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How to Split Fruit Low Wines in Samovar 7.00 and Keep an Aromatic Hearts Cut

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How to Split Fruit Low Wines in Samovar 7.00 and Keep an Aromatic Hearts Cut

When working with fruit raw material, you do not always need to send all the low wines to deep rectification. Rectification gives clean high-proof spirit, but at the same time removes a significant part of the fruit aroma.

A practical compromise: produce low wines, run a second distillation in “Distillation” mode, separate a small aromatic portion (the hearts) and store it separately, and send the rest of the product to rectification. Then the rectified spirit can be blended with the saved aromatic hearts.

Apple low wines processing diagram

1. Calculating the Initial Absolute Alcohol

50 L of cider at 8% ABV theoretically contains:

50 × 8 / 100 = 4 L of absolute alcohol

The actual amount of absolute alcohol is determined from the low wines you actually obtained:

AA = low wines volume × low wines strength / 100

For example, for 12 L of low wines at 30%:

12 × 30 / 100 = 3.6 L AA

2. First Distillation of the Cider

The first distillation is needed to obtain low wines. At this stage there is no point in aiming for high strength or in separating fractions finely. The goal is to process the cider, get low wines and preserve the fruit aroma.

Samovar uses the “Primary distillation” mode. Take-off can continue until the alcohol in the boiler runs out, either until only water is left or until the set boiler temperature limit is reached. When it finishes, measure the volume and strength of the low wines.

3. How to Determine the Size of the Hearts Cut to Keep

The hearts cut is set as a share of the absolute alcohol in the initial low wines, not as a fixed volume of liquid.

If the low wines contain 3.6 L AA and you want to keep 12%:

3.6 × 12 / 100 = 0.432 L AA

This is not 0.432 L of finished distillate. The liquid volume depends on its actual strength.

4. Why the Hearts Percentage Is Calculated from Absolute Alcohol

At the start of the second distillation the take-off strength is higher, and then it falls. So the share of liquid volume is not equal to the share of absolute alcohol. Calculating via AA lets you set the target in terms of a material balance.

Parameter Value
Low wines 12 L
Strength 30%
Initial AA 3.6 L
Share to keep 12%
Target AA of the hearts 0.432 L

5. Principle of the Second Distillation Program

In “Distillation” mode Samovar uses lines of the form:

Type;Value;Container;Voltage

The main condition types: T — boiler temperature; A — absolute alcohol strength in the boiler; S — relative change in alcohol strength in the boiler; P — calculated absolute alcohol strength of the take-off; R — relative change in alcohol strength of the take-off.

The P condition is convenient for separating the aromatic hearts. The example below is calculated for a regulator where the power field is set in watts:

T;85;0;1800
A;80;1;0
P;60.00;2;0
P;57.18;1;0

Container 2 is for the hearts you keep, container 1 is for the rest of the product.

Samovar 7.00 program logic

6. How the Second P Threshold Was Obtained

The percentage of hearts to keep alone does not tell Samovar at which take-off strength it should switch the container. For a preliminary calculation, a simplified batch distillation model with a constant relative volatility coefficient α is used.

The example assumes α = 4.0. This is a conditional model parameter, not a universal characteristic of the apparatus. The calculation is approximate: it is meant for a starting program and must be checked against the actual log of the run.

To keep the material balance correct, the model calculates the composition in moles, accounting for ethanol and water separately. With initial low wines of 12 L at 30%, the start of the hearts at a calculated P=60% and a target of 0.432 L AA, the model gives the end of the hearts at approximately P=57.18%.

This threshold is not a chemical boundary between fractions. Samovar calculates alcohol strength mathematically, and the actual strength and composition of the product may differ. So after the run, record the volume, strength and sensory profile of each fraction; then adjust the threshold for the next batch.

7. What to Send to Rectification

The heads, tails and the remaining part of the hearts that you do not plan to keep go to rectification. The hearts you keep are not included in the column charge.

Before rectification, combine the fractions intended for the column and measure the total volume and strength. For example, for 10 L of remainder at 28%:

10 × 28 / 100 = 2.8 L AA

8. Setting Up the Rectification Program

In rectification mode the lines have a different format:

Type;Volume_ml;Speed_L_h;Container;Switch_temperature;Voltage

For fruit low wines, you can use as starting settings about 8% AA for heads, about 5% AA for tails and a target hearts strength of about 94%. These values are not universal norms.

For the example with 10 L of low wines at 28%, the calculated lines may look like this:

H;238;0.100;1;0;1700
B;2591;0.400;2;0;0
T;149;0.200;1;0;0

Here 1700 is power in watts for the SEM_AVR regulator. For a voltage-type regulator, use the value in volts calculated for your particular heating element.

Fruit spirit and a reflux column

9. Why 94% Is a Target, Not a Guaranteed Strength

The actual strength depends on the diameter and height of the column, the packing, power, take-off rate, cooling and the composition of the charge. So after rectification, measure the strength and, if needed, adjust the power, speed and parameters of the next program.

10. Blending the Rectified Spirit with the Aromatic Hearts

First, it is worth making small test blends with different shares of hearts, for example 5%, 10%, 15% and 20% of the alcohol part. Bring the samples to the same strength of 43–45% and let them rest for at least a week.

Summary Scheme

50 L of cider 8%
→ first distillation until the alcohol runs out
→ measure the volume and strength of the low wines
→ second distillation
→ separately keep the calculated share of hearts
→ the rest goes to rectification
→ rectified spirit at about 94%
→ blend with the aromatic hearts

The main principle is to calculate the hearts to keep from the absolute alcohol, not from the liquid volume. The program thresholds are calculated values and need calibration for your particular apparatus.

Samovar Documentation

This material describes the calculation logic and automation setup. Before working in practice, take into account the design of your setup, the condition of the equipment, ventilation, fire safety and the current rules on the production and handling of strong alcoholic beverages.

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