interaction with a wood container to pick up some of the more
subtle and complex flavors present in traditionally aged spirits.
Much of the expense in spirit making stems from the long latency in
creating the end product as well as the product evaporation from
the barrel. Stock must be stored, often in climate-controlled
environments, and tested repeatedly during maturation. But, it is
difficult to predict markets many years out. Makers that produce
too much product fail to maximize their investment, whereas those
that produce too little fail to capture potentially significant
portions of the upside.
[0057] In one embodiment, a mature spirit can be characterized by
the decreasing concentrations of one or more chemical markers.
Through operation of a process disclosed herein, the concentration
in the distilled spirit may decrease for one or more chemical
markers selected from the group consisting of methanol,
C.sub.2-C.sub.6 fatty acids, and C.sub.2-C.sub.6 fatty acid
esters.
[0058] The concentration in the distilled spirit may increase for
one or more chemical markers selected from the group consisting of
vanillin, phenylated esters, C.sub.7-C.sub.24 fatty acid esters,
and phenolic aldehydes. These things are responsible for the flavor
described as the "finish" in distilled spirits. Three markers in
particular, are thought to be particularly useful for defining a
mature spirit: sinapaldehyde, ethyl decanoate, and ethyl
dodecanoate. Ethyl decanoate and ethyl dodecanoate are often found
in unmature spirits at low concentrations. Sinapaldehyde is
typically not found in an unmature spirit.
[0059] The distilled spirit may be characterized by an increase in
concentration of sinapaldehyde, ethyl dodecanoate, and ethyl
decanoate. The distilled spirit may be characterized by an increase
in concentration of sinapaldehyde. In one embodiment, a mature
spirit may be characterized by an increase of at least about
threefold for ethyl dodecanoate over an unmature spirit. In another
embodiment, a mature spirit is characterized by an increase of at
least about threefold for ethyl decanoate over an unmature spirit.
Increased concentrations may be assessed by any method known in the
art.
[0060] A spirit that presents these three compounds in relative
proportion (as assessed by peak height measured by gas
chromatography mass spectrometry (GCMS)) typically has desirable
flavor characteristics. In this regard, a mature spirit may also be
characterized by a sinapaldehyde peak greater than 80% and less
than 200% of the peak height of ethyl decanoate and ethyl
dodecanoate as measured by GCMS. Without being bound to any theory,
it is believed that sinapaldehyde concentration is
disproportionately important in creating a spirit that meets the
organoleptic properties of a mature spirit.
[0061] In another embodiment, a mature spirit is one that produces
relative peak heights that are substantially similar to the peak
heights shown in FIG. 5 for sinapaldehyde, ethyl decanoate, and
ethyl dodecanoate. "Substantially similar," as used herein, refers
to a relative peak height differing by no more than 30%, no more
than 25%, no more than 20%, no more than 15%, no more than 10%, no
more than 5%, or no more than 2%. In still another embodiment, a
mature spirit is one that produces relative peak heights that are
substantially similar to the relative peak heights shown in FIG. 5
for sinapaldehyde, ethyl decanoate, ethyl dodecanoate, and acetal.
In still a further embodiment, a mature spirit is one that produces
relative peak heights that are substantially similar to the
relative peak heights shown in FIG. 5 for sinapaldehyde, ethyl
decanoate, ethyl dodecanoate, acetyl, and syringaldehyde.
[0062] In yet another embodiment, a mature spirit is one that
produces relative peak heights that are substantially similar to
the relative peak heights shown in FIG. 6 for sinapaldehyde, ethyl
decanoate, and ethyl dodecanoate. In still another embodiment, a
mature spirit is one that produces relative peak heights that are
substantially similar to the relative peak heights shown in FIG. 6
for sinapaldehyde, ethyl decanoate, ethyl dodecanoate, and acetal
(1,1-diethoxyethane). In yet another embodiment, a mature spirit is
one that produces relative peak heights that are substantially
similar to the relative peak heights shown in FIG. 6 for
sinapaldehyde, ethyl decanoate, ethyl dodecanoate, acetal, and
syringaldehyde.
[0063] The unmatured distilled spirit is a spirit that has not
attained the markers or characteristics associated with a matured
distilled spirit. The "unmatured distilled spirit," as described
herein, refers to white or raw spirits, as well as partially
matured spirits, provided that the unmatured distilled spirit is
lacking in certain characteristics of a matured spirit. The
unmatured distilled spirit, as described herein, has an alcohol
content of at least 50% by volume. In some embodiments, the alcohol
content of the unmature distilled spirit is between 50% and 80% by
volume.
[0064] The term "distilled spirit mixture," as used herein, refers
to any distillate on the spectrum from matured to unmatured. The
term "distillate" as used herein refers to the liquid composition
in the vessel and may include an unmatured distilled spirit, a
matured distilled spirit, or a distilled spirit mixture.
[0065] The unmatured distilled spirit is contacted with wood in a
vessel. In one embodiment, the wood is provided as the vessel for
holding the distillate. In such embodiments, the vessel is, for
example, an oak barrel. In other embodiments, wood may be provided
to the inside of the reaction vessel, which is optionally made of
wood. Non-limiting examples of wood can include, but are not
limited to, wood strips, wood chips, wood pellets, wood planks,
wood powder, wood pulp, and the like. For example, wood chips or
wood pellets may be added such that they are submerged or floating
on top of the distillate. Wood may also be provided as various
structural configurations within the vessel including as baffles or
packing. In still other embodiments, wood may include wood extracts
and raw acids designed to mimic the characteristics of wood. In one
embodiment, the wood is oak.
[0066] Of the various advantages of the present disclosure, one is
that no additional ingredients or acids are provided to facilitate
the process. In this regard, the process is free of additives.
Without being bound to any particular theory, it is thought that
the inventive process rapidly extracts acids from the wood. These
acids facilitate the esterification process without the need for
additives beyond the wood and the unmatured distilled spirit.
A. Sequential Temperature and Light Processing
[0067] One aspect of the present disclosure provides a process for
producing a mature spirit using sequential temperature and light
processing. In this regard, the process comprises the steps of (a)
contacting an unmatured distilled spirit with wood at a temperature
between about 140.degree. F. and about 170.degree. F. for a period
of time ranging from about 24 hours to about 336 hours to give a
distilled spirit mixture; (b) contacting the distilled spirit
mixture with wood and actinic light having a wavelength spectrum
ranging from 400 nm to 1 mm for at least one hour to give an
actinic light-treated distilled spirit mixture; and (c) providing
heat to the actinic light-treated distilled spirit mixture produced
in step (b) to maintain a temperature between about 140.degree. F.
and about 170.degree. F. for a period of time ranging from about 12
hours to about 336 hours to produce the mature spirit.
[0068] (i) First Thermal Process
[0069] In the sequential process described herein, the unmatured
spirit is be subjected to thermal processing. In this regard, the
unmatured distilled spirit is contacted with the wood at a
temperature ranging from about 140.degree. F. to about 170.degree.
F. In alternate embodiments, the temperature ranges from about
140.degree. F. to about 150.degree. F., from about 145.degree. F.
to about 150.degree. F., from about 150.degree. F. to about
160.degree. F., or from about 160.degree. F. to about 170.degree.
F. In other embodiments, the temperature may be about 140.degree.
F., about 145.degree. F., about 150.degree. F., about 155.degree.
F., about 160.degree. F., about 165.degree. F., or about
170.degree. F.
[0070] The time period needed to convert the unmatured distilled
spirit to a distilled spirit mixture having partial characteristics
associated with a matured spirit, for example, as shown in FIG. 3,
depends on factors such as the starting composition of the
unmatured distilled spirit and the temperature at which the process
is conducted. In some embodiments, a temperature between about
140.degree. F. and about 170.degree. F. is provided for a period of
time ranging from about 12 hours to about 336 hours. In alternate
embodiments, a temperature between about 140.degree. F. and about
170.degree. F. is provided for a period of time ranging from about
12 hours to about 24 hours, from about 24 hours to about 48 hours,
from about 48 hours to about 96 hours, from about 96 hours to about
168 hours, from about 168 hours to about 226 hours, or from about
226 hours to about 336 hours.
[0071] The heating is conducted in a sealed vessel or under reflux
such that evaporation of volatile compounds is prevented. The
pressure inside the vessel can and will vary in different
embodiments of the disclosure. In general, the internal pressure of
the vessel housing the reaction components climbs to a maximum of
about 6 pounds per square inch (psi). The typical range of
pressures in the vessel is between 2 psi and 6 psi, but can be
altered to relieve pressure and maintain an operating pressure of
less than 1 psi while still achieving the desired chemical
reactions.
[0072] In one embodiment, the temperature is maintained between
about 140.degree. F. and about 150.degree. F. for a period of time
ranging from about 168 hours to about 226 hours.
[0073] In another embodiment, the temperature is maintained between
about 150.degree. F. and about 160.degree. F. for a period of time
ranging from about 24 hours to about 72 hours.
[0074] Generally, heat is applied continuously through the given
time period. But, heat may also be provided for the given time
period in a manner that is not continuous, for example, at
intervals so long as heat is provided totaling the stated time
period. At the end of this time period, a first distilled spirit
mixture is provided. In this embodiment of the disclosure, the
first distilled spirit mixture produced by the heat process is
further reacted as described below.
[0075] The heat process may be conducted in an apparatus as shown
in FIG. 7, which shows a cutaway view of one possible internal
configuration. The vessel 1 may be a wooden barrel.
[0076] In the embodiment depicted in FIG. 8, a cutaway is shown
using dashed lines to reveal another possible internal confirmation
of the vessel 1, where vessel 1 may be a stainless steel container.
In this embodiment, the wood 12 is provided as chips, planks,
pellets, or powder and submerged in or floating on top of the
distillate 2.
[0077] For both FIG. 7 and FIG. 8, heat may be applied to the
distillate 2 inside the vessel 1 via a heat source 4. In one
embodiment, the vessel is sealed under pressure. In another
embodiment, the vessel is heated under reflux to prevent
evaporation of volatile compounds. Any method for introducing
sufficient heat to the distillate including an internal electrical
heating element 9 may be used. In such an embodiment, temperature
may be controlled by manipulating electrical current in the
internal electrical heating element 9 circuit. In alternate
embodiments the heat source 4 is external and may be used with a
conduit 16, conductor, or the like. In one non-limiting example,
steam 18 may be created using an external boiler as the heat source
4 in one embodiment, then passed through a conduit 16 running
through the vessel 1, wherein a conductive portion 16 of the
conduit is submerged in the distillate 2. In such an embodiment,
the temperature of the distillate 2 may be controlled by varying
the amount of steam 18 produced by the boiler. Such control may be
provided by valves or similar means that are not pictured.
