Tequila Production Process Guide

Follow this tequila production process guide from agave field strategy to bottling, then benchmark choices against the agave spirits comparison, explore mezcal contrasts in the mezcal production guide, and clarify terminology in the glossary of agave spirits.

Executive Summary

Field and farming

Field strategy determines sugar potential, disease pressure, and traceability compliance before any agave leaves the soil. Align agronomy plans with CRT requirements, ensuring every hectare is documented and sustainable over successive planting cycles.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Species and DO Agave tequilana Weber blue within DO states Not applicable CRT supplier verification Not applicable Not applicable Only this species within DO is legal [NOM-006 2012][CRT DO] Planting off-DO or wrong species
Piña age at harvest 5 to 9 years 6 to 8 years common Field records Older raises sugars but risk of rot More cooked agave depth None beyond species requirement Over-aged rot or under-ripe low sugars
Sugar content Inulin measured as invert-Brix 24 to 36 degree Bx equivalent Refractometer after mild hydrolysis, HPLC Higher Brix increases ethanol More agave sweetness, less green None Ignoring inulin to invert conversion
Field stress Rainfed vs irrigated Evapotranspiration deficit 0 to 30 percent Soil moisture probes Moderate stress boosts sugars Terpene and ester precursor shifts None Excess stress reduces yield and increases disease
Plant density 2000 to 4000 plants per hectare 2500 to 3500 typical Planting maps Higher density raises tons per hectare Can reduce individual sugar accumulation None Disease spread and small piñas
Fertility program NPK plus micronutrients N 50 to 150 kg per hectare-year Soil and tissue tests Balanced fertility boosts biomass Excess nitrogen dilutes sugars Must meet residue MRLs Lodging and pest susceptibility
Pest and disease control Integrated management for weevils and fungi 2 to 6 interventions per season Scouting, pheromone traps Protects biomass Residues can impart off-notes Use registered agrochemicals within limits Illegal pesticide residues
Altitude and terroir 400 to 2100 meters Site specific GPS and climate records Cool sites slower growth Herbal vs tropical esters None Wrong clone for conditions

Harvest

Well-timed harvest logistics preserve inulin content and prevent unwanted fermentation or microbial spoilage during transport. Capture lot-level data and handling conditions so downstream teams can adjust cooking cycles and fermentation nutrition.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Penca trim height High, medium, low cut 1 to 5 cm from core Visual inspection Lower saponins aid ferment Less bitterness None Excess leaf tissue increases bitterness
Piña size 20 to 120 kg 40 to 80 kg typical Calibrated scales Larger piñas often higher sugars More Maillard potential None Oversized loads cook unevenly
Time to cook Immediate to 7 days Target less than 72 hours Logbook timestamps Shorter wait limits spoilage Reduces sour defects None Microbial souring from delays
Sanitation Wash, biocide rinse Oxidation reduction potential 650 to 800 mV ATP swabs, ORP meter Improves ferment performance Cleaner profile Biocides must be food grade Residual sanitizer inhibiting yeast
Segregation by ripeness Batching by Brix 24 to 36 degree Bx Rapid refractometry Predictable yields Consistent flavor None Mixed ripeness complicates cook profiles

Cooking

Cooking converts stored inulin into fermentable sugars while setting the aromatic foundation for the finished tequila. Choose a hydrolysis path that matches desired throughput and flavor intensity, and verify conversion with saccharification assays.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Method Horno, autoclave, diffuser Not applicable Standard operating procedure Varies by method Horno richest, diffuser neutral All legal if final tequila meets NOM profile Over or under cooking
Horno cycle Passive steam bake 90 to 100 degree C for 36 to 72 hours Temperature charts, saccharification test Moderate hydrolysis Maillard and roasted notes Legal traditional method Core undercooked, channeling steam
Autoclave cycle Pressurized steam 110 to 125 degree C for 8 to 14 hours Pressure and temperature records Higher throughput Balanced cooked agave Legal Scorching or uneven loads
Diffuser use Mechanical leaching of raw agave 20 to 80 degree C for 1 to 3 hours Extraction efficiency calculations Maximum extraction Neutral, herbaceous if unmanaged Legal if juice is hydrolyzed before fermentation High water load and fines management
Hydrolysis completion Post cook saccharification Dextrose equivalents 60 to 95 percent Reducing sugar assay, HPLC Higher completion boosts yield Over caramelization dulls profile Legal Incomplete inulin hydrolysis
Acid enzyme hydrolysis Used with diffuser juice pH 1.5 to 2.5 at 90 to 105 degree C for 30 to 120 minutes pH meter, temperature probe Completes hydrolysis Risk of off notes Must neutralize and avoid corrosion Residual acid carryover

