Distillation Column Packing 101 - - Moonshine Stills

We’ve received a lot of questions about distillation column packing in your moonshine still so I thought I’d write a blog about it. Here, I’m comparing copper mesh and ceramic Raschig Rings, which are the two primary types of column packing used in small-scale distillation in a moonshine still. Note that you would not use either of these types of packing in a flute column because the flute column uses copper bubble plates, which eliminates the need for any other type of column packing. If you need to learn more about flute column packing, check out this blog under Section 2, bullet point 2.

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What’s Better For My Moonshine Still: Copper Mesh or Ceramic Raschig Rings?

This is a matter of preference as well as what you’re distilling in your moonshine still.

Copper mesh is great for reflux distilling, plus the copper reacts with the sulfur compounds formed during fermentation. So the copper helps to eliminate these sulfur compounds from your distillate, which is important when you’re distilling beverage-grade alcohol (where legal) in a moonshine still. The downside to copper mesh is that it does have a shelf life, so you will need to replace it from time to time. You also need to clean it regularly with vinegar. We’ve had several people call in the past who couldn’t figure out why they were getting a foul-tasting product only to reveal that they had NEVER cleaned their copper mesh! EVER! This is the stuff that your vapor passes through, so if you want a clean distillate, you’ll also want to use clean column packing.

Ceramic Raschig Rings are also great for all reflux-type distillation in your moonshine still, including alcohol (where legal). Raschig Rings are also overall better for distilling things like water and essential oils, which require more of an inert type of packing. Unlike with copper mesh, you don’t have to worry about packing the column too tightly, which can cause choking. Choking is when there’s not enough room for the vapor to rise and the refluxing liquid to descend in the column. The ceramic also possesses a greater surface area because of its porous nature, so that combined with the Raschig Rings’ incapacity to cause choking can actually make it easier to attain higher purity distillate than the copper mesh. Raschig Rings are also really easy to clean because you can just use some equipment cleaner—plus, they pretty much last forever. Well, at least until you lose them.

However, Raschig Rings aren’t without their disadvantages either. You’ll need to use them in a distillation column that has a way to hold them in place, such as a screen at the bottom of the lower column portion, so they don’t just fall straight through. This is true for any type of loose column packing, so if you do want to go with Raschig Rings, make sure your distillation column is equipped for it.

How Do I Pack My Distillation Column With Copper Mesh?

1. When you receive a bag of copper mesh, it’s usually in a 30-ft strip. You’re going to cut and roll it to create a kind of mesh “plug” or “roll.” To create a plug for a standard-sized column (2” in diameter), you’ll need to cut a piece about 4 feet long, whereas you’ll need about a 10-foot long strip for a high capacity column (3” in diameter).

2. After you’ve cut your mesh to the length you need, lay it out on the ground. Then loosely roll it up until you have a roll of copper mesh that’s approximately the diameter of your column, about 4-6” wide.

3. Slide this roll into your column. When you slide it into your column, be careful not to squish it too much because that’ll reduce the amount of void space, which is room for the vapor to rise in your column. So it shouldn’t be so tightly packed that you’re cramming it in there, but it also needs to fit snugly enough to hold itself in place.

4. Then cut another piece of copper mesh the same way and repeat the process to make another roll.

5. Make as many rolls as you need until you’ve filled the entire distillation column with copper mesh—both the upper AND lower parts of a 2-piece distillation column. Some people also like to cut small pieces of mesh to put around the cooling lines as well.

How Do I Pack My Distillation Column With Raschig Rings?

1. First, you’ll want to rinse them off with plain water (NO soap!) to remove any dust from packing, transportation, storage, etc. Your vapor is going to climb through these Raschig Rings, so you want them to be clean.

2. Make sure that your distillation column is already assembled. You’re just going to lean it to the side and slowly pour in the Raschig Rings. If any rings catch on the cooling lines on the way down, it’s fine to shake the column a bit to help them work their way to the bottom.

3. Only fill the column to about 1” below where your condenser attaches to the column of your moonshine still. That’s it!

How Much Copper Mesh Do I Need To Buy?

For a standard-sized column (2” diameter), such as the Essential Extractor Pro Series II, expect to use about 1 to 1 ½ bags of copper mesh (approx. 30ft.).

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For a high-capacity column (3” diameter), such as the Essential Extractor PSII High Capacity, you’ll need 3-4 bags of copper mesh depending on how tightly you wrap it.

