Tank GENIO Still Jacketed + Stripping Column 50/100/250/500 series

GENIO Still Jacketed has been specially designed and built for distillation and rectification of liquids containing solids (distillation on-the-grain). GENIO Still Jacketed is compatible with:

Rectification column – for spirit production
Stripper column – for stripping runs

GENIO Still Jacketed is available in the following configurations:

50 liters (13.2 gal) – max amount of liquid / 60 liters (15.9 gal) – Gross
100 liters (26.4 gal) – max amount of liquid / 120 liters (31.7 gal) – Gross
250 liters (66.0 gal) – max amount of liquid / 280 liters (74.0 gal) – Gross
500 liters (122.0 gal) – max amount of liquid / 600 liters (158.0 gal) – Gross

GENIO Still Jacketed utilizes a special heat transfer oil as a heating medium in non-pressurized tanks. Standard features include an agitator with a gear reduction ratio of 1:90. In this configuration, the stirrer turns at 18 rotations per minute. The operation of GENIO Still Jacketed + Stripping Column is done using controls on the power supply module attached to the tank. When the still is operated in the configuration of GENIO Still Jacketed + Rectification column, then the still is controlled using the GENIO touchscreen computer attached to the rectification column.

GENIO Still Jacketed incorporates a number of original innovations that are not found in other devices. All tanks are insulated with a special black foam rubber through which we have achieved minimal energy loss. GENIO Still Jacketed is supplied with complete accessories necessary for immediate operation.

GENIO Still Jacketed, is heated through the use of heat transfer oil, which allows for the distillation of all liquids containing solids such as milled flour, cereals, fruit etc. By mounting the appropriate column on the GENIO Still Jacketed, we can achieve rectified spirit production using a rectification column, or stripping run using a stripping column. With rectification column we can obtain neutral spirit at above 95% ABV (190 proof) for vodkas or choose lower proof alcohol production for spirits such as bourbon, whiskey, gin, rum, grappa, cognac, brandy, rakija, tequila, calvados, vodka. One should always remember that the quality of alcohol is determined by four factors:

Recipe and the quality of the liquid which will be distilled
Skills and experience in alcohol distillation
Equipment used to control the process of mashing, fermenting and distillation (from our side, we offer equipment with state-of-the-art controls)
Final “treatment” of alcohol, (aging, resting, maceration, filtering, etc.)

TANK JACKETED + STRIPPING COLUMN SCHEMATIC DIAGRAM

TANK

The tank is the ethanol vapour generator and plays a key role for the entire distilling process. Excessive amounts of vapor may lead to blockage of the column (column flooding), whereas a small amount of vapor leads to instability and a very inefficient operation of the column.

We offer:

DIRECTLY HEATED TANKS – the electric heating element(s) are placed directly in the batch. This type of heating is intended for batches without solids. The liquid poured into the tank must be clean and clarified. Our heating elements are made using Stainless Steel Alloy 316L.
OIL JACKETED TANKS – the tank is positioned inside another tank with a jacket, which is filled with special oil to provide optimal transfer of heat energy from the electrically heated oil in the jacket to the interior tank wall. For safety purposes, it is a pressure-less jacket system. This type of tank allows heating of batches with solids, without the risk of scorching. As an additional option, you can order an agitator, which will further increase the efficiency of distillation for batches with solids.
AUTOMATIC ADJUSTMENT OF HEATING POWER – a brand new feature for our GENIO stills is the automatic adjustment of heating power during the distillation process for maximum efficiency associated with time and energy consumption. Through pressure and temperature sensors, the algorithm based software analyzes the vapours present in the column versus the column production capacity, and continuously adjusts the amount of heat applied to the batch. The computer makes sure the process is carried out with the greatest possible efficiency, and at the same time monitors for excess vapors so that flooding of the column does not occur.

Heating power can also be adjusted manually during the process if desired.