Extraction

Extraction efficiency governs how much sugar reaches the fermenters and how much fiber remains for nutrient support. Monitor recovery percentages and water usage to balance yield, downstream viscosity, and wastewater load.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Mill type Tahona, roller mill, diffuser bed Not applicable Mass balance Tahona 75 to 85 percent, roller 85 to 92 percent, diffuser 95 to 98 percent Tahona retains more body All legal Low efficiency with worn equipment
Wash water ratio 1 to 3 stages 0.5 to 1.5 liters per kg cooked agave Flow meters Higher washes increase recovery Can dilute flavor precursors Wastewater must be managed High water to treat downstream
Solids in must Viscosity control 8 to 16 percent w/w Filtration, Brix checks Impacts fermentation speed Higher solids add mouthfeel None Excess viscosity stalls fermentation
Clarification Screening, decanting Turbidity 50 to 500 NTU Turbidimeter Improves equipment uptime Too much stripping removes flavor None Over clarification reduces nutrients

Formulation

Formulation choices—category, nutrient program, and gravity targets—bridge raw sugar potential with fermenter capacity. Document every addition to satisfy NOM audits and to maintain consistent organoleptic outcomes.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Category 100 percent agave vs tequila (mixto) Not applicable Recipe documentation Mixto allows external sugars Mixto lighter agave notes Non agave sugars up to 49 percent of reducing sugars only for mixto [NOM-006 2012] Exceeding 49 percent external sugars
External sugar source Cane, beet, corn syrups 0 to 49 percent of total reducing sugars Invert sugar assay Boosts ethanol potential More neutral or foreign notes Forbidden for 100 percent agave Post distillation sweetening outside additive list
Original gravity 12 to 18 degree Bx Specific gravity 1.048 to 1.074 Hydrometer or density meter Sets potential alcohol Modulates ester formation Must support downstream distillation capacity Too high osmotic pressure inhibits yeast
Nutrient strategy DAP, complex nutrients 100 to 300 ppm YAN Formol titration, FAN assay Prevents stuck ferment [Lallemand 2020] Excess nitrogen suppresses esters [Lallemand 2020] Additives must be food grade Residues altering flavor

Fermentation

Fermentation transforms agave sugars into ethanol and sets the congener profile that distillation will refine. Control temperature, pH, and microbial dynamics to deliver predictable hearts cuts and meet NOM congener tables.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Yeast selection Agave-tolerant Saccharomyces strains Pitch 0.2 to 1 g per L Cell counts, viability staining Robust conversion Strain drives ester profile [Arrizon 2006][Fermentis 2021] Wild ferment allowed but riskier Contamination by lactic bacteria
Temperature control Controlled or ambient 28 to 34 degree C Fermenter probes Higher temp speeds conversion High temp raises fusels None Above 35 degree C stalls yeast
pH management Initial acidulation Start 4.2 to 4.8 pH meter Buffers yeast stress pH drift affects ester balance Food grade acids only pH below 3.5 slows fermentation
Fermentation time Rapid vs slow 24 to 120 hours Brix drop, ethanol assay Longer runs increase conversion risk Longer runs increase ester complexity Must avoid contamination Extended lag phases
Aeration Initial oxygen dosing 5 to 15 mg per L DO meter Supports sterol synthesis Modulates ester balance None Over oxygenation causes oxidation
Vessel design Open wooden vs closed stainless Not applicable Standard operating procedure Open systems higher contamination risk Open systems add complexity Ensure sanitary design Biofilm buildup

