Category: Brewery

By: Nan McCreary

Bartley Blume may work twice as hard to produce both beers and spirits in Minnesota’s first combination brewery-distillery, but he also enjoys twice the opportunity to roll out new products that come from his ever-creative brain. They include a hoppy IPA without bitterness and a whiskey aged in American white oak and finished on toasted pimento wood to complement the spice of the grain.

  “When I opened the brewstillery, I wanted to bring more diverse beverages to the market, so we were not always drinking the same old pale ales, IPAs and sours,” Blume told Beverage Master Magazine. “We wanted to get away from mass consumption to a true appreciation of craft beverages, to sip and not swill.” 

  As the brewstillery’s name “Bent” implies, beers and spirits are “bent” and not made strictly to style. “This sometimes comes from combining the best parts of two different styles,” Blume said, “and sometimes from just making something I think my friends and family will like.” 

  Judging by the brewstillery’s success, not to mention its multiple awards, innovation-on-tap has been a big hit with consumers. Clearly, this is the place to go when you want to try something distinctive.

A Way to Make Money Off a Hobby

  Like many craft brewery owners, Blume started making beer as a hobby. While working as an engineer in the aerospace industry— and tiring of the corporate world — his wife gave him a Mr. Beer Kit. “This was in 2007,” he said. “I started brewing little batches of beer and quickly became addicted. I thought to myself, ‘This could be a way to make money off of a hobby,’ so I sat down and wrote a business plan for a brewery.”

  During that time, another brewery opened near Blume’s home in the Twin Cities, adding to the fifth or sixth already in the market. To Blume, that was too many, so he switched his interest to distilling. After poring over distillation books—and crafting whiskey and bourbons on his back porch — he rewrote a business plan for a brewstillery. Combining a brewery and a distillery seemed logical to Blume because the processes are similar, and the skills are complementary. “At the time,” he said, “there were only six brewstilleries in the country. Mine would be the first in Minnesota, which was pretty exciting.”

  Blume introduced the Twin Cities to his first product — and his innovative spirit — at the 2013 St. Paul Summer Beer Fest, wowing the crowd with an American Imperial Stout infused with ghost peppers, the world’s hottest chili pepper. At the time, he was brewing his beers under contract at Pour Decisions Brewing Company in suburban Roseville. Through working together, the two entities decided to merge under the Bent Brewstillery brand. The partnership was serendipitous for Blume. He now had a “home” when breweries and taproom locations were hard to come by. He also acquired the talents of Pour’s head brewer, Kristen England, long-time brewer and Grand Master Beer Judge from the Beer Judge Certification Program.

  After renovating the taproom in Roseville, Bent Brewstillery opened a 1,700-square-foot space in 2014. The taproom seated 115 customers and offered 10 beers on tap. Within months, Blume added the distillery. From the beginning, the brewstillery’s mantra was to set itself apart by creating fresh products and staying at the forefront of innovation. “Even if the market wasn’t ready for it, we’d do it anyway,” Blume said.

  As enthusiastic as Blume was initially, the business presented — and still presents — some challenges in operating as both a brewery and distillery. “Yes, there are some parallels,” he said, “but it isn’t quite as complimentary as I’d hoped it would be. You have to do all the work you need to do for a distillery and all the work you need to do for a brewery.” 

  Specifically, Blume explained that he has to rely on different ingredients, bottle suppliers, distributors, and even different marketing strategies for each entity because the audiences are different. “It’s really twice the amount of work, which is why most people haven’t decided to bite this off.” 

  According to Blume, there are currently only several dozen brewstilleries in the country. “It’s good for me because I’m a workaholic,” he said. “It’s a true family thing. My wife is the bookkeeper and CFO. Even the dog comes to work.”

  Despite the work, or maybe because of it, for a brewer who started with a two-and-a-half gallon Mr. Beer Kit, Blume has seen his vision surpass expectations. Now in its eighth year, Bent Brewstillery has grown into a 20-barrel brewhouse with four 40-barrel fermenters, plus three-, five- and ten-gallon fermenters that allow for the production of small-batch brews. The distillery features a column reflux still with four plates. The still can be converted to a pot still with a restrictor plate on the bottom, designed specifically by Blume for maximum versatility. Annual production is 2,000 barrels of beer and 2,000 gallons of liquor. Beer is sold in the taproom by the glass, pint, growler and crowler. Whiskey is sold straight or in cocktails. Besides offering products in the taproom, Bent Brewstillery distributes 16-ounce cans and liquor bottles to liquor stores and kegs to bars and restaurants. The brewstillery has 450 accounts in Minnesota, the south side of North Dakota and the west side of Wisconsin.