[0078] In one embodiment, the temperature of the distillate 2 in
the vessel 1 is brought up to a temperature of about 160.degree. F.
for a period of up to 48 hours. This process simultaneously
extracts wood derived compounds and acids, some of which are
thought to be esterification catalysts. In one embodiment, the
temperature of the distillate is measured via a temperature sensor
5. Any known temperature sensor may be used. The temperature of the
distillate 2 may be controlled by manually manipulating the heat
source 4. In an alternate embodiment, an electronic temperature
sensor is coupled 10 to a controller 7. The controller 7 may be
configured to present an alert (e.g., flash a light, produce a
sound, produce an electrical signal, transmit a text message,
e-mail or other electronic communication, etc.) when the
temperature of the distillate 2 is outside of a provided range.
Optionally, the controller 7 may be coupled to the heat source 4,
in which case, the controller is configured to manipulate the heat
source to keep the temperature of the distillate 2 within the
provided range.
[0079] Heating in accordance with the disclosure triggers the
esterification of free volatile acids and alcohols in the
distillate 2, while the headspace 3 provides for reflux within the
vessel 1 allowing any weak acids to be rapidly extracted from the
wood. These weak acids, in combination with elevated temperatures,
appear to help catalyze the esterification of free acids in the
distillate per the Fischer process, which would otherwise take many
years in traditional containers.
[0080] The pressure inside the container may be measured by a
pressure sensor 6. The pressure sensor 6 may be coupled to the
controller 7. The pressure sensor may be configured to provide
alerts if the pressure becomes too high. The pressure sensor may
optionally be configured to communicate to open a release valve if
the pressure is too high.
[0081] (ii) Actinic Light Process
[0082] The first distilled spirit mixture provided in step (i) is
generally allowed to cool and transferred for processing with
actinic light. In accordance with one embodiment of the disclosure,
the first distilled spirit mixture is contacted with actinic light
having a wavelength spectrum in the range of 400 nm to 1 mm for at
least one hour to give an actinic light-treated distilled spirit.
In at least one instance, the actinic light process can be cooled
via a cooling system coupled with the actinic light treatment
container.
[0083] The actinic light process is thought to operate through a
combination of the photodegradation of wood polymers,
photodegradation of chemical compounds in the distilled spirit
mixture (including further degradation of products of the
photodegradation of wood polymers), and photocatalytic effects. The
photodegradation of the organic polymers in wood can be achieved
using broad spectrum electromagnetic radiation or very narrow
ranges depending on the embodiment of the systems and methods
employed.
[0084] The actinic light process takes place in a container that
allows amounts of light to pass through. The container is filled
with the spirit to be processed and is also generally filled with
wood as described in the previous step. In one embodiment, glass
carboys are used. The actinic light may come from a variety of
sources including natural, synthetic, or a combination thereof.
Generally, the exposure in this step can be at least one hour. In
some embodiments, the exposure can be up to 336 hours.
[0085] In an alternative embodiment, the exposure in this step can
be at least 2,280,000 lux hours, but sometimes as high as
20,000,000 lux hours. In other embodiments, the total exposure is
at least 1,000,000 lux hours, at least 1,500,000 lux hours, at
least 2,000,000 lux hours, at least 2,500,000 lux hours, or at
least 3,000,000 lux hours. Where very high concentrations of the
chemical markers described herein are sought even greater exposures
might be appropriate.
[0086] In one embodiment, the first distilled spirit mixture is
exposed to the entire broad spectrum of wavelengths from 400 nm to
1 mm. In an alternative embodiment, specific wavelengths of the
light found in the 400 nm to 1 mm range may be concentrated in
relation to others to produce varying effects in the maturing
spirits. For example, wavelengths used may be selected from, but
are not limited to, about 400 nm to about 600 nm, from about 550 nm
to about 650 nm, from about 600 nm to about 700 nm, from about 650
nm to about 750 nm, from about 700 nm to about 800 nm, from about
750 nm to about 850 nm, from about 800 nm to about 900 nm, from
about 850 nm to about 950 nm, from about 900 nm to about 1000 nm,
from about 1000 nm to about 2000 nm, from about 2000 nm to about
6000 nm, from about 6000 nm to about 1 mm, or any range therein. In
particular, the wavelength may range between about 600 nm and about
1000 nm. In the alternative, the wavelength may range between about
183 nm to about 750 nm, about 200 nm to about 2000 nm, from about
375 nm to about 6000 nm, or any range therein. This process may
also be used to isolate the wavelengths most responsible for the
effects observed in the spirit maturation process. Where specific
temperatures are needed to trigger the reactions with the actinic
light, heaters may be used in conjunction with special lamps which
produce specific wavelengths of light at a specific temperature.
Using specific wavelengths alone, or with heaters, to mature the
spirit, would allow for lower energy consumption and lower total
.mu.W/cm.sup.2 to accomplish the same tasks.
[0087] The time period over which the actinic light process is
conducted can and will vary over different embodiments. Where
natural light is used, the total exposure to actinic light may
range from about 100 hours to about 500 hours, from about 250 hours
to about 750 hours, from about 500 hours to about 1000 hours, from
about 750 hours to about 1250 hours, or from about 1000 hours to
about 1500 hours. Where synthetic lights are used, the total
exposure to actinic light may range from about 1 hour to about 12
hours, from about 12 hours to about 24 hours, from about 24 hours
to about 48 hours, from about 48 hours to about 96 hours. If
artificial lights are used that provide a very low lux value, time
is increased proportionally to achieve the lux hour value. In
addition, the time period over which the actinic light process is
conducted can be shorted when a cooling system is coupled with the
actinic light processing container. For example, the actinic light
process can be accelerated to a time as brief as 30 minutes by
actively cooling the distilled spirit mixture to maintain the
temperature below boiling point, allowing a technician to increase
the amount of energy applied in the form of actinic light. In at
least one example, the total exposure to actinic light may range
from about 30 minutes to about 12 hours, from about 30 minutes to
about 2 hours, or from about 30 minutes to about one hour.
[0088] It is generally understood that the time required to
complete the esterification chemical reaction is directly affected
by temperature, with higher temperatures yielding shorter
processing times. The heat cycle times may be shortened to as
little as one hour by employing higher pressure vessels to allow
the distilled spirit mixture to be heated to above boiling point
safely, or by employing pressure vents to maintain safe operating
pressures. In yet another example, the distilled spirit mixture is
heated to boiling point in a container open to a reflux condenser,
allowing the esterification process to be as short as one hour. A
heat cycle can be achieved through conventional means, such as
immersion heaters or steam powered heaters or through
unconventional approaches such as ultrasonication.
[0089] The actinic light process may be conducted below the boiling
point of the spirit. In some embodiments, the amount or duration of
actinic light is controlled, for example, by exposing the spirit to
light in a discontinuous manner, by cooling the spirits, by
temporarily shielding the spirit from the actinic light, or by
other methods for controlling temperature that are known in the art
including, but not limited to, a cooling system. Cooling systems
compatible with the present methods and systems can include, but
are not limited to, inserting a cooling coil, partial cooling
jacket, or any method of cooling that allows the solution the be
kept below boiling point. In at least one instance the cooling
system can maintain the temperature of the spirit at a level
between about 130 and about 180 degrees Fahrenheit, including
between about 130 and about 140 degrees Fahrenheit, between about
140 and about 150 degrees Fahrenheit, between about 160 and about
170 degrees Fahrenheit, between about 170 and about 180 degrees
Fahrenheit, or any range therein. The system could also be fitted
with a very powerful cooling system that maintains the distilled
spirit mixture at room temperature or even below. This process may
also be carried out under reflux to prevent the evaporation of
volatile compounds allowing the process to be carried out at the
boiling point of the distilled spirit mixture.
[0090] Although it has been shown experimentally that pressure, in
particular pressure elevated above atmospheric pressure, is not
critical to the actinic light processing, the actinic light
processing is generally conducted at atmospheric pressures. The
light processing step may accommodate higher or lower
pressures.
[0091] In one embodiment, a tungsten halogen bulb is used to
provide the actinic light. The bulb has an average light
temperature of 2900.degree., and can produce light in a broad
spectrum of wavelengths, including wavelengths from 375 nm to 6000
nm. The spirits can be exposed to the light in a period of at least
one hour. In at least one embodiment, the sprits are placed in
clear containers where about 100 liters of spirit cover a square
meter. The area is illuminated to about 190,000 lux with the light
being toggled off and on in periods of about 2 to about 4 hours to
reach a total exposure of 4,500,000 lux hours. Lux hours, as used
herein, describes the light exposure in a given hour because it
describes the total luminescence in a given time. Radiant flux
measurements were unavailable because the data was not
available.
[0092] The experiments illustrates in FIGS. 1-6 employ tungsten
halogen bulbs which produce actinic light in the range of
approximately 375 nm to 6000 nm. In the alternative, a Mercury lamp
can be employed to produce actinic light in the range of
approximately 183 nm to 750 nm. In an additional alternative, a
Xenon blub can be employed to produce actinic light in the range of
approximately 200 nm to 2000 nm, coated halogen bulbs (heat lamps)
can be used to concentrate light in the range of approximately 600
nm to 6000 nm. While various wavelength spectrums can be employed,
it is critical that the actinic light applied triggers
photodegradation of the wood polymers as shown by a marked increase
in aldehydes produced through wood polymer decomposition such as
syringaldehyde, vanillin and coniferyl aldehyde.
[0093] In another embodiment, a distilled spirit is placed in a
translucent jar that was kept in a greenhouse for 168 hours to
achieve a total of approximately 4,200,000 lux hours.
[0094] In another embodiment, twenty 500-W halogen bulbs are used
to provide light to seventy jars. The lights are toggled on and off
for three days to provide the total lux hours needed for the
reaction.
[0095] In still another embodiment, 500-W halogen bulbs are shined
on both sides of a glass jar. The lights are toggled on and off for
14 hours to provide the total lux hours needed for the
reaction.