Distillation

Distillation shapes spirit purity, copper contact, and texture. Track cut windows precisely to balance yield and compliance with methanol and higher-alcohol specs, especially when integrating column equipment or recycled tails.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Distillation count Batch double distillation, continuous equivalent Minimum two steps Process records More rectification increases recovery High rectification reduces congeners Two distillations required [NOM-006 2012] Single pass insufficient
Copper contact Pot still bodies, plates, mesh Surface area to vapor path Visual audit Removes sulfur Adds brightness Monitor for copper carryover Copper corrosion leading to blue tequila
Cut points Heads, hearts, tails Heads 70 to 82 percent ABV, hearts 55 to 70, tails below 55 Inline ABV meter, sensory Wider hearts increase yield Narrow hearts protect quality Must meet methanol and congener limits Smearing increases off notes
Reflux control Plates, dephlegmator Reflux ratio 0.5 to 3 Temperature and flow meters Higher reflux increases purity Higher reflux lightens profile Ensure spirit retains required congeners Flooding or entrainment
Dilution between runs Reverse osmosis water 25 to 35 percent ABV charge Hydrometer Controls separation Too dilute reduces body Water must be potable Mineral water causing haze

Maturation

Maturation decisions define tequila classes and inventory commitments. Keep thorough barrel records—fill dates, toast levels, and warehouse climate—to substantiate claims for reposado, añejo, and extra añejo lots.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Class selection Blanco, reposado, añejo, extra añejo Not applicable Production plan Defines inventory time Determines maturation profile Must follow NOM class definitions [NOM-006 2012] Mislabeling lots
Reposado aging Oak containers any size Minimum 2 months Warehouse system Minor angel share Oak spice and vanillin No maximum size limit in NOM Using non oak woods
Añejo aging Oak barrels or vats Minimum 1 year, vessel up to 600 L Barrel inventory Angel share 2 to 8 percent per year Deeper oak integration 600 L cap enforced [NOM-006 2012] Over capacity vessels invalidate class
Extra añejo aging Oak barrels or vats Minimum 3 years, vessel up to 600 L Barrel inventory Higher angel share Oxidative complexity 600 L cap enforced [NOM-006 2012] Evaporation losses unmanaged
Oak type American, French, new, refill 200 to 600 L Supplier certificates Impact on evaporation Species shifts lactones vs spice Must be oak Contamination from improper coopering
Warehouse climate Ambient, temperature controlled 15 to 30 degree C, 50 to 80 percent RH Data loggers Changes angel share Influences maturation rate Maintain structural safety Hot spots accelerating evaporation

Filtration and finishing

Finishing steps polish texture and appearance while maintaining legal transparency. Document every filtration and additive move so sensory consistency aligns with NOM abocado limitations and cristalino positioning.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Carbon filtration Powdered carbon, carbon block 0.5 to 5 g per L media dosing Turbidity and sensory checks Minor losses if overused Strips color and congeners Legal across classes Over polishing reduces character
Chill filtration 0 to 5 degree C hold 12 to 48 hours Haze inspection Visual and microscopy Reduces haze risk Removes oils and texture Legal Permanent flavor loss
Cristalino process Carbon polishing to colorless Contact time 0.5 to 6 hours Colorimetry, sensory Small volume loss Removes color and tannins Not a legal class; label remains base class [NOM-006 2012] Market confusion about classification
Abocado additives Caramel, oak extract, glycerin, sugar syrup Combined up to 1 percent by volume Dosing records, density checks Slight volumetric gain Sweetness, color, mouthfeel Only listed additives permitted [NOM-006 2012] Exceeding cap or using unlisted additives