How Many Ceramic Raschig Rings Do I Need To Buy?

For a standard-sized column, you’ll need 1 ½ L of Raschig Rings.

For a high-capacity column, you’ll want to have 5 L of Raschig Rings.

Can I Use Both Raschig Rings and Copper Mesh Together?

Absolutely! The best way to do this is to put Raschig Rings in the column first and then cut up some little pieces of your copper mesh and put them in and around the cooling lines. If you do combine them, remember that Raschig Rings are heavy: If you put your copper mesh in first and THEN the Raschig Rings, it will completely block your column! So put your Raschig Rings in first and copper at the top. Side note: As an alternative to copper mesh, you could even hit up the plumbing department of your local hardware store and get a handful of copper couplings to toss in—you just want it to have some contact with copper to get the reaction in your moonshine still.

Screen Printing vs. Direct to Film Printing: Which Should You Choose? When it comes to customizing apparel and other items, choosing the right printing method is crucial. Two popular techniques are screen printing and direct-to-film (DTF) printing. Each has its own unique advantages and considerations. Here's a detailed look at the differences between these methods and why you might choose one over the other. Screen Printing Process: Screen printing involves creating a stencil (or screen) and using it to apply layers of ink on the printing surface. Each color in the design requires a separate screen. Advantages: Durability: Screen printing produces vibrant, long-lasting colors that can withstand multiple washes without significant fading. Cost-Effective for Large Orders: The setup process can be time-consuming and costly, but once the screens are created, it's very efficient for large production runs. High Quality: Ideal for bold designs and large areas of solid color. The ink used is thick and produces a high-quality print. Direct to Film (DTF) Printing Process: DTF printing involves printing a design onto a special film using a modified inkjet printer. The film is then transferred onto the desired surface using a heat press. Advantages: Versatility: Can print on a wide range of fabrics, including cotton, polyester, and blends, without the need for pre-treatment. Detailed Designs: Capable of producing highly detailed images and color gradients, making it great for intricate artwork. Considerations: Feel of Print: DTF prints can sometimes feel slightly different on the fabric, as the design sits on top of the material rather than being embedded in it. Which Should You Choose? Choose Screen Printing If: You need to produce a large quantity of items. Your design features bold, solid colors without intricate details. Durability and color vibrancy are top priorities. Choose Direct to Film Printing If: You require a small number of items or even single, custom pieces. Your design includes fine details, color gradients, or photographic elements. You want to print on a variety of materials without the need for extensive setup. Ultimately, the best printing method depends on your specific needs, the nature of your design, and your budget. Both screen printing and DTF printing offer distinct benefits that can help you achieve high-quality, customized products.

Screen printing and decal firing are two commonly used glass bottle decoration processes, each with distinct techniques and effects. They are suitable for different needs and applications. 1. Screen Printing Screen printing is a method where ink is pressed onto the surface of the glass bottle through a mesh screen. A mesh screen is coated with ink, and a squeegee is used to push the ink through the screen onto the glass surface, transferring the design or text. Advantages: Vivid Colors: Screen printing can produce bright, vibrant colors and is ideal for high-contrast designs and detailed graphics. Durability: After the ink is baked onto the glass, it has strong resistance to wear and tear, and the print won't easily fade or peel off. Wide Applicability: It is suitable for printing various patterns, logos, and text. It is especially efficient in mass production. Lower Cost: Compared to other decorative methods, screen printing is more cost-effective, especially in large-scale production. Disadvantages: It is less effective for producing complex gradients or highly detailed small patterns. Each color must be printed separately, which can complicate the process. 2. Decal Firing Decal firing is a process where a pattern or design is transferred onto the glass surface, and then baked at a high temperature to fuse the design to the glass. The design is usually printed on special paper, which is then fired onto the glass, making it permanently adhered. Advantages: Rich Detail: Decal firing can accurately represent complex patterns, gradients, and intricate designs. Versatile Effects: It can achieve effects that are difficult to achieve with screen printing, such as transparent or full-coverage patterns. Premium Quality: Decal firing is often used for high-end products, offering an elegant and sophisticated look due to the fine craftsmanship. Disadvantages: Longer Production Time: The process requires multiple firing stages, which can make it more time-consuming, making it better suited for smaller batches or premium products. Higher Cost: Decal firing is generally more expensive than screen printing, especially when using specialized materials and multiple firing processes. Summary: Screen Printing is ideal for large-scale production, simpler designs, or designs with high color contrast. It offers cost efficiency and fast production times. Decal Firing is better for detailed, gradient, or high-end designs. It provides a more refined and elegant finish but requires longer production times and higher costs. Choosing the right method depends on the design requirements, production volume, and budget. #glassbottlefactory #spiritspackaging #bottlemanufacturing #craftalcohol #glasswareinnovation #shandongxiangdi #glass #tequila #vodka #whiskey #gin #rum #distillery #factory #500ml #700ml #750ml #ml #liquor #packaging #custom #quality #inspection

