FM Global

Property Loss Prevention Data Sheets 7-74

January 2010
Page 1 of 10

DISTILLERIES

Table of Contents
Page

1.0 SCOPE ................................................................................................................................................... 2

1.1 Changes .......................................................................................................................................... 2
2.0 LOSS PREVENTION RECOMMENDATIONS ....................................................................................... 2
2.1 Introduction ...................................................................................................................................... 2
2.2 Construction and Location ............................................................................................................... 2
2.2.1 Mashing and Fermenting ...................................................................................................... 2
2.2.2 Distilling ................................................................................................................................. 2
2.2.3 Distilled-liquor Handling ......................................................................................................... 2
2.3 Occupancy ....................................................................................................................................... 2
2.3.1 Mashing and Fermenting ...................................................................................................... 2
2.3.2 Distilling ................................................................................................................................. 3
2.3.3 Distilled-liquor Handling ......................................................................................................... 3
2.4 Protection ......................................................................................................................................... 4
2.4.1 General .................................................................................................................................. 4
2.5 Ignition Source Control .................................................................................................................... 5
2.5.1 Distilling ................................................................................................................................. 5
2.5.2 Distilled-Liquor Handling ........................................................................................................ 5
3.0 SUPPORT FOR RECOMMENDATIONS ............................................................................................... 5
3.1 General ............................................................................................................................................ 5
3.2 Loss History ..................................................................................................................................... 6
4.0 REFERENCES ....................................................................................................................................... 7
4.1 FM Global ........................................................................................................................................ 7
4.2 NFPA Standards .............................................................................................................................. 7
APPENDIX A GLOSSARY OF TERMS ....................................................................................................... 7
APPENDIX B DOCUMENT REVISION HISTORY ....................................................................................... 7
APPENDIX C SUPPLEMENTAL INFORMATION ........................................................................................ 7
C.1 Process Description ........................................................................................................................ 7
C.1.1 Mashing and Fermenting ...................................................................................................... 7
C.1.2 Distilling ................................................................................................................................. 9
C.1.3 Distilled-Liquor Handling ....................................................................................................... 9
C.1.3.1 Wine-Tank Room ..................................................................................................... 10
C.1.3.2 Blending or Cistern Room ....................................................................................... 10
C.1.3.3 Regauging ............................................................................................................... 10
C.1.3.4 Recoopering ............................................................................................................ 10
C.1.3.5 Blending and Bottling .............................................................................................. 10
APPENDIX D NFPA STANDARDS ............................................................................................................ 10

List of Figures
Fig. 1. Flash and fire points of alcohol/water mixtures. ................................................................................. 6
Fig. 2. Flow diagram: grain preparation and fermentation. ........................................................................... 8
Fig. 3. Simplified flow diagram: distilling. ....................................................................................................... 9

List of Tables
Table 1. Sprinkler Protection Requirements for Distilleries .......................................................................... 4

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7-74 Distilleries
Page 2 FM Global Property Loss Prevention Data Sheets

1.0 SCOPE
This data sheet covers the fire and explosion hazards associated with the production of distilled spirits. It
includes recommendations to minimize losses from these hazards.

1.1 Changes
January 2010. Minor editorial changes were made for this revision.
January 2000. This revision of the document has been reorganized to provide a consistent format.

2.0 LOSS PREVENTION RECOMMENDATIONS

2.1 Introduction
2.1.1 Grain handling, milling and feed preparation facilities should be designed, arranged and safeguarded
in accordance with Data Sheet 7-75, Grain Storage and Milling.