Blending and proofing

Blending and proofing equalize batch variability and deliver label-ready ABV. Use calibrated instruments at 20 °C and allow blends to rest so dissolved gases and congeners integrate before bottling.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Proofing water Reverse osmosis, demineralized Total dissolved solids below 10 mg per L TDS meter Minimizes dilution haze Preserves aromatic clarity Must be potable Mineral rich water causing haze
Final ABV Label strength 35 to 55 percent ABV Density meter at 20 degree C Higher ABV reduces case volume Lower ABV increases perceived sweetness Bottle 35 to 55 percent ABV [NOM-006 2012] Temperature compensation errors
Batch blending Cross lot mixing Not applicable Sensory and lab analysis Improves consistency Maintains house style Record lots for traceability Incomplete homogenization

Bottling and labeling

Bottling is the final compliance gate. Confirm that labels, closures, fills, and bottling sites satisfy NOM-006 mandates, and archive line checks for CRT verification.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Bottling location Within DO vs authorized outside Not applicable CRT approvals Logistics impact only None 100 percent agave must be bottled in DO [NOM-006 2012] Unauthorized off DO bottling
Closures Cork, screwcap Torque 9 to 16 in lb screwcap Torque tester Controls loss Impacts oxygen ingress Must be food grade Cork taint or leakage
Label statements Category, class, ABV, NOM, CRT, lot, origin Not applicable Label checklist None None Mandatory per NOM-006 [NOM-006 2012] Missing required declarations
Fill control Net contents 700, 750, 1000 mL Fill volume tolerance per metrology law Checkweigher Protects yield None Must meet NOM-142 or applicable fill standard Underfills leading to fines

Quality and traceability

Continuous quality management protects brand reputation and legal standing. Align analytics, sensory panels, and mass balances with CRT audit expectations and internal release standards.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Lot coding ISO 8601 date time batch Not applicable ERP, label printer Not applicable Not applicable Mandatory for traceability Non unique lot numbers
Analytical profile Congener, methanol, aldehydes Per NOM tables GC FID, HPLC Not applicable Ensures sensory conformance Must meet NOM limits [NOM-006 2012] Diffuser lots exceeding limits
Sensory QC Trained panel 3 to 7 Triangle tests, QDA Panel protocols Not applicable Detects off notes Supports CRT audits Panel drift or fatigue
Mass balance Field to bottle reconciliation ±2 to 5 percent tolerance Yield reconciliation Identifies loss Not applicable Supports audit readiness Unreconciled bulk losses
Micro limits Yeast, bacteria counts Low in finished goods Plate counts, ATP Not applicable Prevents sensory faults Good manufacturing practice Biofilm contamination

Sustainability

Sustainability efforts secure long-term viability of agave landscapes and community partnerships. Track vinasse, bagasse, and resource usage alongside cultural or environmental commitments made to local stakeholders.

Variable Options Typical Numeric Ranges Measurement Method Effect on Yield Effect on Flavor Compliance Notes Common Pitfalls
Vinasse management Neutralization, anaerobic digestion, irrigation reuse 8 to 15 L per L tequila pH, COD, flow meters Energy recovery via heat Not applicable Requires environmental permits Discharging untreated effluent
Bagasse use Compost, biofuel, building panels 250 to 350 kg per ton piñas Scales Fuel offsets Not applicable Waste regulations apply Spontaneous combustion in piles
Water intensity Process reuse, diffuser optimization 8 to 20 cubic meters per L tequila Water meters Lower intake lowers cost Not applicable Track for environmental reporting Diffuser demand stressing supply
Energy recovery Heat exchangers, CHP 10 to 30 percent savings Energy audits Reduces operating cost Not applicable May require permit updates Low grade heat left unused