RECTIFICATION COLUMN

The rectification column is in principle the most important component of the still. It is because the column uses Spiral Prismatic Packing (“SPP”) and the processes occurring within it that we get pure and concentrated distillate of up to 96% ABV. One should always remember that the quality and cleanliness of the SPP has a large effect on the distilled product. The use of SPP allows us to minimize the size of the still, reducing operating costs, while obtaining maximum amount of distillate.

In the GENIO Still 50 / 100 series – SPP is made of stainless steel wire with a diameter of 0.18 mm and the prismatic rings have a diameter of 4.3 x 4.3 mm. SPP is improved packing originally derived from Raschig rings, and currently provides the best column packing material available with regards to the density of packing material and relation to passing vapor resistance. Thanks to a column with a height of 120 cm we are able to obtain 30 theoretical plates or HETP’s (Height Equivalent to a Theoretical Plate).

In the GENIO Still 250 / 500 series – standard packing consists of ceramic Raschig rings (size 10 x 10 mm). There is an option to upgrade to Large SS SPP (9 x 9 mm). Packing material dimensions and properties were specifically selected in relation to the expected amount of vapor to be generated from the tank, the diameter of the column, the column height, and passing vapor resistance.

For GENIO Still 250 / 500 – we offer two packing solutions:

Ceramic Raschig rings – provide about 18-24 theoretical plates (HETP), which allows us to obtain pure alcohol of over 95% ABV, but also appropriate for taste rich products if pot still distillation mode is selected.
Large SS SPP (Large Stainless Steel Spiral Prismatic Packing) – provides a larger field of exchange – cleaning – with less resistance to passing vapors. With Large SS SPP we can obtain production of spirits with the highest purity and concentration of up to 96.5% ABV (inside the column, we are able to obtain 25 to 30 theoretical plates). The increased number of theoretical plates can will result in a very clean distillate with minimal flavours and aromas.

COLUMN HEAD (DEPHLEGMATOR) AND REFLUX

The next operational segment of the column still is the column head (dephlegmator). This is our exclusive innovation in the GENIO Series of Stills. Thanks to the inventive column head design, minimum cooling water is required to condense the ethanol vapor back into a liquid. It should be noted, that with the column head height of only 30 cm, it can even cool vapor produced with heating power of up to 25 kW. The aftercooler is a shelving system required for proper stabilization of the column and the production of pure ethanol.

The column head works together with the automatic needle valve. Utilizing the latest technology and the best materials available, we have achieved the ability with almost “surgical” precision in controlling the flow of distillate, which is a necessary condition to receive pure alcohol from the first to the last drop. This allows us to distinguish ourselves from the competition, as it is unavailable in any of our competitors’ stills.

The whole system of column head and needle valve control to obtain reflux is computer controlled by our proprietary software. It is this design that puts us at the forefront of distilling equipment manufacturers.

OTHER COMPONENTS

The remaining elements serve to increase automation, increase product quality and maximize the effectiveness of the still. The design and construction of each element was accompanied by the following guideline – the component is to be efficient and effective – just like the whole still. Each component in the still has to create many opportunities of use for the individual operator of the GENIO Still.

For example, carbon filter is an element which will not harm the product, but can only make it better in the production of clear spirits. Of course, this element can be omitted, it only serves to broaden the possibilities of using GENIO series stills.

CONTROL, SOFTWARE, AUTOMATION

The last master “module” of control and automation, is our “jewel in the crown”. It consists of six digital temperature sensors, two pressure sensors, flow sensor, liquid level sensor, four solenoids, stepper motor, heating from 5000 watts to 18,000 watts.

The still’s automation is based on direction obtained from our computer with algorithm enabled proprietary software. An automated distillation run is performed in the following manner – fill the tank with your batch, turn on the program parameters and leave the still alone. The entire process will be carried out automatically.

Electronic components (circuit boards) are custom produced based on individual orders according to our technical drawings by companies specializing in producing electronic components for global brands.

