Month: October 2011

DonQ Rum Visit to Puerto Rico

This summer I visited the Destileria Serralles Puerto Rico, the home of DonQ Rum.

DonQ is distilled in the southern part of Puerto Rico, in Ponce. The distillery has been on the same site since 1865. As with most rum distilleries, it was once the site of a sugar refinery and the distillery was a small part of the overall operation. Puerto Rico stopped producing sugar in the 1980s and the distillery became the important business.

As with distilleries in the United States, during Prohibition Destileria Serralles was closed. After Prohibition ended, they rebuilt the distillery, this time with column stills to replace the previous pot stills. One of those distillation columns from 1934 is still in use today.

Making Rum

The molasses for DonQ is purchased on the open market; the low-sugar stuff from the Dominican Republic or thereabouts, and the high-test sugar-rich stuff from Gautemala. (I learned only recently that with improving technology and higher prices for sugar, they are stripping more sugar out of molasses so they need to suplement lower-quality molasses with special high-sugar stuff so that there is enough sugar in the liquid to ferment.)

The molasses is shipped into the port of Ponce and then transported to the distillery, where it is pasteurized to prevent any spontaneous fermentation.

It is then fermented in stainless steel fermenters with their own strain of yeast until it reaches 8-10 percent alcohol by volume. They distill two rums that are later blended; a "light" and "heavy" version. The lighter version ferments for a lesser time than the heavy.

The heavy rum is distilled in the original beer column (the first column of a multi-column still) from 1934. It looks just as old as it is.

The light rum is distilled in the newer, multi-column stills.

After distillation, the rum is aged. The barrels used at DonQ are used twice before they buy them: the first time by the bourbon industry (as with most rums, tequilas, and scotch because barrels can only be used ounce for bourbon by law), but also another time for "light whiskey" which I take to mean blended whiskey like Seagram's.

Thus there should be less wood influence from these barrels than on other products. Furthermore, they reuse them about 20 times and never rechar them.

The rums are aged at a few different proofs, aged separately as light or heavy-style rums, and some is aged as a "medium" rum; a blend of the two. There are also some solera-aged rums in ex-sherry barrels, which are added to some of the blends.

Sustainability Practices

Roberto Serralles is a sixth-gernation Serralles family member who holds a PhD in environmental sciences. He is responsible for making this distillery more eco-friendly with the goal of making it waste-free. If given the chance to see him speak, I highly recommend it because he is engaging, authentic, enthusiastic, and making a real difference. Some of the innovations he has helped develop are already being copied by other distilleries.

The DonQ website has a great overview of the sustainability practices in place, though from what we learned on-site many of these are evolving from how they are described there.

The carbon dioxide released during the fermentation process used to be captured and sold to use to carbonate sodas, but a change in legal regulations has made this undoable in the short term.

The distilled molasses "beer" is only 8-10 percent alcohol, then is distilled up to 75 – 90 percent. That leaves a lot of excess water with organic material leftover – during the height of their production 350,000 gallons of wastewater per day.

The goal is to separate out the organic matter from the water so that you can reuse the water. First they use anaerobic digesters, in which bacteria eat the organic matter and release biogass. (I want to write a book about distillery waste and call it "Everybody Farts".) This biogass is burned to produce heat at the distillery and reduces the distillery's oil consumption by about 50 percent.

The next stage is aerobic decomposition, which further reduces the organic matter and produces brownish water. They used water this for irrigation, but as I understand it the water isn't ideal, so they are replacing this system with a new membrane filtration system that Roberto Serralles was pretty proud of.

That and other systems are in development, but some of the development has been delayed due to a significant business change. You'll learn why in tomorrow's post.

October 7, 2011
Hunting Bison in Poland with ZU Vodka

No bison were harmed in the writing of this blog post.

This summer I flew to Warsaw with ZU vodka, known in the rest of the world as Zubrowka. Zubrowka is bison grass vodka; vodka flavored with grass. The stuff tastes like caramel and jasmine and hay, and makes apple juice taste like apple pie.

Unfortunately, that delicious flavor comes from coumarin, a naturally-occurring compound that is banned as a food additive in the US. It is also in the tonka bean, which is why we can't have a historically-accurate recreation of Abbot's Bitters in the US either. (See this NYTimes story for more on that.)

(Mmm, delcious Coumarin. Image from Wikipedia.)

Coumarin is a blood thinner (anti-coagulant), and it is used to make Coumadin, a medicine that some people with blood clot disorders have to take before flying. Ironically, one of the people on the press trip had to take a shot of Coumadin before coming to Poland. If they had real Zubrowka in the US, she could have just chugged a bottle.

They've recreated the flavor of Zubrowka in ZU, using naturally-derived ingredients. In a blind taste test you can guess which is which, but they're pretty close.

A Trip to the Forest

We took a train for a few hours from Warsaw to Bialystok, where the distillery is located. But before seeing that, we went to see the Bialowieza Forest where the bison live and the bison grass grows.

The forest has various levels of protection in different parts. The first visit we took to it was by carriage, to the most protected part. The carriages aren't just for old-timey charm: no mechanical transportation is allowed in the forest and you must be accompanyed by a licensed guide.

The reason this forest is special is that it has for centuries been the protected property of the kings. It was used as their personal hunting ground for bison and a food reserve for the army. The forest is a UNESCO biosphere preserve and on the World Heritage List.

The forest is quite pretty, with tall skinny trees. This is the type of forest that would have covered most of Europe long ago.

Looking for Bison in All the Wrong Places

But to actually see the bison, you've got to get up pretty early in the morning. At 5AM we drove into the forest (this time, outside of the strict reserve but still where bison can be found) and walked along a path looking for them.

Unfortunately, none were to be found. The guide says at this time of the year the bison go into the deep forest to hide from the mosquitoes and flies, the very same ones that were biting us ferociously.

But it wasn't all for nothing. We also went searching for bison grass. The bison grass for Zubrowka is hand harvested by 21 or 22 families who know secret spots to pick it. Apparently you can grow bison grass on farms, but it doesn't have the same aroma as the natural stuff.

We walked down a trail in the forest, veered off it, cut through the woods, and found a whopping three blades of bison grass. Obviously, this wasn't one of the spots where they harvest it. But still, success!

We did manage to see actual bison, though they weren't free-roaming. We went to a reserve (sort of an outdoor zoo) where they show off the bison and other forest animals. Hi bison!

At the Distillery

After our forest visit, we went to see the distillery in Bialystok. The place is huge, as they make a lot of vodka for their unflavored Zubrowka (not available in the US) as well as other brands. Interestingly, this is not the start-to-finish point for ZU and other brands.

Closer to the farmlands where the rye is grown, there are smaller distilleries that do the fermentation and initial distillation. Polmos Bialystok (the name of this distillery) refines the distillation and adds any flavoring.

The bison grass is stored in a dark, refrigerated room in big paper bags.

The grass used to flavor the vodka is soaked in alcohol and water in a big washing machine thing for a couple days. They make a concentrate of the bison grass flavor, then add whatever amount they need to the final blend.

The grass that's used to decorate each bottle (there is a blade of grass in each) is soaked in higher-proof alcohol to suck out all the coumarin. It's then dried and inserted by hand in the bottling line.

In Your Mouth

The way ZU/Zubrowka is most commonly consumed is mixed with apple juice in a drink called the Szarlotka. It tastes kinda like apple pie. It's dumb and fun and more American bars should offer it. In Poland the apple juice was pretty cruddy, and it would certainly be improved with unfiltered apple juice.

October 3, 2011