Invent, Innovate and Inspire

  With Blume at the helm as distiller and England as head brewer, Bent Brewstillery continues to invent, innovate and inspire. Since the beginning, it’s brewed over 200 beers. “When we started, we made lots of sour beers, reawakening old-style beers that no one had made until recently,” Blume told Beverage Master Magazine. “Now we have a whole line of sours, including barrel-aged sours and straight-up kettle sours.”

  One of their most unique products is a Chilean Stout, made in collaboration with a local brewery in Santiago and created from ingredients that England brings back after judging an annual beer competition there. Next on the agenda is a cold-fermented IPA. “Fermenting an IPA cold as opposed to fermenting it warm is extremely rare,” Blume said. “The process makes it more crisp, clean and clear. It’s the opposite of the hazys.”

  In the spirits category, Bent Brewstillery offers a traditional vodka and a nontraditional gin with 14 different botanicals. Blume prefers to use fresh botanicals when he can get them, which means the gins will vary from batch to batch. Some products are especially distinctive:  Flame Bringer, a bourbon barrel sriracha-infused rum, and Tropical Whiskey, brewed and distilled like any other whiskey, but includes passion fruit, guava, coconut and citrus, added during distillation. “These are the little fun things that make us distinctive in what we create,” Blume said. “These spirits are all great by themselves, but they really compliment a cocktail. Our signature drink is the Old Fashioned created from our whiskey, and the sriracha-infused rum makes a great spicy Margarita or Bloody Mary.”

  According to Blume, it took a while for the public to accept his distinctive beers and spirits. “At first,” he said, “people would say, ‘Oh, that looks weird. It’s different. I’m afraid of that,’ but now I can’t keep those products on the shelves.”

  Customer preference is mixed, Blume said: 50% like the same beer all the time because they are familiar with it; the other 50 percent want something new. It’s the same split in the liquor stores and bars. Blume also sees a mixture in beer versus spirits preferences. “Having a taproom that serves both beer and cocktails is huge for us,” he told Beverage Master Magazine. “We get so many ‘mixed couples,’ where one likes beer and the other prefers spirits. Instead of drinking a beer here and then leaving to get a cocktail, they simply stay here. It’s been pivotal to our growth.”

Pandemic Problems…and Solutions

  Like all breweries and distilleries, Bent Brewstillery’s growth took a big hit during the pandemic. But, again, like others, it turned lemons into lemonade by making hand sanitizer. Blume dived into this project with both feet. The brewstillery bought tankers of ethanol and produced 65,000 to 70,000 gallons of hand sanitizer. It provided supplies to a large portion of the police and fire departments in the state and to hospitals and support companies. Bent also offered raw materials to distilleries at cost so those distilleries could help their local communities. “We went all out,” Blume said, “and it’s a great feeling to know we did so much to help. We had a supply of beer and spirits in our taprooms, so at least we were able to sell products to-go. We survived just fine.”

  With the pandemic waning, Blume plans to go “full-throttle” ahead, both in creating new products and staging events. Traditionally, the brewstillery has offered a winter luau, beer dinners, a St. Patrick’s Day dinner and car shows in their large parking lot. This year Blume hopes to bring back one of the brewstillery’s biggest events — a crawfish boil that attracted 2,500 people. Bent also plans to hold its annual barbecue competition on the anniversary of September 11. The competition, which draws 25 to 30 cooking teams, is a fundraiser for the Invisible Wounds Project. The local charity provides services to Minnesota’s military, first responders, front-line medical staff, corrections, dispatch and their families relating to mental health, PTSD and suicide issues.

  Blume and his staff (the brewstillery has seven employees, not counting the dog) will continue to innovate, always looking for new opportunities. “We’re always looking to grow,” he told Beverage Master Magazine. “On the brewing side, we want to keep giving people something different to try. With the sheer number of breweries out there that are coming out with new beers, people can literally have a beer every day and never have the same beer twice. On the distilling side, we are playing around with different products that people will hopefully like. Growth is difficult, but it’s the challenge we signed up for.”

