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Ferreira Post Distilleries

Our production process

A closer look at the process of making craft rum.

anton ferreira

Introduction

In broad, the production process consists of the following major activities using a batch process methodology:

  1. Fermentation
  2. Distillation
  3. Bottling and packaging

Before fermentation can take place, the wash needs to be prepared.

Distillation consists of two processes, namely the stripping run and the spirit run. The stripping run mainly removes the alcohol from the finished fermentation, resulting in low wines, while the spirit run separates the various cuts.

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Ingredients

The following major ingredients are used:

  1. Water - Mineral rich water from the Kouga area
  2. Molasses - Best quality available
  3. Yeast - Appropriate for a light rum with a Brazilian inclination
  4. Nutrients
  5. Citric acid
  6. Bicarbonate potassium
  7. Demineralised water

Equipment

The following equipment is used in the production process:

  1. Mixing vessel
  2. Fermentation vessels
  3. Stripping still
  4. Spirit still
  5. Bottling equipment

The production area has a sloped floor to drain fluids. Any spillage of a product not allowed in the drainage system is collected in an underground holding tank for safe removal.

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Preparation

All equipment, such as the mash tun, fermentation vessels, the stills, the piping and pumps are properly cleaned, usually before and after use.

During the preparation, chlorine is removed from the water, as it might have a detrimental effect on the yeast. The water is heated to the correct temperature. Molasses, high grade obtained from Sugar Cane Juice, is added to the water. The amount of water and molasses used depends on the specific gravity that needs to be achieved in order for the yeast to give a good quality yield.

During the preparation the water is aerated and the molasses is thoroughly mixed to the correct specific gravity. Nutrients are hydrated and added to the wash. The pH is adjusted to required levels.

The yeast, Saccharomyces Cerevisiae, is added to the fermentation after it is hydrated and prepared for the fermentation process.

Fermentation

The fermentation is sealed and adjustments made to temperature, as needed.

Temperature, specific gravity and pH are checked regularly.

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Stripping run

The wash is distilled using the stripping still and the alcohol is removed.

For both the cooling of the stripping and the spirit still the evaporative cooler system is used.

Spirit run

The low wines are then distilled into the various cuts, such as the heads, the hearts and the tails, using the spirit still.

The hearts are the good alcohol that makes the final product. The hearts are distilled at the proper ABV so that the distillate maintains its taste of the raw materials.

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Preparation for bottling

New bottles are sterilised and washed with the bottle washer.

The appropriate cuts obtained from the spirit run, referred to as the hearts, are prepared for bottling by adding an appropriate water suited to the rum, to the system in order to obtain the required alcohol strength.

Bottling and packaging

The prepared alcohol is bottled with the assistance of a gravity filler.

Before bottles are filled, the final liquid is filtered using an appropriate filter.

The bottles are sealed and labels are attached. After this, the bottles are packed into boxes and appropriately sealed.

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