Process Flow Diagram

flowchart LR
  A[Field maturity\n- Piña age, Brix\n- Penca trim] --> B[Harvest logistics\n- Time to cook\n- Sanitation]
  B --> C{Hydrolysis method}
  C -->|Horno| C1[90-100 C\n36-72 h\n- Rich flavors\n- Lower throughput]
  C -->|Autoclave| C2[110-125 C\n8-14 h\n- Balanced\n- Faster]
  C -->|Diffuser| C3[Room-80 C\n1-3 h\n- Max yield\n- Neutral profile]
  C1 --> D{Extraction}
  C2 --> D
  C3 --> D
  D -->|Tahona| D1[75-85 percent sugar recovery\n- Viscous must]
  D -->|Roller mill| D2[85-92 percent\n- Standard must]
  D -->|Diffuser bed| D3[95-98 percent\n- High solids]
  D1 --> E{Formulation}
  D2 --> E
  D3 --> E
  E -->|100 percent agave| F1[No external sugar]
  E -->|Mixto| F2[51-49 agave-other\npermitted sugars]
  F1 --> G[Fermentation\nYeast, temp, pH, time]
  F2 --> G
  G --> H{Distillation}
  H -->|Pot x2| H1[Copper, batch cuts\n- Congener rich]
  H -->|Column| H2[Plated, continuous\n- Lighter spirit]
  H1 --> I{Maturation}
  H2 --> I
  I -->|Blanco| I1[Rested <60 d]
  I -->|Reposado| I2[>=2 mo in oak]
  I -->|Añejo| I3[>=1 y in oak <=600 L]
  I -->|Extra añejo| I4[>=3 y in oak <=600 L]
  I2 --> J[Filtration and finishing\nCarbon, additive options]
  I3 --> J
  I4 --> J
  I1 --> J
  J --> K[Blending and proofing\n35-55 percent ABV]
  K --> L[Bottling and labeling\nNOM, CRT, class]

Cost Sensitivity Scenarios

Scenario CapEx OpEx Energy OpEx Water Labor Cycle Time Typical Yield (L AA per ton piñas) Flavor Risk Notes
Slow horno Medium High Low Medium 36 to 72 hours 45 to 60 Low
  • Traditional flavor retention
  • Bake capacity bottleneck
Autoclave Medium Medium Low Medium 8 to 14 hours 50 to 65 Low to medium
  • Balanced flavor
  • Requires pressure safety management
Diffuser High Medium High Low 1 to 3 hours 60 to 75 High
  • Needs acid or enzymatic hydrolysis
  • High water handling cost
Long fermentation Low Low Low Medium 72 to 120 hours 0 to -5 percent change vs standard Low to medium
  • Higher ester levels
  • Contamination vigilance needed
Heavy oak Medium Low Low Low 12 to 36 months -2 to -8 percent due to angel share Medium
  • Inventory carrying cost
  • Requires humidity control