[0096] As indicated above, exposure to actinic light can alter the
amount of various chemical markers present in the spirit including,
but not limited to, vanillin, syringic aldehyde, coniferyl
aldehyde, which is a precursor to vanillin, hydroxymethylfurfural,
and vanillic acid. An increase in such chemical markers can
correlate to the desired taste of a matured spirit. For example,
the compounds indicated in Table 1, below, show at minimum a
1.5.times. increase in chemical marker beyond what could be
extracted from the same wood during only a heating process. Often
concentrations can reach 2.times. or greater that which is
available through a heating process. In at least one example, the
retention times as measured via GCMS of various chemical markers
after exposure to actinic light are provided in Table 1, below.
TABLE-US-00001 TABLE 1 Chemical Presence after Actinic Light
Exposure Vanillin 43.5 Syringic aldehyde 50.5 Coniferyl aldehyde
56.9 Hydroxymethylfurfural 42.4 Vanillic Acid 39.8
[0097] When the actinic light processing is complete, the resulting
actinic light-treated spirit mixture is removed from the light
source.
[0098] (iii) Second Thermal Process
[0099] The sequential process further involves a temperature
process conducted with the resulting mixture from Section A(ii). In
this regard, the actinic light-treated distilled spirit mixture is
heated to maintain the temperature of the actinic light-treated
distilled spirit mixture between about 140.degree. F. and about
170.degree. F. for a period of time ranging from about 12 hours to
about 336 hours in a sealed vessel or under reflux such that
evaporation of volatile compounds is prevented to produce a mature
spirit.
[0100] The process of heat treating the actinic light-treated
spirit is conducted in the manner described in Section A(i) except
that the process is performed on the actinic light-treated
distilled spirit mixture produced in accordance with Section A(ii).
Beneficially, this step triggers a marked reduction in ethyl
acetate concentrations generated during the actinic light
treatment, shown experimentally to be greater than 60%.
[0101] (iv) Optional Further Processing
[0102] Optionally, the spirit produced by the process described in
Sections A(i) through A(iii) may be followed by one or more
additional actinic light or thermal processing steps. For example,
a second actinic light processing step may be conducted on the
product obtained by the second thermal processing step. A third
thermal processing step may also be utilized after a second actinic
light processing step. In one embodiment, the processes includes a
further step of (d) of contacting the product of step (c) with wood
and actinic light at a wavelength spectrum ranging from 400 nm to 1
mm for at least one hour. In still another embodiment, the process
further comprises the step (e) of contacting the product of step
(d) with wood at a temperature between about 140.degree. F. and
about 170.degree. F. for a period of time ranging from about 24
hours to about 336 to give a first distilled spirit mixture.
[0103] In one embodiment, the sequential process may be repeated
until a desired chemical marker profile is obtained.
[0104] (v) Inverted Sequential Embodiment
[0105] In still another embodiment of the present disclosure, the
sequential process begins with an unmature distilled spirit
contacted with actinic light as described in Section (A)(ii) to
form an actinic light-treated distilled spirit mixture. Following
this treatment, the actinic light-treated distilled spirit mixture
is treated thermally as described in Section (A)(i). These steps
may be repeated until a desired flavor profile is obtained as
determined by the chemical markers described herein.
B. Alternative Sequential Temperature and Light Processing
[0106] An additional aspect of the present disclosure provides a
process for producing a mature spirit using an alternative
sequential temperature and light processing. In this regard, the
process comprises the steps of (a) providing heat to a mixture
consisting essentially of an unmatured distilled spirit; (b)
removing an amount of the distilled spirit mixture from step (a);
(c) contacting the amount of the distilled spirit mixture with wood
and actinic light at a wavelength spectrum ranging from 400 nm to 1
mm for at least one hour to give an actinic light-treated distilled
spirit mixture; (d) transferring the actinic light-treated
distilled spirit mixture to the remaining distilled spirit mixture
from step (b) to give a distilled spirit and actinic-light treated
distilled spirit mixture; and (e) providing heat to the distilled
spirit and actinic light-treated distilled spirit mixture to
maintain a temperature of between about 140.degree. F. and about
170.degree. F. for about 12 hours to about 336 hours to produce the
mature spirit.
[0107] (i) First Thermal Process
[0108] In the sequential process described herein, the unmatured
spirit is be subjected to thermal processing. In this regard, the
unmatured distilled spirit is contacted with the wood at a
temperature for a period of time as described in section A(i),
above.
[0109] (ii) Removal of Distilled Spirit Mixture
[0110] The first heat-treated distilled spirit mixture provided in
step B(i), is generally allowed to cool and a portion is removed
and then exposed to an actinic light process in step B(iii).
[0111] In an embodiment, the amount of first heat-treated distilled
spirit mixture removed from step B(i) can and will vary depending
upon the parameters used in the subsequent steps(s). In an
embodiment, the amount of first heat-treated distilled spirit
mixture removed from step B(i) may be from about 1% to about 99% of
the total volume. In some embodiments, the amounts of first
heat-treated distilled spirit mixture removed from step B(i) may be
from about 1% to about 99%, from about 1% to about 90%, from about
1% to about 85%, from about 1% to about 80%, from about 1% to about
75%, from about 1% to about 70%, from about 1% to about 65%, from
about 1% to about 45%, from about 1% to about 40%, from about 1% to
about 35%, from about 1% to about 30%, from about 1% to about 25%,
from about 1% to about 20%, from about 1% to about 15%, or from
about 5% to about 15% of the total volume. In other embodiments,
the amount of first heat treated distilled spirit mixture removed
from step B(i) may be from about 1% or about 10% of the total
volume.
[0112] (iii) Actinic Light Process
[0113] In accordance with one embodiment of the disclosure, an
amount of the first heat-treated distilled spirit mixture is
contacted with wood and actinic light having a wavelength spectrum
in the range of 400 nm to 1 mm for at least one hour to give a
heat-treated and actinic light-treated distilled spirit.
[0114] The actinic light process can be performed in a container
similar to that described in section A(i). The container can be
filled with an amount of first heat-treated distilled spirit to be
processed and is also generally filed with wood as described in the
previous step. In one embodiment, glass carboys are used. The
actinic light may come from a variety of sources including natural,
synthetic, or a combination thereof, as described above.
[0115] The actinic light process can be performed as described in
detail above. During the actinic light processing the wood off
gasses thereby increasing the pressure inside the vessel but may be
optionally vented to maintain a pressure level below about 10 psi.
The actinic light processing step may accommodate higher or lower
pressures depending on the characteristics and structure of the
vessel and eliminating the need for optional venting.
[0116] When the actinic light processing is complete, the resulting
amount of first heat-treated and actinic light-treated spirit
mixture is removed from the light source.
[0117] (iv) Transfer Process
[0118] The resulting amount of first heat-treated and actinic
light-treated spirit mixture is generally transferred to the first
heat-treated distilled spirit mixture from step B(i) that was not
subjected to the actinic light process to give a combined mixture
of first heat-treated distilled spirit and first heat-treated and
actinic light-treated distilled spirit mixture.
[0119] A person of ordinary skill in the art would appreciate that
all or a portion of the first heat-treated and actinic
light-treated spirit mixture may be transferred to all of the first
heat-treated distilled spirit mixture from step B(i) that was not
subjected to the actinic light process to give a combined mixture
of first heat-treated distilled spirit and first heat-treated and
actinic light-treated distilled spirit mixture. Alternatively, all
or a portion of the first heat-treated and actinic light-treated
spirit mixture may be transferred to a portion of the first
heat-treated distilled spirit mixture from step B(i) that was not
subjected to the actinic light process to give a combined mixture
of first heat-treated distilled spirit and first heat-treated and
actinic light-treated distilled spirit mixture.
[0120] (v) Second Thermal Process
[0121] The sequential process further involves a temperature
process conducted with the resulting mixture from Section B(iv). In
this regard, the combined mixture of first heat-treated distilled
spirit and first heat-treated and actinic light-treated distilled
spirit mixture is heated to maintain the temperature of between
about 140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours in a sealed vessel
or under reflux such that evaporation of volatile compounds is
prevented to produce a mature spirit.
[0122] The process of heat treating the combined mixture of first
heat-treated distilled spirit and first heat-treated and actinic
light-treated distilled spirit mixture is conducted in the manner
described in Section B(i) except that the process is performed on
the combined mixture of first heat-treated distilled spirit and
first heat-treated and actinic light-treated distilled spirit
mixture produced in accordance with Section B(iv). Beneficially,
this step triggers a marked reduction in ethyl acetate
concentrations generated during the actinic light treatment, shown
experimentally to be greater than 60%.
[0123] (vi) Optional Further Processing
[0124] Optionally, the spirit produced by the process described in
Section B(i) through Section B(v) may be followed by one or more
additional actinic light or thermal processing steps. For example,
a second actinic light processing step may be conducted on the
product obtained by the second thermal processing step from step
B(v). A third thermal processing step may also be utilized after a
second actinic light processing step. In one embodiment, the
processes includes a further step of contacting the product or a
portion of the product of step B(v) with wood and actinic light at
a wavelength spectrum ranging from 400 nm to 1 mm for at least one
hour. In still another embodiment, the process further comprises
contacting the product or a portion of the product that has been
optionally further processed with actinic light with wood at a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 24 hours to about 336 hours
to give a first distilled spirit mixture.
[0125] In one embodiment, the process or processes may be repeated
until a desired chemical maker profile or organoleptic profile is
obtained.
C. Mixed Batch Process
[0126] In another embodiment, the present disclosure provides a
mixed batch process for producing a mature spirit. In this
embodiment, the process comprises (a) contacting an amount of a
first unmatured distilled spirit with wood at a temperature between
about 140.degree. F. and about 170.degree. F. for a period of time
ranging from about 24 hours to about 336 hours to give a first
distilled spirit mixture; (b) contacting a second unmatured
distilled spirit with wood and actinic light at a wavelength
spectrum ranging from 400 nm to 1 mm for at least one hour to give
a second distilled spirit mixture; and (c) mixing the first and
second distilled spirit mixtures to produce the mature spirit.
Optionally, the mixture may then be heated with wood to between a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 24 hours to about 336 hours
to produce a mature spirit.
