Malt Spirits Plants - pssdistillation.com

MALT SPIRIT PLANTS

From grain to glass – PLC-SCADA automated solutions for world-class malt spirit production

EXPLORE

MALT SPIRIT PLANTS

From grain to glass – PLC-SCADA automated solutions for premium malt spirit production

EXPLORE

Malt Spirit Plant Solutions in North India

Engineered to Maintain Product Integrity, Maximize Output & Ensure Compliance

Custom Malt Spirit Plants

PSS Distillation supplies premium-grade malt spirit plants engineered to meet the stringent quality standards of global bottlers. The process design maximizes alcohol recovery per ton of malt while preserving desirable flavor and aroma characteristics. Turnkey project execution covers the entire production sequence, from grain intake and milling to fermentation, distillation, and maturation housing, with advanced process automation for consistent control.

Online CIP systems are integrated to support continuous, hygienic operation with minimal downtime. Energy optimization measures are embedded throughout the plant to reduce utility consumption while maintaining tight quality parameters.

Infrastructure Includes:

Premium Malt Spirit Quality
High Recovery per ton Malt
End-to-End Turnkey Execution
Online CIP Hygienic Operation
PLC-SCADA Process Automation
Temperature and Pressure Control Systems
Grain-to-Maturation Complete Scope

DID YOU KNOW ?

PSS Distillation offers advanced malt spirit plants engineered to consistently deliver premium-quality output that meets the exacting standards of global bottlers. Our precision-driven systems maximize alcohol recovery per ton of malt while safeguarding the rich flavor and aroma profiles that define exceptional spirits.

We have 39+ years of expertise in supporting premium gin producers in scaling production while preserving authentic botanical profiles.

As a complete turnkey solution provider, we cover every stage, from grain handling to maturation, integrating cutting-edge automation and process control for seamless operations. Our plants are equipped with online CIP (clean-in-place) systems, ensuring uninterrupted, hygienic production with minimal downtime.

With a strong focus on energy efficiency, PSS solutions significantly reduce utility costs while maintaining strict quality consistency and operational excellence across the entire distillation process.

Malt production follows a structured sequence beginning with the selection of a neutral grain-based alcohol base, typically derived from wheat, barley, or corn.

Soak barley in water, allow it to germinate, then dry and cool it to develop the enzymes and color needed for distilling.

The malt passes through 4- or 6-roller mills to produce a coarse powder called grist. This is mixed with hot, filtered water in a lauter tun. Natural enzymes (amylases) break down starch into fermentable sugars (maltose, glucose) and dextrins. The resulting sweet, clear liquid, known as wort, is drained off for fermentation.

The cooled wort is transferred to stainless steel fermenters, and specific strains of Saccharomyces cerevisiae yeast are added. Over 3–7 days, yeast metabolizes sugars into ethanol, carbon dioxide, and flavour congeners (esters, higher alcohols). The liquid, now called wash or beer, reaches 6–8% v/v alcohol, ready for distillation.

The wash undergoes double distillation in copper pot stills. The first distillation (wash still) separates volatile alcohols and flavours from water and solids, producing low wines (~20–25% ABV). The second (spirit still) purifies this further. Distillers carefully collect the “middle cut” (heart), discarding foreshots and feints, yielding clean new-make spirit.

The clear new-make spirit is filled into wooden casks—often ex-bourbon or ex-sherry oak—and stored in bonded warehouses. Over several years, the spirit extracts colour, tannins, and vanillin from wood. Oxidation and slow evaporation (the “angel’s share”) mellow harsh compounds, transforming the spirit into complex, smooth whisky.

After reaching the desired maturity, the aged whisky is filtered to remove charcoal particles and diluted with de-mineralized water to bottling strength (usually 40–46% ABV). It is then filled into glass bottles, labeled, sealed, and packed. Finally, the whisky is dispatched for commercial sale and consumer enjoyment.