GENIO software is unique, a one of a kind product that is only compatible with GENIO Series Stills – the concept for the software was the result of distilling knowledge, but the algorithms and methods to control the automation are the result of hundreds of hours of testing and trials. It is essentially the collected “essence” of the entire distilling experience. Our software and algorithm is the part of our intellectual property that cannot be “replicated” and it is the “flagship” of our company.

GENIO STILL SPECIFICATIONS CHART

EXTRA

We believe to be the only still manufacturer that will offer the possibility of trading in your previously purchased GENIO still when buying a newer or larger version. Our stills come with a 24-month written warranty, which includes couriering replacement parts and requesting the return of the defective component. We provide sales and after-sales service by personnel with specialization in distilling, and who work out of an operational distillery showroom located in each region of the world.

Tank GENIO Jacketed 50 + Stripping Column

GENIO Still Jacketed 50 + Stripping Column is ideal for producing small amounts of alcohol for the purpose of developing new recipes for subsequent implementation on larger units. The entire unit comes fully complete and ready for immediate operation.

GENIO Still Jacketed 50 + Stripping Column can be used with liquids containing solids (distillation on-the-grain) that would have otherwise been scorched if used in tanks with direct heating elements.

GENIO Still Jacketed 50 + Stripping Column allows you to manually make your cuts: foreshots, heads, hearts and tails. The cuts can be determined based on the temperature of the vapors in the column, or on the basis of the alcoholic strength of the produced spirit utilizing alcoholmeters.

0,0 l/h (0.8 gal/h)

Achievable production output

0L (13 gal)

Tank operating capacity

0 - 96% ABV

Production od alcohol

Tank GENIO Jacketed 100 + Stripping Column

GENIO Still Jacketed 100 + Stripping Column is ideal for producing small amounts of alcohol for the purpose of developing new recipes for subsequent implementation on larger units. The entire unit comes fully complete and ready for immediate operation.

GENIO Still Jacketed 100 + Stripping Column can be used with liquids containing solids (distillation on-the-grain) that would have otherwise been scorched if used in tanks with direct heating elements.

GENIO Still Jacketed 100 + Stripping Column allows you to manually make your cuts: foreshots, heads, hearts and tails. The cuts can be determined based on the temperature of the vapors in the column, or on the basis of the alcoholic strength of the produced spirit utilizing alcoholmeters.

0,0 l/h (0.8 gal/h)

Achievable production output

0L (26 gal)

Tank operating capacity

0 - 96% ABV

Production od alcohol

Tank GENIO Jacketed 250 + Stripping Column

GENIO Still Jacketed 250 + Stripping Column is ideal for producing taste rich alcohols and for persons / companies developing recipes. The unit comes fully complete and ready for immediate operation.

GENIO Still Jacketed 250 + Stripping Column can be used with liquids containing solids (distillation on-the-grain) that would have otherwise been scorched if used in tanks with direct heating elements.

GENIO Still Jacketed 250 + Stripping Column allows you to manually make your cuts: foreshots, heads, hearts and tails. The cuts can be determined based on the temperature of the vapors in the column, or on the basis of the alcoholic strength of the produced spirit utilizing alcoholmeters.

0,0 l/h (4.2 gal/h)

Achievable production output

0L (66 gal)

Tank operating capacity

0 - 96% ABV

Production od alcohol

Tank GENIO Jacketed 500 + Stripping Column

GENIO Still Jacketed 500 + Stripping Column is ideal for producing taste rich alcohols and for persons / companies developing recipes. The unit comes fully complete and ready for immediate operation.

GENIO Still Jacketed 500 + Stripping Column can be used with liquids containing solids (distillation on-the-grain) that would have otherwise been scorched if used in tanks with direct heating elements.

GENIO Still Jacketed 500 + Stripping Column allows you to manually make your cuts: foreshots, heads, hearts and tails. The cuts can be determined based on the temperature of the vapors in the column, or on the basis of the alcoholic strength of the produced spirit utilizing alcoholmeters.

0,0 l/h (4.8 gal/h)

Achievable production output

0L (122 gal)

Tank operating capacity

0 - 96% ABV

Production od alcohol