[0127] Step (a) of the process can be conducted as described in
Section (A)(i) or Section (B)(i). The resulting first distilled
spirit mixture is not reacted with light. Separately, a second
unmatured distilled spirit mixture is treated with actinic light as
described in Section (A)(ii) or Section (B)(iii). The resulting
second distilled spirit mixture is not necessarily treated by the
thermal processing step of Section (A)(i) or Section (B)(i).
Instead, the first distilled spirit mixture and the second
distilled spirit mixture are mixed together.
[0128] The first distilled spirit mixture and the second distilled
spirit mixture may be mixed in any ratio without limitation. In one
embodiment, the ratio ranges between about 70:30 and about 30:70 of
the first distilled spirit mixture to the second distilled spirit
mixture. In particular embodiments, the ratio of the first
distilled spirit mixture and the second distilled spirit mixture is
about 70:30, about 65:35, about 60:40, about 55:45, about 50:50,
about 45:55, about 40:60, about 35:65, or about 30:70. High
concentration products may range from 99:1 to 1:99, or, such as
from a ratio of 95:5 to 5:95 of the first distilled spirit mixture
to the second distilled spirit mixture.
[0129] The mixture of the first distilled spirit mixture and the
second distilled spirit mixture is generally allowed to react for
at least 1 hour. Without being bound to any theory, it is believed
that chemical reactions occur during this time period that enhance
the flavor profile over the flavor profile of the separately
produced first distilled spirit mixture and the second distilled
spirit mixture.
[0130] In a different embodiment, the process comprises (a) mixing
an amount of a first actinic light-treated spirit mixture from
Section B(iii) and a second actinic-light treated spirit mixture
form Section B(iii) to give a mixed actinic light-treated spirit
mixture and (b) subjecting the mixed actinic light-treated spirit
mixture to the thermal process as described above in Section B(i)
or Section B(v).
[0131] In a different embodiment the process comprises (a) mixing
an amount of a first actinic light-treated spirit mixture from
Section B(iii) with an amount of first unmatured distilled spirit
and (b) subjecting the mixed actinic light-treated spirit mixture
to the thermal process as described above in Section B(i) or
Section B(v).
[0132] In a further embodiment, the process for producing a mature
spirit, the process comprising (a) providing heat to a mixture
consisting essentially of an unmatured distilled spirit and wood,
to maintain a temperature of between about 140.degree. F. and about
170.degree. F. for about 24 hours to about 336 hours to give a
distilled spirit mixture; (b) removing an amount of the distilled
spirit mixture from step (a); (c) contacting the amount of the
distilled spirit mixture with wood and actinic light at a
wavelength spectrum ranging from 400 nm to 1 mm for at least one
hour to give an actinic light-treated distilled spirit mixture; (d)
mixing the actinic light-treated distilled spirit mixture with an
amount of an unmatured distilled spirit to give an unmatured
distilled spirit and actinic light-treated distilled spirit
mixture; and (e) providing heat to the unmatured distilled spirit
and actinic light-treated distilled spirit mixture to maintain a
temperature of between about 140.degree. F. and about 170.degree.
F. for about 12 hours to about 336 hours to produce the mature
spirit.
[0133] In a different embodiment, the process for producing a
mature spirit, the process comprising (a) containing a mixture
consisting essentially of a first unmatured distilled spirit and
wood at a wavelength spectrum ranging from 400 nm to 1 mm for at
least one hour to yield a actinic light-treated distilled spirit
mixture; (b) transferring the actinic light-treated distilled
spirit mixture or a portion thereof to a second unmatured distilled
spirit or a portion thereof to yield a combined mixture of
light-treated distilled spirit and unmatured distilled spirit; and
(c) providing heat to the combined mixture of light-treated
distilled spirit and second unmatured distilled spirit from step
(b) to maintain a temperature of between about 140.degree. F. and
about 170.degree. F. for about 12 hours to about 336 hours to
produce the mature spirit.
[0134] In another embodiment, the process for producing a mature
spirit, the process comprising (a) containing a first mixture
consisting essentially of an unmatured distilled spirit and wood at
a wavelength spectrum ranging from 400 nm to 1 mm for at least one
hour to yield an actinic light-treated distilled spirit mixture;
(b) providing heat a second mixture consisting essentially of an
unmatured distilled spirit and wood to maintain a temperature of
between about 140.degree. F. and about 170.degree. F. for about 12
hours to about 336 hours to yield a heat-treated distilled spirit
mixture; (c) combining the actinic light-treated distilled spirit
mixture or a portion thereof and the heat-treated distilled spirit
mixture or a portion thereof to yield a combined mixture of an
actinic light-treated distilled spirit and heat-treated distilled
spirit; and (d) providing heat to the actinic light-treated
distilled spirit and heat-treated distilled spirit to maintain a
temperature of between about 140.degree. F. and about 170.degree.
F. for about 12 hours to about 336 hours to yield a mature
spirit.
D. Simultaneous Heat and Light Processing
[0135] In still another embodiment, the present disclosure provides
a simultaneous process for producing a mature spirit. In this
embodiment, the process comprises contacting a unmatured distilled
spirit with wood and maintaining the temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours, and at the same
time, contacting the unmatured distilled spirit with actinic light
at a wavelength spectrum ranging from about 400 nm to 1 mm for at
least one hour to give a mature spirit. Thermal processing is
conducted as described in Section (A)(i) or Section (B)(i). Actinic
light exposure is as described in Section (A)(ii) or Section
(B)(iii).
E. Production of a Matured Spirit by Measuring Chemical Markers
[0136] In still another embodiment, the disclosure provides a
process for producing a spirit having characteristics of FIG. 5 or
6, as described herein. The process comprises (a) obtaining a
marker concentration of an ester in a target matured distilled
spirit thereby giving a target marker concentration, such as ethyl
decanoate, as shown in FIG. 5 or 6, (b) contacting an unmatured
distilled spirit with wood and processing as described in Sections
A-D to form a distilled spirit mixture, measuring the marker
concentration of the distilled spirit mixture, and (d) processing
the distilled spirit mixture as described in Sections A-D until the
marker concentration of the distilled spirit mixture reaches the
target marker concentration.
[0137] Once the chemical marker concentration of the distilled
sprit mixture is obtained it may be compared to the target marker
concentration in order to determine if heating and/or actinic light
treating steps as described in Sections A-D can be discontinued.
When the target concentration is not met, heating and/or light
treatment steps are repeated. Thus, the method provides a tunable
process for producing a distilled spirit having characteristics
associated with, for example, FIG. 5 or 6. In one embodiment, the
chemical marker associated with a matured distilled spirit may be
ethyl decanoate. The process disclosed above, however, is not
limited to ethyl decanoate, but can be any other ester that has
higher concentrations in a matured distilled spirit as compared to
an unmatured distilled spirit. Esters are ideal markers for a heat
process because the heat process excels at forming esters as
opposed to other semi-volatile compounds like sinapaldehyde.
[0138] Markers for the process include, but are not limited to
ethyl decanoate, ethyl dodecanoate, ethyl octanoate, ethyl
butyrate, and ethyl hexadecanoate. In some embodiments, volatile
esters can be used as chemical markers. But, semi-volatiles behave
more predictably during processing.
F. Wood Washing
[0139] In still another embodiment, where higher concentrations of
a specific ester are desired, the wood described in Sections A-E
above is washed prior to use in the method. Wood washing has the
effect of increasing the concentrations of certain chemical markers
that are important to the flavor of the matured spirit. In
particular, wood washing prior to conducting the method can lead to
a higher ethyl acetate concentration in the matured spirit.
[0140] Wood washing may be conducted by contacting the compound
described below with wood. This contacting includes submerging the
wood for a period of time in a solution containing the compound or
by pouring a solution containing the compound over the wood.
[0141] In one embodiment, the wood is washed with a carboxylic acid
containing 1 to 10 carbon atoms. The carboxylic acid may be
selected from, for example, acetic acid, propionic acid, butanoic
acid, pentanoic acid, hexanoic acid, heptanoic acid, octanoic acid,
nonanoic acid, decanoic acid, branched carboxylic acids such as
isobutyric acid, and aromatic acids such as benzoic acid and
2-phenylacetic acid.
[0142] The carboxylic acid may be diluted in water for the washing
process. For example, the carboxylic acid can be a dilute solution
having a concentration from about 0.0001% and about 1% by volume,
or about 1% to about 10% by volume of the carboxylic acid, or the
solution may be concentrated to about 20% by volume, about 30% by
volume, about 40% by volume, about 50% by volume, about 60% by
volume, about 70% by volume, about 80% by volume, about 90% by
volume, or higher.
[0143] In one embodiment, the wood is washed with vinegar (i.e., a
dilute solution of acetic acid in water). When wood washing is
conducted with any one of the processes described in Sections A-E,
the final matured spirit has higher ethyl acetate concentrations.
For example, the ethyl acetate concentration may be increased by
1.5.times. or more compared to spirit matured using this process
without the vinegar washing. These higher concentrations can give
flavors characteristic to whiskeys such as bourbon and rye whiskeys
where higher ethyl acetate concentrations are common.
G. Negative Pressure Processing
[0144] In combination with one or more processes disclosed in
Section A-F herein, air is percolated through a distilled spirit in
a container with a headspace until the alcohol concentration of the
distilled spirit is reduced. "Percolating" refers to gas aspirating
or filtering gradually through a porous surface or substance. The
air may be untreated air from the ambient atmosphere, or it may be
filtered, dried, and or deoxygenated air. Alternatively, the air
may comprise one or more gases selected from the group consisting
of nitrogen, oxygen, argon, water, carbon dioxide, and helium,
which are the principal gases of the terrestrial atmosphere.
[0145] In particular, the concentration of water in the air may be
adjusted to attain a particular "relative humidity," which is the
ratio of the amount of water vapor actually present in the air to
the greatest amount possible at the same temperature. Without
wishing to be bound by theory, a high relative humidity leads to a
net loss of alcohol, whereas a low relatively humidity leads to a
net loss of water. The relative humidity (RH) of the air may be
selected from between about 0% and about 100%, such as between
about 0% and about 10%, between about 10% and about 20%, between
about 20% and about 30%, between about 30% and about 40%, between
about 40% and about 50%, between about 50% and about 60%, between
about 60% and about 70%, between about 70% and about 80%, between
about 80% and about 90%, or between about 90% and about 100%. The
relative humidity may be selected to mimic a geographical location,
for example, Kentucky, Scotland, or Jamaica.