For more information on Bent Brewstillery, visit www.bentbrewstillery.com

By: Kris Bohm: Owner of Distillery Now Consulting LLC.

Breweries make beer and often their equipment has the capacity to brew more beer than there is necessarily a demand for. Plain and simple, idle equipment does not help generate cash flow. An alternative use to consider to keep idle brewery equipment running is whiskey. American single malt whiskey is the new hot trend in spirits. Single malt whiskey has been touted for decades in America as a premium whiskey, and now bourbon whiskey is absolutely booming worldwide. If your brewery has a brew house that is sometimes sitting idle, it is time to put it to work. With the addition of a commercial still for distilling, a brewery can turn an idle brew house back on, and start producing single malt whiskey. The addition of a distillery will create a new business avenue for a brewery that can bring in new customers and generate more revenue for the overall business.       

Brewers Making Whiskey

  A few of the well known breweries, who have jumped into the distilled spirits world, are Ballast Point and Rogue Ales. There are amazing spirits being produced and distilled by breweries all over the world and your brewery can seize this opportunity as well. Brewstilleries, as we will call them, are pioneering a new business model. By using existing equipment to produce the wort or mash for distilled spirits, a brewery can create a diverse portfolio of products which can appeal to a broad base of customers.

  Ballast Point Brewery is a notable and very successful brewery that added a distillery to their operation. The Ballast Point took on a wild side project in 2007 where they added a still to their brewery in California, to experiment in spirits production. The brewers there mashed a beer recipe, then lautered an un-hopped wort that was then fermented and distilled into single malt whiskey. They also used their equipment to cook corn mash for bourbon production. A few years later, their whiskies had aged in barrels and it was bottled then released. Both their single malt and bourbon were wildly successful and well received spirits. Ballast Point Brewery sold a few years after the distillery was started and their distillery branched off to become Cutwater Spirits.

Tools of the Trade

  Breweries and distilleries use equipment that is very similar for the production of beverage alcohol. Fermenters, pumps, hoses, yeast, mash tuns, lauter tuns, and fermenters are common tools utilized by both distillers and brewers. Some breweries have capitalized on this opportunity and co-utilize their equipment and expand into distillery operations.  Let’s detail a few of the tools that brewers use that distillers can co-utilize for whiskey production. Of course this can only work if the brewers are willing to share.

Brew House Mash Tun

  A brew house is the essential tool used for the production of beer. This brew house will sometimes be idle when there is not enough demand. The steam heated mash tun in a 4 vessel brew house is used to mash malted barley for brewing beer. This equipment can also be utilized to produce mash for whiskey. With a few small changes, a mash tun can be used to produce cereal mash, made with corn or rye, that is cooked and fermented for bourbon whiskey.

  The production of malt whiskey in the Scottish tradition, using 100% malted barley, requires more complex equipment than the basic cereal cooker utilized by most distilleries. The lauter tun is a unique equipment for separating barley from the sugary wort in beer production. When making American single malt whiskey, the lauter tun is used to produce wort for distillation in the same way it is used to make wort for beer.

Fermenters

  Every brewer and distiller has fermenters in which they transform grain from sugary liquid into alcohol through fermentation. The fermenters used in a brewery work perfectly for fermenting wash or wort destined to become whiskey. If the excess space is available to ferment, a distillery can make use of otherwise empty tank space. Often distillers ferment their wort for whiskey fast and warm. A fermentation is often finished and ready to distill in as little as 4 days.

Pumps and Hoses

  The workhorse tools of brewers and distillers are their pumps, hoses and tri-clamps. The same pumps and hoses can be used to accomplish liquid transfers in a brewery and a distillery. Sanitization is important to mention here as it is easy to introduce unwanted bacteria or yeast into hoses if a distiller is not careful and conscientious of proper sanitization, which is required in a brewery for beer production, but not as necessary for a distillery.

Yeast

  The essential ingredient that all producers of beverage alcohol must utilize every day is saccharomyces cerevisiae, or the fungi simply known as yeast. The yeast used by distillers and brewers is closely related. In fact, many brewstilleries will use the exact same strains for both brewing and distilling. The use of yeast and the knowledge of how to handle yeast effectively is similar for brewers and distillers. Sharing yeast strains and yeast propagation equipment between a brewery and distillery increases the value reaped from every batch of yeast.

