A dive into the centuries-old tradition of making vodka from grain
Preparing the raw materials: the foundation of the spirit’s character
Main steps
The process begins with choosing the “gold reserve”, the grain. Rye, wheat, barley, oats, buckwheat, corn and even peas form an orchestra of flavors. The grain is carefully cleaned of impurities: stones, straw, weed seeds. Then the malt is prepared, which is sprouted grain that activates the enzymes that break down starch.
Technical parameters
- Malt to grain ratio: 1:8 (for 1 part of malt, 8 parts of unmalted grain).
- Grain moisture: no more than 14-15% (over-dried grain gives up its sugars less readily).
- Malt sprouting temperature: 15-20°C (sprouts 5-6 mm long are ideal).
Example: A batch of 50 kg of grain needs 6.25 kg of malt.
Warnings
- Do not use feed grain — a high risk of fungal toxins.
- Avoid overheating when drying malt — a temperature above 40°C will kill the enzymes.
Recommendations
- Rye malt adds spicy notes, barley malt adds smoothness.
- Historical fact: In the 19th century peasants added oats to the grain bill to soften the taste, and buckwheat for astringency.
Milling: the balance between flour and grits
Main steps
The grain is crushed to a state of “coarse flour” (particles of 0.5-1 mm). The malt is milled separately or together with the main grain.
Technical parameters
- Particle size: 0.5-1 mm (a fine grind blocks filtration, a coarse one lowers the sugar yield).
- Equipment: millstones (traditional) or roller mills (modern).
Warnings
- The dust-like fraction clumps together, disrupting saccharification.
- Metal impurities from mills can oxidize the wort.
Recommendations
- Checking the grind: a handful of the crushed grain should crumble like damp sand.
- Life hack: Moisten the grain slightly before crushing, which reduces dust.
Mashing: the alchemy of turning starch into sugar
Main steps
The crushed grain is mixed with water in a mash tun. The mixture is heated in stages, activating the malt enzymes.
Technical parameters
- Water-to-grain ratio: 1:5 (5 L of water per 1 kg of grain).
- Temperature rests:
- 50°C — protein breakdown (20 min).
- 63-65°C — starch saccharification (1.5-2 hours).
- 72°C — final dextrinization (15 min).
Example: 10 kg of grain needs 50 L of water.
Warnings
- Overheating above 70°C kills the enzymes, and the starch will not turn into sugar.
- If the grain is poorly milled, “dead zones” without contact with water will remain.
Recommendations
- Iodine test: A drop of iodine in the mash should not turn blue, a sign of complete saccharification.
- Historical method: In villages the mash was wrapped in sheepskin blankets to keep the heat.
Fermentation: the birth of alcohol
Main steps
The mash, cooled to 26-28°C, is pitched with yeast. The fermentation vessel is fitted with an airlock to vent CO₂.
Technical parameters
- Temperature: 26-30°C (at 35°C the yeast dies).
- Duration: 3-5 days (until the airlock stops bubbling).
- Wash strength: 8-12% ABV (depends on the sugar content of the grain).
Warnings
- Wild yeast causes off-aromas, so pure cultures must be used.
- Mold on the surface is a sign of contamination and requires restarting the process.
Recommendations
- Yeast strains: Use special strains for grain washes to enhance the aroma.
- Tip: Add 5% barley malt, which contains nitrogen that stimulates the yeast.
First distillation: separating the soul of the wash
Main steps
The wash is traditionally distilled in a copper still, collecting a distillate (“first run”, pervach) of 25-30% ABV.
Technical parameters
- Heating: gradual (copper vessels distribute heat evenly).
- Cutting fractions (take-off):
- “Heads” (the first 5-7%) — contain methanol and acetone (discarded).
- “Hearts” (the main fraction) — the target spirit.
- “Tails” (the last 10-15%) — fusel oils (redistilled).
Warnings
- Sudden heating causes scorching, as the wash sticks to the walls of the boiler (kettle).
- Insufficient cooling of the vapor leads to alcohol losses.
Recommendations
- Copper wire in the boiler binds sulfur compounds, cleaning the distillate.
- Watching the drops: The first drops have a sharp smell, the signal to start taking off the “heads”.
Second distillation: polishing the character
Main steps
The low wines, diluted to 20-25% ABV, are distilled again, carefully separating the fractions.
Technical parameters
- Boiling point:
- 78.4°C — ethyl alcohol.
- 82.6°C — isoamyl alcohol (fusel oil).
- Strength of the “hearts”: 75-80% ABV (40-45% ABV after dilution).
Warnings
- Mixing the “heads” and “tails” with the “hearts” spoils the taste.
- Hard water causes cloudiness when diluting.
Recommendations
- Resting: Letting it settle in glass bottles for 7-10 days rounds out the taste.
Filtration and clarification: the path to crystal clarity
Main steps
The distillate can be passed through layers of rye bread, charcoal or quartz sand.
Technical parameters
- Filtration rate: 1-2 L/hour (a slow process increases effectiveness).
- pH of the dilution water: 6.5-7 (neutral, so that salts do not precipitate).
A historical life hack
In tsarist times, egg white was used for clarification — 1 white per 50 L of spirit.
Summary: the philosophy of quality
Making bread wine is a synthesis of science and art. Every stage demands meticulousness: from choosing the grain to controlling the distillation temperature.
- The golden rule: Better to lose some volume but keep the purity of the taste.
- A master’s secret: Use local grain, which gives the drink a unique “terroir”.
“Bread wine is a dialogue with the earth. Every drop holds the whisper of the ears of grain, the heat of the oven and the wisdom of our ancestors.”