[0146] Generally, the air is introduced into to the container is at
about atmospheric pressure. An air inlet at the bottom of the
container permits the air to contact the distilled spirits. In
large containers, the air inlet may be fluidly connected to a
diffuser or perforated disk to distribute the air over a larger
surface area, thus enhancing contact between the air and the
distilled spirit.
[0147] During the process, the headspace of the container is under
controlled negative gauge pressure. Although the container is open
to the atmosphere or an air source, thereby allowing the air to
percolate through, the headspace is enclosed by the top surface of
the distilled spirit and the walls of the container, thereby
allowing a negative gauge pressure to be exerted. Absolute pressure
is zero-referenced against a perfect vacuum, so it is equal to
gauge pressure plus atmospheric pressure. Gauge pressure is
zero-referenced against ambient air pressure, so it is equal to
absolute pressure minus atmospheric pressure, wherever the gauge is
located. In stating the gauge pressure, negative signs may be
omitted, but are used herein for clarity.
[0148] "Inch of mercury" (inches of Hg, inHg, or "Hg) is a unit of
measurement for pressure exerted by a column of mercury of 1 inch
(25.4 mm) in height at the standard acceleration of gravity. This
simple gauge measures the difference in the levels of the mercury
from 0 inches at atmospheric pressure up to 29.92 inches of Hg at
the best vacuum attainable. Typically, this scale is shown as 0 to
30 inches of Hg on gauges, such a Bourdon dial gauges.
[0149] The range of gauge pressures used herein can and will vary.
The gauge pressure of the headspace inside the container may be
between about -25 inHg and about -30 inHg, such as between about
-25 inHg and about -25.5 inHg, between about -25.5 inHg and about
-26 inHg, between about -26 inHg and about -26.5 inHg, between
about -26.5 inHg and about -27 inHg, between about -27 inHg and
about -27.5 inHg, between about -27.5 inHg and about -28 inHg,
between about -28 inHg and about -28.5 inHg, between about -28.5
inHg and about -29 inHg, between about -29 inHg and about -29.5
inHg, or between about -29.5 inHg and about -30 inHg. The gauge
pressure may be between about -27 inHg and about -28 inHg. In
particular, the gauge pressure may be about -27.75 inHg.
[0150] During the process, the distilled spirit may chill due to
evaporative cooling, especially in large batches. As such, the
temperature of the distilled spirit may be heated during the
process to hold the temperature constant. Alternatively, the
temperature may be lowered or raised relative to the ambient
conditions. In these embodiments, the temperature may range from
between about 0.degree. F. and about 140.degree. F., such as
between about 0.degree. F. and about 10.degree. F., between about
10.degree. F. and about 20.degree. F., between about 20.degree. F.
and about 30.degree. F., between about 30.degree. F. and about
40.degree. F., between about 40.degree. F. and about 50.degree. F.,
between about 50.degree. F. and about 60.degree. F., between about
60.degree. F. and about 70.degree. F., between about 70.degree. F.
and about 80.degree. F., between about 80.degree. F. and about
90.degree. F., between about 90.degree. F. and about 100.degree.
F., between about 100.degree. F. and about 110.degree. F., between
about 110.degree. F. and about 120.degree. F., between about
120.degree. F. and about 130.degree. F., or between about
130.degree. F. and about 140.degree. F. The temperature may be
greater than 0.degree. F. The temperature may be less than about
140.degree. F.
[0151] The volume of distilled spirits used in the process can and
will vary. For example, the volume may range from about 100 mL to
about 10,000 L, such as between about 100 mL and about 500 mL,
between about 500 mL and about 1 L, between about 1 L and about 1.5
L, between about 1.5 L and about 2 L, between about 2 L and about 5
L, between about 5 L and about 10 L, between about 10 L and about
50 L, between about 50 L and about 100 L, between about 100 L and
about 500 L, between about 500 L and about 1,000 L, between about
1,000 L and about 2,000 L, between about 2,000 L and about 5,000 L,
or between about 5,000 L and about 10,000 L. The volume may be
greater than about 100 mL. The volume may be less than about 10,000
L. The volume may be about 325 mL. The volume may be about 750 mL.
The volume may be about 1.5 L.
[0152] The process disclosed herein decreases the concentration of
alcohol within the distilled spirit, and thereby selectively
removes the most volatile organic compounds and azeotropes and/or
increases the concentration of desirable chemical markers. The
disclosed process is very sensitive and is preferably monitored
carefully to the target alcohol concentration. (As used throughout
this disclosure, "alcohol" without further qualification takes its
common meaning of "ethanol.") The alcohol concentration of the
distilled spirit may be determined during the process using an
in-line density meter connected to the container. In these
embodiments, the vacuum chamber should be fitted with an in-line
density meter to carefully monitor the changes in alcohol
percentage in the spirit, allowing for very precise processing. An
in-line density meter is critical to scaling the system to larger
volumes. If the disclosed process is run too long, the distilled
spirits becomes very bitter. If the disclosed process is run for
too short of a time, the distilled spirit retains chemical markers
which gives the perception of heat to a consumer.
[0153] The disclosed process can be used on either full strength
spirits or bottling strength spirits with the adjustments to the
target alcohol concentration, as described herein. The unmatured
distilled spirit, as described herein, has an alcohol content of at
least 50% by volume. In some embodiments, the alcohol content of
the unmature distilled spirit is between 40% and 95.5% by volume.
"Full strength" is the strength of distilled spirit straight from
the cask (barrel) with no water added. Full strength spirits
typically have an alcohol concentration of greater than 60% by
volume, such as greater than 65%, as greater than 70%, as greater
than 75%, as greater than 80%, as greater than 85%, or as greater
than 90% by volume. The initial concentration of alcohol may be
between about 40% and about 95.5% by volume. "Bottling strength"
refers to the concentration to which distilled spirits are diluted
to when transferring from the cask (barrel) to a bottle, which is
between about 40% and about 57% by volume for most bottled spirits,
such as between about between about 40% and about 45% by volume,
between about 45% and about 50% by volume 50% and about 55% by
volume, or between about 52% and about 57% by volume.
[0154] As such, the alcohol concentration of full strength
distilled spirit may be reduced by between about 1% and about 2% by
volume, such as between about 1.1% and about 1.2% by volume,
between about 1.2% and about 1.3% by volume, between about 1.3% and
about 1.4% by volume, between about 1.4% and about 1.5% by volume,
between about 1.5% and about 1.6% by volume, between about 1.6% and
about 1.7% by volume, between about 1.7% and about 1.8% by volume,
between about 1.8% and about 1.9% by volume, or between about 1.9%
and about 2.0% by volume. As such, the alcohol concentration of
bottle strength distilled spirit may be reduced by between about
0.3% and about 1% by volume, such as between about 0.3% and about
0.4% by volume, between about 0.4% and about 0.5% by volume,
between about 0.5% and about 0.6% by volume, between about 0.6% and
about 0.7% by volume, between about 0.7% and about 0.8% by volume,
between about 0.8% and about 0.9% by volume, or between about 0.9%
and about 1.0% by volume.
[0155] Unlike traditional methods, which lose between about 30% and
about 50% of the volume to evaporation in the barrelhouse, the
disclosed process removes less than about 20% of the total volume
of the spirit, while creating substantially the same flavor
characteristics as associated with very old spirits. For example,
the disclosed process may remove less than about 20% of the total
volume of the spirit, such as less than about 19%, less than about
18%, less than about 17%, less than about 16%, less than about 15%,
less than about 14%, less than about 13%, less than about 12%, less
than about 11%, less than about 10%, less than about 9%, less than
about 8%, less than about 7%, less than about 6%, less than about
5%, less than about 4%, less than about 3%, less than about 2%, or
less than about 1% of the total volume of the spirit. As described
above, the parameters selected for the process determine whether
the net loss from the lost volume is net water or net alcohol.
[0156] One aspect of the present disclosure provides a process for
maturing a distilled spirit using sequential pressure processing.
In this regard, the process comprises the steps describe above,
wherein the distilled spirit in step (a) begins with an alcohol
concentration greater than 60% by volume. The process then further
comprises (b) diluting the distilled spirit of step (a) with water
to an alcohol concentration between about 50% and about 55% by
volume, and then (c) percolating air through the diluted distilled
spirit in the container with the headspace at a gauge pressure
between about -25 inHg and about -30 inHg until the alcohol
concentration of the diluted distilled spirit is reduced an
additional amount of between about 0.3% and about 1% by volume. The
alcohol concentration of the distilled spirit may be determined
during the process using an in-line density meter connected to the
container.
[0157] As in the first sequence of pressure treatment, the gauge
pressure may be between about -27 inHg and about -28 inHg, such as
at about -27.75 inHg. Any pressure described herein is sufficient.
The temperature of the distilled spirit may be held constant during
the step (c) above.
[0158] In particular, the present disclosure provides a process for
maturing a distilled spirit. (a) Air percolated through a distilled
spirit in a container with a headspace at a gauge pressure between
about -27 inHg and about -28 inHg until alcohol concentration of
the distilled spirit is reduced by between about 1% and about 2% by
volume, as determined by an in-line density meter connected to the
container. In this process, the total volume of the spirit is
reduced by about 10% or less. The distilled spirit begins step (a)
with an alcohol concentration greater than 60% by volume. And then
optionally, (b) air is percolated through the distilled spirit of
step (a) in the container with the headspace at a gauge pressure
between about -27 inHg and about -28 inHg until the alcohol
concentration of the distilled spirit is reduced by an additional
amount of between about 0.3% and about 1% by volume, as determined
by the in-line density meter. And then (c) the distilled spirit of
step (b) is diluted with water to an alcohol concentration between
about 50% and about 55% by volume. And then (d) air is percolated
air through the diluted distilled spirit in the container with the
headspace at a gauge pressure between about -27 inHg and about -28
inHg until the alcohol concentration of the diluted distilled
spirit is reduced by an additional amount of between about 0.3% and
about 1% by volume, as determined by the in-line density meter.
[0159] As described elsewhere in this disclosure, the distilled
spirit may be selected from the group consisting of sugar cane
spirits, grain spirits, fruit spirits, or agave spirits.
Alternatively, the distilled spirit may be selected from the group
consisting of rum, tequila, mescal, whiskey, brandy, gin, and
vodka.