  All of these tools above can be made to serve double duty for a brewstillery. Careful planning, management, and execution are key to successful sharing of equipment.

Behind the Scenes

  Many questions come up in the discussion of adding a distillery to a brewery. Let’s go through and look at some of the common questions.

  How does a brewstillery function and get licensed from a legal perspective?

  The answer to this question will vary widely depending on the location of the brewstillery. Every state and country has different laws on what a brewery and distillery are allowed to do when working in conjunction. Typically, the distillery operations are required to be separate from the brewery both in physical location and in bookkeeping. The way a brewery meets this requirement of separation is as simple as a wall that keeps the two businesses apart with a separate exterior door to enter the distillery. A distillery can share steam for heating and glycol for cooling with a brewery, but the key here is that the still and the vessels holding distilled spirits are kept separate from the beer. On licensing a distillery will need to get a federal and state distiller’s permit before they can start producing spirits and may also need local licenses or permits.

  How are records and bookkeeping managed for a brewstillery?

  When it comes to bookkeeping, the distillery part of the brewery is typically an entirely separate business. This means a separate business entity or LLC must exist for the distillery which will hold its own business license, separate books, and tax reports. For the day to day operations and transactions, a distillery within a brewery will often buy the grain from the brewery and lease the brewing equipment on a daily basis to make wort for whiskey production.

  How is a distillery taxed?

  Taxes are a big concern because distilleries and distilled spirits are taxed very differently than beer. Although they are taxed differently, by having the distillery operate as a separate business it makes the bookkeeping and taxes simple by not mixing them with the brewery. Volumes have been written on taxes of distilled spirits all about proof gallons, wine gallons, and gauging, but we will save a deep dive into taxes for another day.

  How much beer does it take to make whiskey?

  In the production of a single malt whiskey the sugar content of the wort is on the high side to maximize the potential amount of whiskey produced per batch.

  Often the ABV of a fermented wash is as low as 7% to upwards of 12%

  There are a multitude of factors that will affect the amount of whiskey produced per pound of malt, including mash procedures, fermentation, distillation and maturation.

  When distilling a beer you can expect to roughly see the following yields. This estimated yield includes the distiller’s cuts and loss from barrel aging.

  A single 31 gallon barrel of 10% abv beer can produce upwards of 25 bottles of whiskey.

Beer to Whiskey and the Hops in It

For the vast majority of whiskies both malt and bourbon are strictly made from grain. No hops or other flavoring agents are added. Beer, of course, has hops and specialty grains in it. A beer that is distilled into whiskey which we will call “hopped malt whiskey,” will carry the distinct flavor of hops and into the spirits. This can be good or bad, depending on who you ask.

  Let’s weigh the good side of whiskey made from hopped beer.

  Hopped malt whiskey tastes very different from traditional Scottish malt whiskey. Because it tastes so different and can be marketed as part of the beer story, a hopped malt whiskey is often well accepted by the public as a new kind of whiskey, since it is not compared against bourbon or scotch.

  There is a downside to distilling hopped beer into whiskey. Beer that is distilled into whiskey and then barrel aged carries a strong and unique flavor profile dominated by the hops. For some consumers, this flavor is off putting even to the biggest IPA loving hopheads. Most people that enjoy whiskey have a pallet that is trained to like bourbon or scotch single malt. A hopped malt whiskey tastes nothing like either of these spirits, your average whiskey drinker may not like unique flavors of such a spirit. This warning is not to deter a creative brewstillery from distilling such things, but to merely inform.

Let’s Make Some Whiskey!

  For those currently running breweries, you may be considering getting into distilling. If you are, be sure to do your homework or hire a pro to help you, as there are many differences between brewing and distilling. This learning curve can be expensive without prior experience. For those just getting started, the brewstillery model is a business worth considering that will give you access to a larger customer base, and create better returns on your equipment. Consideration of state laws is essential as they vary widely on the legality and requirements to operate on this business model. The future is looking bright for craft beverage alcohol production and brewstilleries are on the lead in producing new variations of traditional spirits.

  Authored by Kris Bohm the Owner of Distillery Now Consulting LLC. When Kris is not helping folks build distilleries and creating great whiskies, he is out riding cyclocross or defending his beer mile record. Would you like to talk about making whiskey? Drop us a line. Distillerynow@gmail.com