20-Point Production Checklist

  1. Verify raw agave species and supplier CRT paperwork.
  2. Measure lot Brix after mild hydrolysis and record.
  3. Trim pencas to target height and wash piñas.
  4. Schedule cook to keep pre cook wait under 72 hours.
  5. Set horno or autoclave recipe and confirm temperature sensors.
  6. Confirm hydrolysis parameters and acid permits for diffuser lots.
  7. Measure reducing sugars at cook end for saccharification completion.
  8. Adjust extraction mill gaps and wash ratios; track extraction efficiency.
  9. Define category (100 percent agave or mixto) and sugar plan.
  10. Prepare nutrients and adjust must pH to 4.2 to 4.8.
  11. Rehydrate and pitch yeast; confirm cell counts and viability.
  12. Track temperature and Brix drop; correct deviations within 2 hours.
  13. Run first distillation and second or continuous equivalent per SOP.
  14. Set heads and tails cuts; record ABV ranges and captured volumes.
  15. Allocate distillate to blanco, reposado, añejo, or extra añejo production.
  16. Record maturation vessel size, oak type, fill date; verify class rules.
  17. If cristalino, validate filtration SOP and retain pre and post samples.
  18. If abocado, dose only permitted additives within 1 percent combined; verify math.
  19. Proof with RO water to label ABV and run haze test at 0 to 5 degree C.
  20. Complete final QC analytics, sensory, and label review for NOM, CRT, class, ABV, lot; release.
Legal Requirements Producer Choices
  • Use Agave tequilana Weber blue grown within the DO [NOM-006 2012].
  • Adhere to tequila and 100 percent agave category sugar rules [NOM-006 2012].
  • Execute at least two distillation steps or continuous equivalent [NOM-006 2012].
  • Bottle finished tequila at 35 to 55 percent ABV [NOM-006 2012].
  • Meet aging minima and vessel caps for reposado, añejo, extra añejo [NOM-006 2012].
  • Limit additives to caramel, oak extract, glycerin, sugar syrup within 1 percent total [NOM-006 2012].
  • Bottle 100 percent agave tequila within the DO; mixto in authorized facilities [NOM-006 2012].
  • Comply with mandatory labeling items including NOM, CRT seal, class, lot [NOM-006 2012].
  • Maintain CRT certification records and audit access [CRT DO].
  • Select agave maturity profile and field management approach.
  • Choose cooking equipment (horno, autoclave, diffuser) and cycle design.
  • Pick extraction technology and wash strategy.
  • Set fermentation yeast, temperature, nutrient, and aeration recipes.
  • Design still configuration, copper contact, and cut strategy.
  • Choose oak types, toast levels, warehouse climate, and aging duration beyond minima.
  • Decide on filtration intensity, cristalino finishing, and abocado application within legal caps.
  • Establish blending schemes and proofing water treatments.
  • Invest in sustainability initiatives for vinasse, bagasse, water, and energy.

Controversies and Divergent Practices

Requests for Confirmation

Sources (ISO Dates)

One-Page Cheat Sheet

Stage Variable Options Typical Numeric Ranges Measure Yield Impact Flavor Impact Compliance Flags
Field Ripeness Invert Brix sampling 24 to 36 degree Bx Refractometer, HPLC High High Must be blue agave within DO [NOM-006 2012]
Harvest Penca trim High to low cut 1 to 5 cm leaf base Visual Medium Medium None
Cooking Method Horno, autoclave, diffuser Cycle times per method Data logging Medium High All methods accepted
Extraction Technology Tahona, roller, diffuser 75 to 98 percent recovery Mass balance High Medium Manage wastewater
Formulation Category 100 percent vs mixto 0 to 49 percent non agave sugars Reducing sugar assay High Medium Mixto only for external sugars [NOM-006 2012]
Fermentation Yeast and temperature Agave strains 28 to 34 degree C Pitch 0.2 to 1 g per L Cell counts, probes High High None
Distillation Stills and cuts Pot x2 vs column Hearts 55 to 70 percent ABV ABV meter Medium High Two steps min [NOM-006 2012]
Maturation Class rules Repo 2 months, añejo 1 year <=600 L, XA 3 years <=600 L Time in oak Inventory system Low High Vessel caps enforced [NOM-006 2012]
Finishing Filtration Carbon, chill, cristalino Dose 0.5 to 5 g per L Lab tests Low Medium Cristalino not separate class
Additives Abocado Caramel, oak extract, glycerin, sugar syrup Combined <=1 percent Dosing logs Low Medium Only listed additives [NOM-006 2012]
Proofing Water and ABV RO water, 35 to 55 percent ABV Density at 20 degree C Hydrometer Medium Medium ABV window enforced [NOM-006 2012]
Bottling Site and labels DO vs authorized off DO NOM, class, lot Label review None None 100 percent bottled at origin [NOM-006 2012]
Quality Congener compliance Methanol, aldehydes limits NOM tables GC FID None High Must pass NOM analysis [NOM-006 2012]
Traceability Lot coding ISO 8601 format ERP None None Supports CRT audits [CRT DO]
Sustainability Vinasse, bagasse Vinasse 8 to 15 L per L tequila, bagasse 250 to 350 kg per ton pH, COD, scales Cost savings None Environmental permits