[0160] The gauge pressure in each of step (a) and step (c) may be
about -27.75 inHg. The temperature of the distilled spirit may be
held constant during each of step (a), step (b), and step (c).
[0161] The concentration in the distilled spirit may be decreased
for one or more chemical markers selected from the group consisting
of methanol, C.sub.2-C.sub.6 fatty acids, and C.sub.2-C.sub.6 fatty
acid esters. Alternatively or in addition, the concentration in the
distilled spirit may be increased for one or more chemical markers
selected from the group consisting of vanillin, phenylated esters,
C.sub.7-C.sub.24 fatty acid esters, and phenolic aldehydes. In
particular, the distilled spirit may be characterized by an
increase in concentration of sinapaldehyde, ethyl dodecanoate, and
ethyl decanoate. The distilled spirit may characterized by an
increase in concentration of sinapaldehyde. The total loss of
volume of distilled spirits during the process may be less than
about 20%.
[0162] Optionally, the spirit produced by the process described
herein may be followed by one or more additional pressure
processing steps. In one embodiment, the sequential process may be
repeated until a desired chemical marker profile is obtained.
[0163] The present disclosure also provides a distilled spirit
produced according to a process described herein.
[0164] The compounds described herein have asymmetric centers.
Compounds of the present disclosure containing an asymmetrically
substituted atom may be isolated in optically active or racemic
form. All chiral, diastereomeric, racemic forms and all geometric
isomeric forms of a structure are intended, unless the specific
stereochemistry or isomeric form is specifically indicated.
[0165] When introducing elements of the present disclosure or the
embodiments(s) thereof, the articles "a," "an," "the," and "said"
are intended to mean that there are one or more of the elements.
The terms "comprising," "including," and "having" are intended to
be inclusive and mean that there may be additional elements other
than the listed elements.
[0166] Having described the disclosure in detail, it will be
apparent that modifications and variations are possible without
departing from the scope of the disclosure defined in the appended
claims.
EXAMPLES
[0167] The following examples are included to demonstrate certain
embodiments of the disclosure. It should be appreciated by those of
skill in the art that the techniques disclosed in the examples
represent techniques discovered by the inventors to function well
in the practice of the disclosure. Those of skill in the art
should, however, in light of the present disclosure, appreciate
that many changes can be made in the specific embodiments that are
disclosed and still obtain a like or similar result without
departing from the spirit and scope of the disclosure, therefore
all matter set forth is to be interpreted as illustrative and not
in a limiting sense.
Instrumentation
[0168] Gas Chromatography Mass Spectrometry (GCMS) Data was
obtained using a Shimadazu GCMS Model QP2010 with a Restek
Column--Rxi-5Sil MS, 30 meter, 0.24 mmID, 0.24 umdf. Program
conditions were as follows:
TABLE-US-00002 TABLE 2 Analytical Line 1 # of Rinses with
Presolvent: 1 # of Rinses with Solvent(post): 5 # of Rinses with
Sample: 1 Plunger Speed(Suction): Middle Viscosity Comp. Time: 5.0
sec Plunger Speed(Injection): High Syringe Insertion Speed: High
Injection Mode Normal Pumping Times: 3 Inj. Port Dwell Time: 10.0
sec Terminal Air Gap: No Plunger Washing Speed: High Washing
Volume: 6 uL Syringe Suction Position -2.0 mm Syringe Injection
Position: 0.0 mm Solvent Selection: All A, B, C
TABLE-US-00003 TABLE 3 GC PARAMETERS Column Oven Temp.:
35.0.degree. C. Injection Temp.: 265.0.degree. C. Injection Mode:
Split Flow Control Mode: Linear Velocity Pressure: 56.0 kPa Total
Flow: 23.9 mL/min Column Flow: 1.12 mL/min Linear Velocity: 38.0
cm/sec Purge Flow: 0.5 mL/min Split Ratio: 20.0 High Pressure
Injection: OFF Carrier Gas Saver: ON Carrier Gas Saver Split Ratio:
5.0 Carrier Gas Saver Time: 10.00 min
TABLE-US-00004 TABLE 4 OVEN TEMP. PROGRAM Rate Temperature
(.degree. C.) Hold Tim (min) 35.0 5.00 16.00 300.0 1.44
TABLE-US-00005 TABLE 5 MS PARAMETERS IonSourceTemp: 220.00.degree.
C. Interface Temp.: 280.00.degree. C. Solvent Cut Time: 1.80 min
Detector Gain Mode: Relative Detector Gain: 0.20 kV Threshold: 500
Start Time: 1.80 min End Time: 23.00 min ACQ Mode: Scan Event Time:
0.50 sec Scan Speed: 1000 Start m/z: 35.00 End m/z: 500.00
Comparative Example 1: Fresh Rum
[0169] A sample of fresh, unmature pot distilled rum was analyzed
by GCMS. FIG. 1 shows the semi-volatile fingerprint of an un-aged
pot distilled rum. This is largely defined by a lack of activity
for compounds having a retention time ranging from 5 to 30 minutes.
Noteworthy characteristics include, but are not limited to, the
starting height of peak 1 corresponding to acetyl, peak 2
corresponding to ethyl decanoate, and peak 3 corresponding to ethyl
dodecanoate. The absence of a peak for sinapaldehyde, which is
described further in later examples, is noteworthy. FIG. 1 also
shows an absence of white noise in the chromatogram starting at the
6 minute retention time point.
[0170] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 110,000 .mu.g/L.
Comparative Example 2: Rum Aged for 33 Years by Conventional Aging
Process
[0171] A sample of a commercially-available rum which has been aged
for 33 years by conventional aging processes was also analyzed by
GCMS. FIG. 2 illustrates a semivolatiles profile characteristic of
33 year aged pot distilled rums. Key characteristics include the
high acetal spike (peak 1) the high ethyl decanoate spike (peak 2)
the high ethyl dodecanoate spike (peak 3) and the high
sinapaldehyde spike (peak #4). The relative heights of peaks 2, 3,
and 4 in relation to each other is also important. Organoleptically
maintaining this approximate ratio of peak heights to each other
proved significant for creating the flavor characteristics
associated with aged rum. Further noteworthy is the cluster of
medium level peaks centered on the 15-minute mark (thought to be
caramel additives and found to include significant amounts of
glucose--this phenomena was also observed in known adulterated
rum).
[0172] The critical differences between the un-aged rum and the
33-year-old rum, that were ascertainable in the semi-volatile
chromatograms included the presence of sinapaldehyde (not found in
the white rum) alongside peaks showing significantly elevated ethyl
decanoate and ethyl dodecanoate levels (both of which are found in
the white rum characterized by relatively low peak values). Finally
a significant layer of "white noise" (representing a complex
mixture of many semi-volatile compounds) lined the bottom of the
chromatogram in the 33-year-old rum and was absent in the un-aged
rum.
[0173] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 770,000 .mu.g/L. A more typical reading for ethyl
acetate in a 33 year-old sample is 200,000 .mu.g/L.
Comparative Example 3: Heat Only Process
[0174] Otherwise unprocessed heavy pot distilled rum was added to a
stainless steel tank and mixed with charred oak slabs and heated to
between 150.degree. F. and 170.degree. F. Temperature was held in
that range for 48 hours. FIG. 3 shows the GCMS chromatogram of the
resulting product. The GCMS shows promising (but inadequate)
developments of acetyl (peak 1) ethyl decanoate (peak 2), ethyl
dodecanoate (peak 3) and sinapaldehyde (peak 4). It also shows the
development of some white noise. Overall this sample did not
produce all of the organoleptic properties displayed in aged rum.
The flavor and aroma of the sample was abnormally thin and lacked
the smoky/woody flavors found in the 33 year-old sample.
Qualitatively it was unable to meet two of the key chemical marker
criteria for the production of aged rum. As can be seen, the white
noise level was low. The ethyl dodecanoate (peak 3) and
sinapaldehyde (peak 4) failed reach peak heights similar to the
ethyl decanoate (peak 2).
[0175] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 38,000 .mu.g/L.
Comparative Example 4: Actinic Light Only Process
[0176] Otherwise unprocessed heavy pot distilled rum was placed in
a sealed flint glass jar along with charred oak slabs and placed in
a greenhouse for 30 days. The sample was not subjected to any heat
treatment. The sample was analyzed by GCMS. The GCMS shows
significant development of acetyl (peak 1) ethyl decanoate (peak
2), ethyl dodecanoate (peak 3) and sinapaldehyde (peak 4). It also
shows the development of the level of white noise expected in a
mature spirit. But, this sample did not produce the organoleptic
properties displayed in aged rum. It was extremely bitter.
Qualitatively it was unable to meet one key chemical marker
criteria for the production of an aged spirit. The sinapaldehyde
(peak 4) was extremely high. It was hypothesized that the extreme
level of sinapaldehyde was partially causing the bitterness along
with some other observed and abnormally high peaks including
furfural (peak 5) and syringaldehyde (peak 6).
[0177] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 62,000 .mu.g/L.
Example 5: Mixed Batch Heat and Actinic Light Process
[0178] Otherwise unprocessed heavy pot distilled rum was added to a
stainless steel tank and mixed with charred oak slabs and heated to
between 150.degree. F. and 170.degree. F. Temperature was held in
that range for 48 hours. Separately, an otherwise unprocessed heavy
pot still rum was placed in a sealed flint glass jar along with
charred oak slabs and placed in a greenhouse for 30 days. The
product of the heat treatment and the product of the light
treatment were then mixed together with a ratio of 60% of the heat
process product and 40% of the actinic light processed rum. This
mixture was allowed to react for 24-48 hours. After this time
period, the resulting product was analyzed by GCMS. The GCMS
chromatogram is shown in FIG. 5. The chromatogram shows some
unexpected results along with major developments. The acetyl
concentration (peak 1) unexpectedly fell to a concentration lower
than that of either of its constituent parts (FIGS. 3 and 4). But,
the acetal level was still elevated in comparison to the
unprocessed rum (FIG. 1) by a factor of 1.75.times.. The furfural
concentration (peak 5) and syringaldehyde concentration (peak 6)
unexpectedly fell sharply correcting the overabundance of these
compounds displayed in the actinic light-treated rum (FIG. 4). The
ethyl decanoate concentration (peak 2) unexpectedly (and
counterproductively) fell to levels lower than those observed in
either of the constituent components--yet the peak still remained
more than 3.times. higher than the starting concentration in the
unprocessed rum satisfying our minimum criteria for an aged spirit.