2.2 Construction and Location

2.2.1 Mashing and Fermenting

2.2.1.1 Mashing and fermenting areas should preferably be of fire-resistive or noncombustible construction.

2.2.2 Distilling
2.2.2.1 Distilling operations should be separated from other buildings by at least 100 ft (30 m). Existing
still-buildings that adjoin other buildings should be completely cut off by blank fire walls, parapeted above
adjoining buildings. Avoid basements, pipe trenches and other spaces beneath still-buildings.
2.2.2.2 Preferably locate distilling equipment in the open with a minimum of enclosing structure. Any
structures should be of damage-limiting construction (see Data Sheet 1-44, Damage-Limiting Construction).
Load-bearing steel members and exposed steel equipment supports should be fireproofed with a material
having a minimum two hours fire-resistance rating. For existing buildings of substantial construction, provide
explosion venting capacity through venting windows and roof panels in as high a ratio as practical.
2.2.2.3 Floor cutoffs are advisable at operating levels in high, enclosed buildings. If complete floor cutoffs
are not practical, provide solid noncombustible mezzanines with curbs at levels supporting receivers or other
equipment containing appreciable quantities of flammable liquids.
2.2.2.4 Unless the maximum possible spill can be extinguished by dilution while confined, provide emergency
drainage facilities for the distilling area or building to prevent escaping liquids from exposing other areas
or buildings.

2.2.3 Distilled-liquor Handling

2.2.3.1 Distilled-liquor handling areas should preferably be of fire-resistive or noncombustible construction.
2.2.3.2 Distilled-liquor handling areas should be cut off from surrounding occupancies. Vertical cutoffs
should be provided in multistory buildings. Cutoffs should have at least a one hour fire-resistance rating.
2.2.3.3 Provide curbs, ramps or trapped floor drains at doorways and other openings to prevent the spread
of flammable liquids to other departments. Floor drains in each distilled-liquor handling area should be
designed to handle expected sprinkler discharge unless the maximum possible spill can be extinguished by
dilution while confined.

2.3 Occupancy

2.3.1 Mashing and Fermenting

2.3.1.1 Grain meal should be discharged to precookers only through tight connections to prevent liberation
of dust.

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FM Global Property Loss Prevention Data Sheets Page 3

2.3.2 Distilling
2.3.2.1 Pressure vessels should be designed and constructed in accordance with applicable codes, stan-
dards, state and local laws and regulations.
2.3.2.2 Stills should be equipped with vacuum and pressure relief devices piped to outdoors. Any con-
denser vents should also be piped to outdoors. Vents should be sized to discharge the maximum vapor gen-
eration possible at zero feed and maximum heating within the pressure limitations of the protected equipment.
Vents should terminate at least 20 ft (6.1 m) above the ground and preferably at least 6 ft (1.8 m) above
roof level and be so located that vapor will not re-enter the building. Vent terminals should be equipped with
flame arresters.
2.3.2.3 Equipment should be designed and maintained to eliminate or at least minimize any liquid and vapor
leaks.
2.3.2.4 Where gauges are needed, use Factory Mutual Research Approved1 gauging devices. If ordinary
gauge glasses are used, both connections should be normally kept closed and be provided with weight-
operated, quick-closing valves. Protect the glass against mechanical injury. Tail boxes should be replaced
with armored rotameters and specific gravity indicators where possible, or with other instrumentation not sub-
ject to accidental breakage or leakage.
2.3.2.5 The steam supply for distillation should be thermostatically controlled and interlocked to shut down
and sound an audible alarm on cooling-water failure. Alternately, powered standby pumps or gravity sup-
plies of cooling water should be provided.
2.3.2.6 Stills and other large equipment containing flammable liquids should be purged with steam or an
inert gas (steam will be most generally available) before opening for inspection or repair. Equipment should
be washed with water following steaming.
2.3.2.7 Ventilation designed and installed to ensure air movement throughout the entire structure should
be provided to prevent the accumulation of explosive vapor-air concentrations within the building. The stack
effect (i.e., natural ventilation) may suffice if the building is high, permanent openings are provided at grade
and roof elevations, the equipment can be drained and cleared of vapors during shutdowns, and heat losses
from the equipment maintain a temperature above that of the outdoors during all operating periods. If these
operating conditions cannot be satisfied, or if block walls or solid floors interfere with natural ventilation,
mechanical exhaust ventilation should be designed to provide 1 cfm/ft2 (0.3 m3/min/m2) of floor area. Locate
suction intakes near floor level to ensure a sweep of air across the area.