What’s the DTG pretreatment? DTG printing is commonly widely used in the texture market and is an easy way for anyone with a green thumb to launch a single-printing business. It is simple to print clothes with just one person within minutes. It’s a practical and cost-effective method. Why not make use of screen printing? The process of establishing and implementing screen printing is a bit complicated. Screen printers have to print large quantities to be profitable. This is because they must pay for the screens, and then put them in the press. Contrary to screen printing DTG printing is a simple way to print small amounts of orders. Did you know there’s a specific step to follow in DTG digital printing? This is to, before printing, spray the pretreatment liquid onto the garment material. It is simple to understand. Primer is used to prevent the paint from absorbing into the drywall. The color will fade if the paint has to absorb into the wall. Pretreatment is similar to DTG T-shirts. The pretreatment enables the white ink to adhere to and rest on the top of the shirt. If the ink were to soak in the shirt, it would not be white – it would look more grey. It won’t create an ideal surface to print CMYK on. Find out about the ingredients of this liquid pre-treatment first. The pre-treatment liquid is a type of milky or transparent liquid that has been mixed with water for use while some are not needed. Due to its low molecular weight, the liquid is easy to get into fiber and can modify the surface and the interior of the fiber uniformly and adsorb on the fiber through physical action. It prevents ink and pigment molecules from getting into the fiber. The color will then be able to stick to the surface of the curing layer. Then, the colors appear really bright. How to use the Right DTG Pretreatment? It’s very common for new DTG users to be confused as to the best way to go about it. or dark pretreatment. If you have a light pink shirt one would use a light pretreat, right? In most cases no – but it also depends on the color of the image you print. It is crucial to remember one simple rule: no regardless of what color your shirt is, it must use a dark-colored pretreatment if want to print anything with white ink. It’s similar to “White Ink Pretreatment” but it would be confusing for those wearing white shirts. We’ll discuss the what, why, and what to do with Light and Dark Pretreatment. If you treat a white shirt with light pretreat you will observe a massive difference when compared to no pretreatment. The colors will appear more vibrant and darker colors will be more sturdy and rich. There will be a higher quality of detail and no blurring of the pattern. The pretreatment will also act as a bonding agent once it is heated and will increase the washability. Light garment pretreatment is for white t-shirts and white material. We’ll start with some background information and know-how about printing white shirts with DTG printers. The thing ...

Advantages of UV flatbed printers in photo frame printing The production of photo frame albums belongs to the field of wedding photography. In the early days, it was printed by photo printing machine, and the pattern was printed on special paper, and then mounted in the photo frame. Later, it developed into using weak solvent printers for pattern printing. Due to the heavy pollution and the high requirements of printing on the surrounding environment, it has become less and less suitable in recent years. The corresponding processing companies have adopted UV printing technology as a substitute, which mainly has three advantages: 1. Reduced scrap rate: Solvent printing has high requirements for the surrounding environment. Since it cannot be printed and dried immediately, dust and particles falling on the surface during the solidification process will affect the quality of the pattern and increase the scrap rate of the finished product. Secondly, it needs to be dried and aired. On the one hand, the labor cost is raised, and on the other hand, the printing efficiency is reduced. 2. Although the cost is relatively low to print patterns on special paper using photo printing technology, the pattern has a short storage time, is easy to yellow and curl, and gives users a low-end feeling. 3. In recent years, due to environmental protection requirements, many companies that previously used solvent printing technology need to eliminate backward processes and upgrade to new UV printing, which has also promoted the development of UV printers. Photo frame album UV printing effect diagram: Applicable photo frame album materials: 1. Wood 2. Plastic; 3. Digital; 4. Glass; 5. Aluminum alloy; 6. Crystal; 7. PVC, etc. Considering the final effect of the photo frame album, a layer of varnish will be applied on its surface after UV printing. This not only makes the pattern brighter and the color more vivid, but also has the characteristics of waterproof and scratch resistance, which can ensure that the pattern of the frame will not fall off for decades. The latest machines have built-in varnish function. Generally, photo studios send photos to users with UV printers for printing and processing after shooting. If you are in this market, you may wish to cooperate with local shooting companies, so that it will be easier to get orders. https://lnkd.in/g-8xxFWU