Ethyl dodecanoate (peak 3) was unaffected by combining the
products. Critically, the sinapaldehyde (peak 4) fell to a
concentration lower than expected given the extremely high peak
found in the actinic light reacted product (FIG. 4). The "white
noise" fell significantly and unexpectedly, failing to fully
satisfy criteria for an aged spirit. Despite the failure of this
product to fully meet some markers of the 33-year-old spirit, this
product did produce the organoleptic properties displayed in aged
rum, albeit a highly idiosyncratic aged rum. It did not display any
of the extreme bitterness found in the actinic light reacted rum
(FIG. 4), or the thinness of flavor displayed in the temperature
treated rum (FIG. 3). It was observed that the peak heights of
ethyl decanoate, ethyl dodecanoate, and sinapaldehyde were all
elevated and had come closer to aligning than had been possible in
either the heat-treated product or the actinic light-treated
product alone. Therefore the mixture of the two products had
produced a final product that approached meeting all of the key
chemical markers outlined in our definition of a mature spirit.
[0179] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 170,000 .mu.g/L.
Example 6: Sequential Temperature and Light Processing
[0180] An otherwise unprocessed heavy pot distilled rum was added
to a stainless steel tank and mixed with charred oak slabs and
heated to between 150.degree. F. and 170.degree. F. Temperature was
held in that range for 48 hours. The resulting product was then
placed in a sealed flint glass jar along with charred oak slabs and
placed in front of a 500-W halogen bulb for 3 days. Seventy glass
jars are placed on a shelf surrounded by a total of 20 lights. The
lights were toggled on and off in 2-4 hour cycles to prevent
boiling. The resulting product was then placed in a stainless steel
tank and mixed with charred oak slabs and heated to between
150.degree. F. and 170.degree. F. Temperature was held in that
range for 48 hours. The resulting product was analyzed with
GCMS.
[0181] FIG. 6 shows the GCMS chromatogram from a rum sample that
has been processed with both heat and light in accordance with
Example 6. It shows some unexpected results along with major
developments. Unlike the mixture of the heat and actinic
light-treated rum described in FIG. 5, the acetyl concentration
(peak 1) is as high as it is in the actinic light reacted rum (FIG.
4) more than 3.times. the starting concentration found in the
unprocessed rum (FIG. 1) satisfying the acetyl chemical marker
criteria for an aged spirit. The furfural concentration (peak 5)
does not exhibit the overabundance displayed in the actinic
light-treated rum (FIG. 4). The ethyl decanoate concentration (peak
2) shows a peak height 25%+/- higher than that found in the mixture
of heat treated rum and actinic light reacted rum described in FIG.
5. The peak shows a relative concentration roughly 5.times. higher
than the starting concentration in the unprocessed rum satisfying
our minimum ethyl decanoate marker criteria for an aged spirit. The
ethyl dodecanoate (peak 3) peak height was identical to that found
in the mixture described in FIG. 5 and lines up almost identically
with the ethyl decanoate concentration. The sinapaldehyde (peak 4)
fell slightly from the light/heat mixture rum described in FIG. 5
critically aligning with the ethyl decanoate (peak 2), and the
ethyl dodecanoate (peak 3) satisfying the elusive chemical marker
criteria of having peaks 2, 3, and 4 roughly aligned. The "white
noise" peaks also rose (as compared to the mixture product
displayed in FIG. 5) as a consequence of this modified process
satisfying that chemical marker criteria for the production of an
aged spirit. As is expected from reading the chromatogram, this
product did produce the organoleptic properties displayed in aged
rum. It did not display any of the extreme bitterness found in the
actinic light reacted rum (FIG. 4), or the thinness of flavor
displayed in the temperature treated rum (FIG. 3). It was observed
that the peak heights of ethyl decanoate, ethyl dodecanoate, and
sinapaldehyde were all elevated and roughly aligned in a way that
had not been possible in either the heat-treated product or the
actinic light-treated product, or even the mixture of the two
(shown in FIG. 5). This process had successfully satisfied all of
the key chemical markers outlined in our definition of a mature
spirit, elegantly solving the industries "30 years in a barrel"
problem. It incidentally and beneficially triggered a marked
reduction in ethyl acetate concentrations, shown experimentally to
be greater than 60% over the batch process (FIG. 5). The process
also produced no evaporation of the finished product as would be
expected in conventional barrel aging. The finished product not
only mimicked the key marker ratios a traditionally aged product,
but ultimately improved the process by shortening the time to
maturity, eliminating the evaporation, and reducing the ethyl
acetate.
[0182] Concentration of ethyl acetate was measured by direct
injection mass spectrometry. The concentration of ethyl acetate was
shown to be about 59,000 .mu.g/L.
Example 7: Sample Process
[0183] An otherwise unprocessed heavy pot distilled rum (25
gallons) was added to a stainless steel tank and mixed with charred
oak slabs and heated to between 150.degree. F. and 160.degree. F.
Temperature was held in that range for 48 hours. Ten percent of the
remaining product (about 2.5 gallons) was then placed in a sealed
borosilicate glass tube along with charred oak slabs and placed in
front of 16500-kW halogen bulbs for 24 hours. The resulting product
was then transferred back to the remaining unprocessed pot
distilled rum and heated to between 150.degree. F. and 160.degree.
F. Temperature was held in that range for 48 hours.
[0184] Numerous examples are provided herein to enhance
understanding of the present disclosure. A specific set of
statements are provided as follows.
[0185] Statement 1: A process for producing a mature spirit
comprising (a) providing heat to a mixture consisting essentially
of an unmatured distilled spirit and wood, to maintain a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 24 hours to about 336 hours
to give a distilled spirit mixture; (b) contacting the distilled
spirit mixture with wood and actinic light at a wavelength spectrum
ranging from about 183 nm to about 1 mm for at least one hour to
give an actinic light-treated distilled spirit mixture; and (c)
providing heat to the actinic light-treated distilled spirit
mixture produced in step (b) to maintain a temperature between
about 140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to produce the
mature spirit; wherein steps (a), (b), and (c) are performed
sequentially.
[0186] Statement 2: A process in accordance with Statement 1,
wherein the wavelength spectrum ranges from about 183 nm to about
750 nm.
[0187] Statement 3: A process in accordance with Statement 1,
wherein the wavelength spectrum ranges from about 200 nm to about
2000 nm.
[0188] Statement 4: A process in accordance with Statement 1,
wherein the wavelength spectrum ranges from about 375 nm to about
6000 nm.
[0189] Statement 5: A process in accordance with Statement 1,
wherein the wavelength spectrum is within the infrared spectrum,
ranging from about 700 nm to about 1 mm.
[0190] Statement 6: A process in accordance with Statement 1,
wherein the wavelength spectrum is within the UV spectrum, ranging
from about 183 nm to about 400 nm.
[0191] Statement 7: A process in accordance with Statements 1-6,
further comprising cooling the distilled spirit mixture during the
actinic light exposure via a cooling system at a temperature below
boiling point.
[0192] Statement 8: A process in accordance with Statements 1-7,
wherein the temperature is between about 174.degree. F. to about
182.degree. F.
[0193] Statement 9: A process in accordance with Statements 1-8,
further comprising conducting one or more of step (a), step (b),
and step (c) are under reflux at a temperature ranging from about
140.degree. F. to about 182.degree. F.
[0194] Statement 10: A process in accordance with Statements 1-8,
further comprising conducting one or more of step (a), step (b),
and step (c) in high pressure vessels at a temperature ranging from
about 140.degree. F. to about 328.degree. F.
[0195] Statement 11: A process in accordance with Statements 1-10,
wherein ultrasonication is used during step (a) and step (c) to
produce heat.
[0196] Statement 12: A process in accordance with Statements 1-11,
further comprising introducing oxygen and/or air to the distilled
spirit mixture to autooxidize aldehydes in the distilled spirit
mixture.
[0197] Statement 13: A process in accordance with Statements 1-12,
further comprising introducing oxygen and/or air to the distilled
spirit mixture under a vacuum of up to about -29 inHg to
autooxidize aldehydes in the distilled spirit mixture and remove
highly volatile VOCs and ethanol.
[0198] Statement 14: A process in accordance with Statements 1-13,
wherein the mature spirit has an ethyl acetate concentration of
about 59,000 .mu.g/L.
[0199] Statement 15: A process in accordance with Statements 1-14,
wherein step (a) and step (c) are maintained at a temperature
between about 140.degree. F. and about 150.degree. F. for a period
of time ranging from about 168 hours to about 226 hours.
[0200] Statement 16: A process in accordance with Statements 1-14,
wherein step (a) and step (c) are maintained at a temperature
between about 150.degree. F. and about 160.degree. F. for a period
of time ranging from about 24 hours to about 72 hours.
[0201] Statement 17: A process in accordance with Statements 1-16,
wherein the unmature distilled spirit is selected from the group
consisting of sugar cane spirits, grain spirits, fruit spirits, and
agave spirits.
[0202] Statement 18: A process in accordance with Statements 1-17,
The process of claim 1, wherein the unmature distilled spirit is
selected from the group consisting of rum, tequila, mescal,
whiskey, brandy, gin, and vodka.
[0203] Statement 19: A process for producing a mature spirit
comprising (a) providing heat to a mixture consisting essentially
of an unmatured distilled spirit and wood, to maintain a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 24 hours to about 336 hours
to give a distilled spirit mixture; (b) dividing the distilled
spirit mixture into a first portion and a second portion, (c)
contacting the first portion of the distilled spirit mixture of
with wood and actinic light at a wavelength spectrum ranging from
about 183 nm to about 1 mm for at least one hour to give an actinic
light-treated distilled spirit mixture concentrate; and (c) adding
the distilled spirit mixture concentrate to the second portion of
the distilled spirit mixture and providing heat to maintain a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 12 hours to about 336 hours
to produce the mature spirit; wherein steps (a), (b), and (c) are
performed sequentially.
[0204] Statement 20: A process in accordance with Statement 19,
wherein the first portion of the distilled spirit mixture is from
about 1% to about 99% of the distilled spirit mixture.
[0205] Statement 21: A process in accordance with Statement 19 or
Statement 20, wherein the wavelength spectrum ranges from about 183
nm to about 750 nm.