2.3.3 Distilled-liquor Handling

2.3.3.1 Noncombustible, vapor-tight construction should be used for all tanks containing flammable con-
centrations of alcohol. Tanks should be kept tightly closed except when taking samples.
2.3.3.2 Tanks should be equipped with vents of adequate size terminating outdoors. See Data Sheet 7-88,
Storage Tanks for Flammable and Combustible Liquids, for sizing vents using 50% of the recommended
area per the Emergency Venting section. Vents should be equipped with Approved flame arresters if the flash-
point of the contents is less than 100°F (38°C).
2.3.3.3 Approved liquid-level gauges should be installed on all tanks. If ordinary gauge glasses must be
used, weight-operated, normally closed valves should be installed at both tank connections and the glass pro-
tected against physical damage. Wherever possible, top tank connections should be provided and liquids
transferred by pumping through the top rather than by gravity flow. If draw-off stations are located in the same
area as the supply tank, automatically operated emergency shutoff valves should be provided in gravity-
feed lines. Flexible metallic hose should be used on all connections to scale tanks where fire exposure would
release the tank contents or expose its vapor space.

References to ‘‘Approved’’ in this data sheet means the product and services have satisfied the criteria for Factory
Mutual Research Approval. Refer to the Approval Guide for a complete listing of products and services that are
Factory Mutual Research Approved.

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7-74 Distilleries
Page 4 FM Global Property Loss Prevention Data Sheets

2.3.3.4 Mechanical exhaust ventilation should be provided as needed. Ventilation should be arranged with
suction near floor level to ensure air movement throughout the building. At dump troughs and similar instal-
lations, localized intakes are desirable. Careful attention should be given to below-grade installations, win-
dowless buildings, sumps, pipe trenches and similar installations. Usually, 0.25 cfm of air per ft2 of floor area
(0.075 m3/min/m2) will be adequate. The use of Approved portable flammable vapor indicators to check the
need of adequacy of ventilation is recommended.

2.4 Protection

2.4.1 General
2.4.1.1 Provide automatic sprinkler protection for distilleries in accordance with Table 1.

Table 1. Sprinkler Protection Requirements for Distilleries

Type of Sprinkler Density Area of
Sprinkler Temperature Rating°F gpm/ft2 Demand
Occupancy System (°C) (mm/min) ft2 (m2)
Mashing and Wet Any 0.15 (6) 2500 (232.2)
Fermenting1 Dry Any 0.15 (6) 3500 (325.2)
Still House2,3 Wet 212-286 (100-141) 0.30 (12) 5000 (464.5)
1st level, solid at roof and each level
intermediate levels
and roof 0.15 (6)
grated intermediate
levels
Tank Rooms4 Wet 212-286 (100-141) 0.25 (10) 3000 (278.7)
Wet 160 (71) 0.25 (10) 4000 (371.6)
Dry 212-286 (100-141) 0.25 (10) 5000 (464.5)
Dry 160 (71) 0.25 (10) 6000 (557.4)
Barrel Dumping and Wet 212-286 (100-141) 0.25 (10) 4000 (371.6)
Filling Areas Wet 160 (71) 0.25 (10) 6000 (557.4)
Bottling Areas Wet 212-286 (100-141) 0.20 (8) 3000 (278.7)
Wet 160 (71) 0.20 (8) 4000 (371.6)
Dry 160 (71) 0.20 (8) 5000 (464.7)
1
For combustible construction or equipment only. Automatic sprinkler protection is not needed if both construction and equipment are
noncombustible.
2
Considering the water solubility of ethyl alcohol and the lower flammability compared to hydrocarbons assume that 50% of the sprinklers
over the area of demand will open for multi-level facilities.
3
Provide automatic sprinkler or water spray protection for enclosed still areas in accordance with Data Sheet 7-14, Fire & Explosion
Protection for Flammable Liquid, Flammable Gas & Liquefied Flammable Gas Processing Equipment & Supporting Structures.
4
Tanks exceeding 10 ft2 (0.9 sq m2) in bottom surface area should have sprinklers provided beneath them. In determining water require-
ments, include any such sprinklers located within the area of demand specified in Table 1.

2.4.1.2 Sprinkler control valves, dry pipe valves and riser drains should be readily accessible at all times
to plant personnel. This is particularly important for areas under direct government supervision that may be
locked during non-operating periods.
2.4.1.3 Small hose with combination shutoff nozzles should be provided throughout the distillery in accor-
dance with Data Sheet 4-4N, Standpipe and Hose Systems (NFPA). Hose stream demand is a minimum of
500 gpm (1900 dm/min3) for at least 60 minutes.
2.4.1.4 Suitable portable fire extinguishers should be provided throughout the distillery in accordance with
Data Sheet 4-5, Portable Extinguishers.