The A3 L Desktop DTF (Direct-to-Film) printer is a specialized printer used primarily for printing designs on film that are later transferred onto textiles, such as t-shirts, bags, and other fabric items. Unlike traditional printing methods, DTF printing does not require a pre-treatment process for fabrics, making it more efficient for certain types of textile printing. Key Features: Print Size: Typically supports A3-sized prints, allowing for fairly large designs. Ink: Uses a specialized set of CMYK (Cyan, Magenta, Yellow, Black) and White inks. The white ink layer is essential for creating a solid base on dark fabrics. Film Transfer: Prints onto a special DTF transfer film, which is then heat-pressed onto the fabric. Ink Efficiency: The ink consumption is relatively low compared to other textile printing technologies, making it cost-effective for small businesses or personal use. Durability: Prints are durable and can survive multiple washes without significant fading or peeling. No Pre-Treatment Needed: One of the key benefits of DTF printing over DTG (Direct-to-Garment) is that it does not require pre-treatment of the fabric before printing. Compatible Fabrics: Works well on a variety of fabrics, including cotton, polyester, blends, and more. Workflow: Design Creation: The design is first prepared using software like Photoshop or Illustrator. Printing on Film: The design is printed onto DTF film, with white ink as a base layer for vibrant color transfer. Powder Application: A special adhesive powder is applied to the printed film while the ink is still wet. Curing: The powder-coated film is cured in a heat press or curing oven. Heat Transfer: The cured film is then heat-pressed onto the garment at a specified temperature. Peeling: After pressing, the film is peeled off, leaving the design firmly adhered to the fabric. This printer is ideal for small businesses, custom t-shirt shops, or individuals looking to create high-quality prints for personal or commercial use.

In DTF printing, special inkjet printers are used to print designs onto a film transfer. These printed transfers are then applied directly to fabric using heat and pressure. Unlike traditional methods such as screen printing or DTG (Direct to Garment), DTF doesn’t require pre-treatment and can be used on a wide variety of materials, including cotton, polyester, and blends. Process of DTF Printing: Design Creation: The design is prepared using design software like Photoshop or CorelDRAW. Printing: The design is printed onto a special PET (polyethylene terephthalate) film using DTF ink, which includes CMYK colors and white ink. Powder Application: After printing, a special adhesive powder is applied to the wet ink on the film. This powder is what helps the design bond to the fabric. Curing: The printed film with the powder is then passed through a curing process, typically using a heat press, to solidify the adhesive. Transfer: Once cured, the printed film is placed onto the fabric, and a heat press is used to apply the design permanently. The film is peeled away, leaving the printed design on the fabric. Advantages of DTF Printing: Versatility: Works on various fabric types, unlike DTG, which is primarily for cotton. No Pre-treatment Needed: Unlike DTG printing, where the fabric needs to be pre-treated, DTF does not require this step. Vibrant Colors: Produces sharp, vibrant prints with a wide color range. Durability: The prints are durable, resistant to washing and stretching, and feel soft to the touch. Cost-Effective for Small Batches: It’s well-suited for small-scale productions or custom prints without the setup costs of screen printing. Limitations: Complex Setup: While not as expensive as screen printing in terms of setup, DTF does require specialized equipment and materials like films and powders. White Ink Requirement: It relies on white ink for opaque prints, which can add to the cost. Learning Curve: Achieving the right print quality and curing process requires some trial and error.