[0206] Statement 22: A process in accordance with Statement 19 or
Statement 20, wherein the wavelength spectrum ranges from about 200
nm to about 2000 nm.
[0207] Statement 23: A process in accordance with Statement 19 or
Statement 20, wherein the wavelength spectrum ranges from about 375
nm to about 6000 nm.
[0208] Statement 24: A process in accordance with Statement 19 or
Statement 20, wherein the wavelength spectrum is within the
infrared spectrum, ranging from about 700 nm to about 1 mm.
[0209] Statement 25: A process in accordance with Statement 19 or
Statement 20, wherein the wavelength spectrum is within the UV
spectrum, ranging from about 183 nm to about 400 nm.
[0210] Statement 26: A process in accordance with Statements 19-25,
further comprising cooling the distilled spirit mixture during the
actinic light exposure via a cooling system to a temperature below
boiling point of about 174.degree. F. to about 182.degree. F.
[0211] Statement 27: A process in accordance with Statements 19-26,
further comprising conducting one or more of step (a), step (b),
and step (c) under reflux at a temperature ranging from about
140.degree. F. to about 182.degree. F.
[0212] Statement 28: A process in accordance with Statements 19-26,
further comprising conducting one or more of step (a), step (b),
and step (c) in high pressure vessels at temperature ranging from
about 140.degree. F. to about 328.degree. F.
[0213] Statement 29: A process in accordance with Statements 19-26,
wherein step (a) and step (c) are maintained at a temperature
between about 140.degree. F. to about 150.degree. F. for a period
of time ranging from about 168 hours to about 226 hours.
[0214] Statement 30: A process in accordance with Statements 19-26,
wherein step (a) and step (c) are maintained at a temperature
between about 150.degree. F. to about 160.degree. F. for a period
of time ranging from about 24 hours to about 72 hours.
[0215] Statement 31: A process in accordance with Statements 19-30,
further comprising introducing oxygen and/or air to the distilled
spirit mixture to autooxidize aldehydes present in the distilled
spirit mixture.
[0216] Statement 32: A process in accordance with Statements 19-31,
further comprising introducing oxygen and/or air to the distilled
spirit mixture under vacuum of up to about -29 inHg to autooxidize
aldehydes in the distilled spirit mixture and remove highly
volatile VOCs and ethanol.
[0217] Statement 33: A process in accordance with Statements 19-32,
wherein the unmature distilled spirit is selected from the group
consisting of sugar cane spirits, grain spirits, fruit spirits, and
agave spirits.
[0218] Statement 34: A process in accordance with Statements 19-33,
wherein the unmature distilled spirit is selected from the group
consisting of rum, tequila, mescal, whiskey, brandy, gin, and
vodka.
[0219] Statement 35: A process for producing a mature spirit
comprising (a) contacting the distilled spirit mixture with wood
and actinic light at a wavelength spectrum ranging from about 183
nm to about 1 mm for at least one hour to give an actinic
light-treated distilled spirit mixture; and (b) providing heat to
the actinic light-treated distilled spirit mixture to maintain a
temperature between about 140.degree. F. and about 170.degree. F.
for a period of time ranging from about 12 hours to about 336 hours
to produce the mature spirit; wherein steps (a), and (b), are
performed sequentially.
[0220] Statement 36: A process in accordance with Statement 35,
wherein the wavelength spectrum ranges from about 183 nm to about
750 nm.
[0221] Statement 37: A process in accordance with Statement 35,
wherein the wavelength spectrum ranges from about 200 nm to about
2000 nm.
[0222] Statement 38: A process in accordance with Statement 35,
wherein the wavelength spectrum ranges from about 375 nm to about
6000 nm.
[0223] Statement 39: A process in accordance with Statement 35,
wherein the wavelength spectrum is within the infrared spectrum,
ranging from about 700 nm to about 1 mm.
[0224] Statement 40: A process in accordance with Statement 35,
wherein the wavelength spectrum is within the UV spectrum, ranging
from about 183 nm to about 400 nm.
[0225] Statement 41: A process in accordance with Statements 35-40,
further comprising cooling the distilled spirit mixture during the
actinic light exposure via a cooling system to a temperature below
the boiling point.
[0226] Statement 42: A process in accordance with Statements 35-41,
wherein the distilled spirit mixture is cooled to a temperature of
about 174.degree. F. to about 182.degree. F.
[0227] Statement 43: A process in accordance with Statements 35-42,
further comprising conducing one or more of step (a) and step (b)
under reflux at a temperature range of about 140.degree. F. to
about 182.degree. F.
[0228] Statement 44: A process in accordance with Statements 35-43,
further comprising conducting one or more of step (a) and step (b)
in a high pressure vessel at a temperature ranging from about
140.degree. F. up to about 328.degree. F.
[0229] Statement 45: A process in accordance with Statements 35-44,
further comprising using ultrasonication to produce heat during
step (b).
[0230] Statement 46: A process in accordance with Statements 35-45,
further comprising introducing oxygen and/or air to the distilled
spirit mixture to autooxidize aldehydes in the distilled spirit
mixture.
[0231] Statement 47: A process in accordance with Statements 35-46,
further comprising introducing oxygen and/or air to the distilled
spirit mixture under a vacuum of up to about -29 inHg to
autooxidize aldehydes in the distilled spirit mixture and the
remove highly volatile VOCs and ethanol.
[0232] Statement 48: A process in accordance with Statements 35-47,
wherein the mature spirit has an ethyl acetate concentration of
about 59,000 .mu.g/L.
[0233] Statement 49: A process in accordance with Statements 35-48,
wherein step (b) is maintained at a temperature between about
140.degree. F. and about 150.degree. F. for a period of time
ranging from about 168 hours to about 226 hours.
[0234] Statement 50: A process in accordance with Statements 35-49,
wherein step (b) is maintained at a temperature between about
150.degree. F. and about 160.degree. F. for a period of time
ranging from about 24 hours to about 72 hours.
[0235] Statement 51: A process in accordance with Statements 35-50,
wherein the unmature distilled spirit is selected from the group
consisting of sugar cane spirits, grain spirits, fruit spirits, and
agave spirits.
[0236] Statement 52: A process in accordance with Statements 35-51,
wherein the unmature distilled spirit is selected from the group
consisting of rum, tequila, mescal, whiskey, brandy, gin, and
vodka.
[0237] Statement 53: A process for producing a mature spirit
comprising (a) contacting a distilled spirit mixture with wood and
actinic light at a wavelength spectrum ranging from about 183 nm to
about 1 mm for at least one hour to give an actinic light-treated
distilled spirit mixture concentrate; and (b) adding the distilled
spirit mixture concentrate to a mixture consisting essentially of
an unmatured distilled spirit and wood and providing heat to the
resulting mixture produced to maintain a temperature between about
140.degree. F. and about 170.degree. F. for a period of time
ranging from about 12 hours to about 336 hours to produce the
mature spirit; wherein steps (a), and (b), are performed
sequentially.
[0238] Statement 54: A process in accordance with Statement 53,
wherein the wavelength spectrum ranges from about 183 nm to about
750 nm.
[0239] Statement 55: A process in accordance with Statement 53,
wherein the wavelength spectrum ranges from about 200 nm to about
2000 nm.
[0240] Statement 56: A process in accordance with Statement 53,
wherein the wavelength spectrum ranges from about 375 nm to about
6000 nm.
[0241] Statement 57: A process in accordance with Statement 53,
wherein the wavelength spectrum is within the infrared spectrum,
ranging from about 700 nm to about 1 mm.
[0242] Statement 58: A process in accordance with Statement 53,
wherein the wavelength spectrum is within the UV spectrum, ranging
from about 183 nm to about 400 nm.
[0243] Statement 59: A process in accordance with Statements 53-58,
further comprising cooling the distilled spirit mixture during the
actinic light exposure via a cooling system to a temperature below
the boiling point.
[0244] Statement 60: A process in accordance with Statements 53-59,
wherein the distilled spirit mixture is cooled to a temperature of
about 174.degree. F. to about 182.degree. F.
[0245] Statement 61: A process in accordance with Statements 53-60,
further comprising conducting one or more of step (a) and step (b)
under reflux at a temperature range of about 140.degree. F. to
about 182.degree. F.
[0246] Statement 62: A process in accordance with Statements 53-61,
further comprising conducting one or more of step (a) and step (b)
in a high pressure vessel at temperature of about 140.degree. F. up
to about 328.degree. F.
[0247] Statement 63: A process in accordance with Statements 53-62,
further comprising using ultrasonication to produce heat in step
(b).
[0248] Statement 64: A process in accordance with Statements 53-63,
further comprising introducing oxygen and/or air to the distilled
spirit mixture to autooxidize aldehydes in the distilled spirit
mixture.
[0249] Statement 65: A process in accordance with Statements 53-64,
further comprising introducing oxygen and/or air to the distilled
spirit mixture under vacuum of up to about -29 inHg to autooxidize
aldehydes in the distilled spirit mixture and remove highly
volatile VOCs and ethanol.
[0250] Statement 66: A process in accordance with Statements 53-65,
wherein the mature spirit has an ethyl acetate concentration of
about 59,000 .mu.g/L.
[0251] Statement 67: A process in accordance with Statements 53-66,
wherein step (b) is maintained at a temperature between about
140.degree. F. and about 150.degree. F. for a period of time
ranging from about 168 hours to about 226 hours.
[0252] Statement 68: A process in accordance with Statements 53-67,
wherein step (b) is maintained at a temperature between about
150.degree. F. and about 160.degree. F. for a period of time
ranging from about 24 hours to about 72 hours.
[0253] Statement 69: A process in accordance with Statements 53-68,
wherein the unmature distilled spirit is selected from the group
consisting of sugar cane spirits, grain spirits, fruit spirits, and
agave spirits.
[0254] Statement 70: A process in accordance with Statements 53-69,
wherein the unmature distilled spirit is selected from the group
consisting of rum, tequila, mescal, whiskey, brandy, gin, and
vodka.
[0255] While specific embodiments have been described above with
reference to the disclosed embodiments and examples, such
embodiments are only illustrative and do not limit the scope of the
disclosure. Changes and modifications can be made in accordance
with ordinary skill in the art without departing from the
disclosure in its broader aspects as defined in the following
claims.
* * * * *