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FM Global Property Loss Prevention Data Sheets Page 5

2.5 Ignition Source Control

2.5.1 Distilling
Electrical equipment, including wiring and lights, should be suitable for Class 1, Group D locations in
accordance with Data Sheet 5-1, Electrical Equipment in Hazardous Locations. Still-buildings should be con-
sidered Division 2 locations.

2.5.2 Distilled-Liquor Handling

Electrical equipment, including wiring and lights, should be suitable for Class 1, Group D locations in
accordance with Data Sheet 5-1, Electrical Equipment in Hazardous Locations. Tank storage areas should
be treated as Division 2 locations. For other distilled-liquor handling areas, follow the guidelines of Figure 1
of Data Sheet 5-1, for determining proper electrical equipment.

3.0 SUPPORT FOR RECOMMENDATIONS

3.1 General
Distilleries are often located in rural districts because large supplies of pure water are needed for process pur-
poses. Remoteness from city water supplies and fire departments places the responsibility for fire protec-
tion almost entirely on the facility itself. Safety also depends on good construction, and proper arrangement
and safeguards for processes.
Because of the fire and explosion hazards inherent in handling large quantities of flammable liquids, safety
depends on supervision by well-trained operators, good maintenance and process equipment safeguards.
Grain handling, milling and feed preparation at distilleries present dust explosion hazards. Although grains and
feeds are slow burning, fires in these materials may be deep-seated and difficult to extinguish. Wet grains
will heat and sour if not dried promptly.
Process fire and explosion hazards are present during distilling, but are considered negligible during mash-
ing and fermenting. Strict government regulations which require seals on every pipe joint, valve and spigot
reduce the probability of flammable liquid or vapor being released during distilling operations.
Flammable liquid hazards are also present in varying degrees in the various distilled-liquor handling areas.
The flash and fire points of alcohol/water mixtures are shown in Figure 1.
Because of ethyl alcohol’s lower heat of combustion, and radiant heat energy, and its complete miscibility
with water, lower sprinkler system demands are required than with other flammable liquids of equivalent
flashpoint.
Bottled distillery products vary in alcohol content:

U.S. Proof Alcoholic Content, % by volume

Whiskeys 80-100 40-50
Gins 80-95 40-471⁄2
Vodkas 80-100 40-50
Rums 80-140 40-70
Brandies 80-140 40-70
Cordials, Liqueurs 40-100 20-50
Cocktails 20-100 10-50
Alcohol (Neutral Spirits) 110-192 55-96

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7-74 Distilleries
Page 6 FM Global Property Loss Prevention Data Sheets

Fig. 1. Flash and fire points of alcohol/water mixtures.

The quantity of water needed to extinguish fires in alcohol-water mixtures depends upon the temperature of
the liquid above its fire point and the effectiveness of mixing. The amount of water can be estimated from
the following formula, assuming perfect mixing:
Volumes of water needed per volume of burning liquids = % alcohol in solution before fire -1
% alcohol at point of fire extinguishment

Assume that a solution will be extinguished when the alcohol concentration is reduced to 20%. Applying
the formula, a mixture containing 95% alcohol would require 3.75 volumes of water to extinguish each vol-
ume of burning liquid. A mixture containing 50% alcohol would require 1.5 volumes.

3.2 Loss History

A survey2 of distilling industry losses for the years 1933-1981 indicated that approximately 65% of all prop-
erty damage resulted from fires in 14 unsprinklered distilled spirits warehouses. However, several serious
fire and explosion losses occurred in still-buildings and bottling-houses. All of the serious bottling-house fires
also occurred in unsprinklered buildings. The most serious losses in still-buildings involved explosions with
ensuing fires where sprinkler systems were damaged by the explosion. Several fires also occurred in driers
processing dried grains from spent stillage or slops.
Appendix G of Recommended Fire Protection Practices for Distilled Spirits Beverage Facilities-A Suggested
Guide, prepared by the Distilled Spirits Council of the United States, Inc. (DISCUS) dated December, 1981.

©1999 Factory Mutual Insurance Company. All rights reserved.