Steps to customize roll stock film, do you know it? Customizing roll stock film typically involves the process of printing or applying labels on the film to add branding, product information, or other desired elements. Here are the general steps to customize roll stock film: 1. Determine the Design: Decide on the design elements you want to incorporate on the film. This may include logos, text, images, barcodes, nutritional information, or any other relevant information like eyemark. Besides, the impression/ repeat size which suitable for your product is also important before your design. 2. Graphic Design: Create or prepare the graphic design files that will be printed or applied to the film. You can use graphic design software like Adobe Photoshop or Illustrator to create the design. Ensure that the design is in the appropriate format for printing, such as high-resolution images (usually in vector format for scalability). 3. Select the Printing Method: There are various printing methods available for customizing roll stock film, including flexographic printing, rotogravure printing, digital printing, or even applying labels. Choose the method that suits your requirements, budget, and the complexity of the design. 4. Film Structure: It is the most important thing for roll film. Based on the products, we can use different film structure and thickness. For example, for products need avoid moisture or light, we will use foil film , for products need keep in frozen temp, we will use Nylon material. Besides, we also need know your Auto-packing machine operating condition like sealing temperature to design the material structure. 5. Finished Roll film size and unwind orientation : We need consider the rewind width, and roll and core diameter to suit your packing machine. Besides, the unwind orientation is also need be consider. we have different way to make it. 6. Quality Control: After printing or labeling, perform quality control checks to ensure the customization meets your standards. Inspect the printed film for color accuracy, legibility of text, image clarity, and overall appearance. Address any issues before moving forward. 7. Roll and Package: Once the customization is complete and quality control is passed, roll the film back onto suitable cores or reels. Package the rolls securely, considering protection against dust, moisture, and other environmental factors that may affect the film.

FOIL EMBELLISHMENT FOR PRINTING In the world of printing, foil embellishment is a popular technique used to add a touch of sophistication and luxury to printed materials. Foil embellishment involves the application of a thin layer of metallic foil to paper or card stock using a specialized printing process. This results in a shiny and reflective finish that catches the light and adds a high-end feel to the printed piece.   Foil embellishment is typically done using a process called hot foil stamping. In this process, a design or text is first printed onto the paper or card stock using traditional printing methods, such as offset printing or digital printing. Once the base design is printed, a metallic foil sheet is placed over the printed area and the paper is then run through a heated press. The heat and pressure from the press cause the foil to adhere to the paper, creating a shiny and metallic finish on the printed piece.   Foil Colors and Finishes Foil embellishment comes in a variety of colours and finishes to suit different design needs. Some popular foil colours and finishes include:   - Gold: a classic choice for a luxurious and high-end look, exist in bright gold, rose gold, mat gold, old gold - Silver: a sleek and sophisticated option that works well with a variety of designs, available in bright or mat silver - Copper: a warm and vibrant choice that adds a unique touch to printed materials - Holographic: a fun and eye-catching option that adds a touch of magic to any design. - A whole range of almost all metallic colours is also available from our 2 suppliers   In conclusion, foil embellishment is a versatile and luxurious technique that can elevate the look of printed materials and make them stand out. Whether used on business cards, invitations, packaging, or stationery, foil embellishment adds a touch of sophistication and luxury that is sure to impress. If you're looking to take your printed materials to the next level, consider incorporating foil embellishment into your design. I have used extensively foil embellishment over the past 20 years.

Steps to customize roll stock film: Customizing roll stock film typically involves the process of printing or applying labels on the film to add branding, product information, or other desired elements. Here are the general steps to customize roll stock film: 1. Determine the Design: Decide on the design elements you want to incorporate on the film. This may include logos, text, images, barcodes, nutritional information, or any other relevant information like eyemark. Besides, the impression/ repeat size which suitable for your product is also important before your design. 2. Graphic Design: Create or prepare the graphic design files that will be printed or applied to the film. You can use graphic design software like Adobe Photoshop or Illustrator to create the design. Ensure that the design is in the appropriate format for printing, such as high-resolution images (usually in vector format for scalability). 3. Select the Printing Method: There are various printing methods available for customizing roll stock film, including flexographic printing, rotogravure printing, digital printing, or even applying labels. Choose the method that suits your requirements, budget, and the complexity of the design. 4. Film Structure: It is the most important thing for roll film. Based on the products, we can use different film structure and thickness. For example, for products need avoid moisture or light, we will use foil film , for products need keep in frozen temp, we will use Nylon material. Besides, we also need know your Auto-packing machine operating condition like sealing temperature to design the material structure. 5. Finished Roll film size and unwind orientation : We need consider the rewind width, and roll and core diameter to suit your packing machine. Besides, the unwind orientation is also need be consider. we have different way to make it. 6. Quality Control: After printing or labeling, perform quality control checks to ensure the customization meets your standards. Inspect the printed film for color accuracy, legibility of text, image clarity, and overall appearance. Address any issues before moving forward. 7. Roll and Package: Once the customization is complete and quality control is passed, roll the film back onto suitable cores or reels. Package the rolls securely, considering protection against dust, moisture, and other environmental factors that may affect the film.

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