How Long Does A Pot still Take?

Regarding the practice of distilling spirits, perhaps the most frequent inquiry a novice or even a seasoned distiller may ask is: how long does a pot still take? This will, of course, depend on many variables: the type of still apparatus you’re using, the size of your pot still, the type of wash or mash you’re working with, and how high a distillate purity you aim for. These pieces of knowledge will give you the ability to better estimate the time needed, maximize your output, and improve the quality of the spirits you produce.

Here, we will analyze the distillation steps, time expected within each step, and the major variables influencing how long each takes when using a pot still.

What is a Pot Still?  

A pot still is a type of distilling equipment and one of the most basic and traditional types available. It is composed of a large boiler (or pot), a neck, or column and a condenser. The original pot stills are and still most commonly are made of copper because copper, unlike other metals, reacts with the sulfur compounds in the distillate to improve its taste and smell.

Unlike continuous stills, which operate with no interruptions and generate spirits in a steady, unbroken stream, pot stills work in a series of separate intervals. Therefore, every distillation cycle, also referred to as a “run,” needs to be finished before a subsequent batch can be initiated. This also means that pot still distillation takes longer, but the spirits produced will have more complexity and depth of flavor.

Pot stills are most often used to make:

 ● Whiskey

 ● Rum

 ● Brandy

 ● Gin

 ● Tequila

 ● Craft spirits and small-batch liquors

Time Required to Distill with a Pot Still

When estimating how long a pot still will take to complete each distillation cycle, the size of the still and the heat source are the main factors that will influence the time. A very general overview looks like this:

These estimations take into account the time to heat, cool, and distill the wash, however, there are a large number of variables that will affect the time including the wash composition, distilling temperature, and distillate purity levels.

The Three Phases of a Pot Still Run

In order to properly understand how long a pot still takes, one must examine the three main components of a distillation cycle: heating, distillate removal, and cooling.

1. Heating the Wash (1–2 Hours)

The first step is to heat the wash or mash until it begins to boil. Alcohol vaporizes at a lower temperature than water (around 78°C or 173°F), so the goal is to gradually raise the temperature to separate alcohol from water and impurities.

  ● If you heat too quickly, you risk foaming or scorching your wash.

  ● A steady, even heat gives better separation and flavor retention.

This stage can run from 1 to 2 hours, depending on the size of your still, and what you are using (gas, electric, or steam) to heat it.

2. Collecting the Distillate (3–10 hours)

After the still has been heated and the wash temperature has been stabilized, spirit vapors will rise into the still head or column, and then condense into liquid in the condenser. At that point you can collect your distillate. It can mostly be separated as: foreshots, heads, hearts, and tails.

 1. Foreshots: The first steam vapors are removed as they contain highly volatile compounds, including methanol.

 2. Heads: It contains highly aromatic light alcohol, and esters with a strong pungent odor. Some collectors will keep it, but the majority will be disposed.

 3. Hearts: The key part of the collection, it contains the main ethanol spirit, and the ethyl alcohol.

 4. Tails: Heavy alcohol compounds and fusel oils are left at the end, and can be recycled into the next batch.

Collecting data can be exhausting. For small stills, this might take 3 to 5 hours. For large stills, it may take 8 hours to 10 hours or even longer.  

3. Cooling and Cleaning 30 minutes to 1 hour  

The still requires time to cool before the cleaning begins. Adequate post-distillation cleaning is essential to avoid possible contamination, buildups, or unwanted flavor carryover to the next distillation. This step 30 minutes to 1 hour to your total process time.

Key Factors That Affect Distillation Time  

1. Still Size and Design  

The larger the pot still, the longer it takes to heat and cool. For example, a 500L copper pot still may take more than 10 hours to complete a distillation run, whereas a 20L still designed for home use may complete a run in 4 hours.  

The still’s design impacts the speed of distillation. For example, the still head shape, column height, and condenser can all impact vapor condensation and separation.  

2. Heat Source and Power  

The speed and control of distillation depend on the heat source.  

 ● Electric stills heat slowly, but the heat is precise.  

 ● Gas-heated stills warm up quickly, but the process needs constant supervision.  

 ● Commercial setups use steam-heated stills, which provide consistent heating. This is ideal for larger distilling equipment.

Total distillation time can be minimized without compromising the quality of the resulting spirit by optimizing the process for efficient heating.

3. The Wash's Alcohol Content

Distillation time is affected by the initial alcohol content of your wash or mash. An ABV of about 10–12% will help you achieve the desired purity more quickly. If your wash is low in alcohol, it will take more time for you to retrieve enough ethanol.

4. Purity Targets and Cuts

Purity will dictate the necessary method of distillation. If you want to produce a pure distillate, like vodka or a neutral spirit, you will have to perform distillation very slowly and in a controlled manner, and even then, you may need to do multiple distillation runs. In contrast, whiskey and rum can be distilled more rapidly, as the distiller is actively retaining more congeners which will be used for flavor.

5. The Distiller's Approach

An experienced distiller understands the principle of patience. If a still is operated very quickly, it may leak undesirable substances as it transitions from the heads to the hearts, and then the tails. Watching, in particular, the temperature and flow rate, as well as the aroma, will help you achieve cleaner cuts and a more refined spirit.

Single vs. Double Distillation: Why It Takes Longer To Perform Two Runs

Many distillers perform double distillation when using pot stills—especially for whiskey and brandy.

 ● First Run (Stripping Run): The goal is to extract alcohol quickly without worrying about purity.

 ● Second Run (Spirit Run): The collected low wines are distilled again for refined cuts and improved flavor.

Although each run takes several hours, double distillation results in a smoother, more balanced spirit. This means the total time for both runs might reach 16–24 hours in total.

Ways to Shorten the Time of Pot Still Runs

Having patience while distilling is a must, however, you could potentially save time with the following:

 ● Preheating and using insulated tanks for the mash will shorten the time it takes to heat.

 ● Use consistent power to avoid wild swings in temperature.

 ● Having highly effective condensers and using copper stills will cool the vapor much faster.

 ● Clean and gather your gear after each run to ensure a smooth and well thought out plan.

 ● Use automation on modern stills to control the distillation variables of temperature and pressure.

The right distilling equipment to pour resources into will save a lot of time, and good quality spirits will be produced.

Conclusion: The Secret to Great Spirits is Patience

So, how long does a pot still take? Expect a run to take anywhere from 4 to 12 hours, with the still size, heat source, and distilling goals heavily influencing the time. Home distillers will take around 6 hours to finish, while commercial distilleries tend to run their equipment for an entire shift.

Using a pot still is not a sprint—it is a craft. The meticulous nature of the distillation process contributes to the unique depth of complexity achieved with traditional spirits like whiskey, rum, and brandy. With the appropriate still apparatus, precise temperature regulation, and meticulousness, you will produce spirits that are truly admirable.