Distilleries 7-74
FM Global Property Loss Prevention Data Sheets Page 7

4.0 REFERENCES

4.1 FM Global
Data Sheet 1-44, Damage-Limiting Construction.
Data Sheet 4-4N, Standpipe and Hose Systems.
Data Sheet 4-5, Portable Extinguishers.
Data Sheet 5-1, Electrical Equipment in Hazardous Locations.
Data Sheet 7-14, Fire & Explosion Protection for Flammable Liquid, Flammable Gas & Liquefied Flammable
Gas Processing Equipment & Supporting Structures.
Data Sheet 7-75, Grain Storage and Milling.
Data Sheet 7-88, Storage Tanks for Flammable and Combustible Liquids.

4.2 NFPA Standards

NFPA 30, Flammable and Combustible Liquids Code, National Fire Protection Association, Quincy, MA.

APPENDIX A GLOSSARY OF TERMS

Proof: numerical value normally equivalent to two times the alcohol content by volume of a distilled spirit
product.

APPENDIX B DOCUMENT REVISION HISTORY

This document does not have any revision history.

APPENDIX C SUPPLEMENTAL INFORMATION

Spirituous-liquor distilleries primarily produce whiskeys, gins, vodkas, rums, brandies and similar beverages.
Industrial grain alcohol, denatured alcohol and stock feed are by-products.
Whiskey is obtained by the distillation of a fermented mash of cereal grains such as corn, rye or barley. About
10 bu (352 dm3) of grain are required to produce a 50 gal (189 dm3) barrel of 100 proof (50% alcohol)
whiskey.
Gins, cordials and liqueurs are obtained by redistillation in contact with flavoring substances, aromatic
tinctures and sugar syrups. Another method is to add flavoring and coloring materials directly to neutral alcohol
solutions without distillation.
Vodka is obtained by filtering grain neutral spirits through charcoal.
Rum is produced by distilling fermented molasses. Some whiskeys and industrial alcohols are also produced
from molasses. Brandies are the product of distillation of wines or fermented fruit juices.

C.1 Process Description

The basic steps in the production of distilled spirits are mashing and fermenting, distilling and distilled-liquor
handling.

C.1.1 Mashing and Fermenting

The first step in the production of distilled spirits is the manufacture of beer. The flow diagram for grain
preparation and fermentation is shown in Figure 2. Meal from storage bins is weighed, charged with water,
and transferred to mash tubs or pressure cookers where the mixture is cooked for several hours. Mash tubs
operate at atmospheric pressure and a temperature of about 212°F (100°C). Steam pressure cookers may

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7-74 Distilleries
Page 8 FM Global Property Loss Prevention Data Sheets

operate at temperatures in excess of 300°F (149°C) and 50 to 75 psi (3.5 to 5.2 bar) pressure. In a continu-
ous process, mash is heated in a precooker and pumped through the cooker at 350°F (177°C) for three to
five minutes.

Fig. 2. Flow diagram: grain preparation and fermentation.

Mash passes from the cooker to cooker drop tubs and is then pumped through coolers to fermenters together
with thin stillage from the beer stills, water and yeast. After a fermenting period of 72 to 96 hours, the result-
ing beer, with an alcohol content of 7 to 13% is pumped to a beer well.
Yeast culture is the growth of a selected yeast strain(s) in sterile mash. It is cultivated first in small labora-
tory quantities and then in successively larger amounts until a quantity sufficiently large to inoculate a fer-
menter is accumulated. Though the process is nonhazardous, it is essential to the distilling operation. An
interruption could cause production losses.
Fermenting tanks may be wood or steel with either closed or open tops, depending on whether they are
intended to collect carbon dioxide gases. They may be of various capacities, with 75,000 gallons (284 m3)
tanks not uncommon.
Fermenting houses are usually single-fire area buildings and may be of various types of construction and
sizes.

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C.1.2 Distilling
The flow diagram for the distilling process is shown in Figure 3. Distillery buildings are usually the equiva-
lent of several stories high and of various types of construction. Newer distilleries are mostly of noncombus-
tible construction. Because of the height of stills and rectifying columns, intermediate floors are usually limited
to operating decks and platforms.

Fig. 3. Simplified flow diagram: distilling.

