The processes of crushing and saccharifying, above referred to, which are almost entirely used to-day, require steam. The following methods provide for the isolation of the fecula or starch, without steam and the production of a wash of a more watery consistency, therefore easier to handle in ordinary stills, and with less liability to burn.
Two operations are necessary by this method: First, rasping, or reducing the potatoes to a finely crushed and pulpy condition by means of a machine described in the chapter on Beet Mashing; and second, the separation of the fecula.
To this latter end the potato pulp is placed on a sieve, having side walls and net work of horse-hair, which is placed over a suitable tub. Water is run gradually through the pulp and sieve, while the pulp is rubbed up by hand. When the water comes through clear, then all the fecula of the pulp has been washed out, and the refuse left in the sieve can be thrown aside or used as a food for cattle.
For a mashing tub of say about 32 bushels capacity, the fecula from about 800 lbs. of potatoes is used. This is deposited in the mash tub with sufficient cold water to form a fairly clear paste. About twice as much water as fecula will bring the paste to proper consistency. This mixture should be constantly stirred as otherwise the fecula will sink to the bottom. About 40 gallons of boiling water are then added gradually. The mixture has at first a milky appearance, but at the last becomes entirely clear.
This liquid is mashed with about 45 lbs. of malted barley or Indian corn, ground into coarse flour. In ten minutes the mixture will be completely fluidified. It is then left to subside for three or four hours when it will have acquired a sweetish taste and be what is termed as “sweet mash.” The fluid is then further diluted by the addition of sufficient water to give about 290 gallons of wash. Two or three pints of good yeast will bring this mixture to a ferment.
A less laborious method of accomplishing the same result is that at one time used in English distilleries. In this a double bottom tub is used, something like that shown in Fig. [41], the upper bottom of which is perforated, and raised above the solid lower bottom. A draw-off cock opens out from the space between the two bottoms.
Assuming that the tub is of 220 gallons capacity, then from 2 to 20 lbs. of chaff are spread over the perforated bottom and pulp from 800 lbs. of raw potatoes placed on that. This is thoroughly drained for half an hour, through the draw-off cock. The pulp is then stirred while from 90 to 100 gallons of boiling water are added gradually. The mass then thickens into a paste. The paste is mashed with about 65 lbs. of well steeped malt, and the liquid left to subside for three or four hours. It is then drained off through the perforated bottom into a fermenting back or tub. For this amount of material the back should be of about 300 gallons capacity.
The leavings left in the preparatory tub still contain considerable starch, and after they are well drained they should be mixed with from 50 to 55 gallons of boiling water. The mixture is then agitated and drained off into the fermenting back. The sediment left is again sprinkled with water, this time cold, which is drained off into the back. This completely exhausts the husks left on the upper bottom. By this process 200 lbs. of potatoes should produce something over 12½ gallons of spirit.
The objection to the last method described is that the spirit so obtained is unpleasant to taste and smell, but this would probably not be an objection for industrial uses.
The only means of obtaining alcohol of good quality from potatoes is to extract the starch separately and then convert it into sugar. This saccharification of the starch may be accomplished by sulphuric acid or by the action of diastase.