Distilling operations are usually continuous, except for some pot-still operations for producing gin and cer-
tain types of whiskey, or redistillation of off-grade products. Beer is pumped through preheaters to the top
of a beer still. It flows over baffles countercurrently to rising alcohol-rich vapors from below. Vapors are con-
densed and the condensate or ‘‘low wine’’ (40 to 70% alcohol) flows to small receivers. It is then pumped
to storage tanks, or directly to steam-heated rectifying columns or doublers for further concentration into ‘‘high
wines’’ (55 to 75% alcohol) or commercial alcohol (95% alcohol). High wines (or alcohol) and by-products
such as aldehydes and fusel oil are pumped to storage tanks. Residue from the beer still is pumped to spent-
stillage or slop tanks for sale or processing as a constituent of stock feed. Stills are steam-heated. Some
units involve vacuum distillation at lower temperatures. Vacuum and pressure-relief devices are usually pro-
vided; in some older facilities they discharge into the still building proper creating an explosion hazard.

C.1.3 Distilled-Liquor Handling

After distillation, the liquor is usually handled in separate buildings or fire areas. Because of government
regulations concerning the handling of distilled liquors, adequate cutoffs are usually provided, particularly in
newer distilleries.

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7-74 Distilleries
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C.1.3.1 Wine-Tank Room

Raw spirits from the still buildings are usually stored temporarily in black iron, tin-lined copper, or stainless-
steel tanks of varying capacities in the wine-tank room or closed receiver building.
High-wine tanks and weigh tanks are usually of black iron or lightweight tin-lined copper or stainless steel
construction. They vary in capacity from a few hundred to several thousand gallons. Although these tanks are
under government supervision and have locked covers, sealed valves and fittings, they may not be air tight,
particularly in older facilities. Sampling for proof and gauging may be through manholes. Tanks may be
equipped with long, unprotected gauge glasses. Many elevated tanks are on wood or unprotected steel
supports.

C.1.3.2 Blending or Cistern Room

After quality-control tests, the spirits are pumped to tanks of similar construction (except for black iron) in
the cistern room. Proof is reduced to desired barreling strength by adding distilled water, and the final product
is put into charred white-oak barrels. Filling is by gravity flow or pumping with a valve arranged to shut off
when the barrel is full. Unless the filling equipment is properly maintained, some leakage results.

C.1.3.3 Regauging
After spirits have aged, they are removed from the warehouse and regauged. The federal tax is paid on
the number of proof gallons. In the United States a proof gallon is 1 U.S. gallon (3.8 dm3) of 100 proof alcohol.
In Britain and Canada, standard proof spirits or 100 proof is pure ethyl alcohol diluted with an equal amount,
by weight, of distilled water (57.06% alcohol by volume) at 60°C (16°C). Older processes required opening,
dumping, weighing, and testing each barrel or selected barrels of each lot to determine proof. In newer
processes, the contents of all the barrels in a specific lot are dumped into open troughs and pumped to scale
tanks. The quantity is determined by weight and a single test is made to determine the proof. Contents of the
tanks are agitated prior to testing.

C.1.3.4 Recoopering
When excessive leakage cannot be stopped by calking, the barrel is removed to a recoopering room for
repairs or transfer of the contents to another barrel.

C.1.3.5 Blending and Bottling

Spirits are usually blended by dumping barrels of aged spirits into troughs with screened outlets, from which
they flow or are pumped to large storage tanks. Alcohol, water, flavorings and color are added to obtain the
desired blend. Blends range from 80 to 100 U.S. proof (40 to 50% alcohol). Mixing is usually accomplished
by mechanical agitation and sometimes by air. Spirits from blending tanks or bonded storage are usually
pumped to elevated, bottle-filling tanks at the bottling plants. Bottles are filled by gravity and vacuum.
Tanks in all of the above processes have varying degrees of vapor tightness. They range in capacity to more
than 40,000 gal (151 m3). Since government regulations call for tanks to be completely emptied and all lines
blown free of liquids, bottom connections and centrifugal pumps are generally used.

APPENDIX D NFPA STANDARDS

There is no NFPA standard dealing specifically with distilleries. There are no known conflicts with related
NFPA standards except for the tank venting change which previously was consistent with NFPA 30.

©1999 Factory Mutual Insurance Company. All rights reserved.