Making Single Malt Whiskey

There are many steps involved in making whiskey, and the specific process can vary depending on the type of whiskey being made.

Whiskey is created from just grain, water, and yeast. Yet the spectrum of aromas and flavors that can be found in an aged whiskey can be downright wonderful and beguiling.

Here is a general overview of the process:

1. Malting: is the process of germinating and partially drying cereal grains, such as barley, to prepare them for use in brewing or distilling. It involves soaking the grains in water to allow them to germinate and then drying them in a kiln. The kiln can be heated using various methods, such as wood, peat, or gas, which can give the grains a distinct flavor. During the malting process, enzymes are produced within the grains that will later be used to convert the grains’ starches into sugars during the mashing process. The degree of germination and the amount of kilning can be varied to produce different types of malt with different flavors and properties.
2. Mashing: this is the process of combining ground-up grains (usually barley, corn, rye, or wheat) with water

   

   to create a porridge-like substance called a mash. The grains are typically first malted, which involves soaking them in water to germinate them and then drying them in a kiln. During the mashing process, the grains are mixed with hot water in a large vessel called a mash tun. The temperature of the water and the length of time the grains are mixed with the water can be varied to produce different types of mash with different flavors and properties.The main purpose of mashing is to convert the grains’ starches into sugars, which can then be fermented to produce alcohol. This is done by the enzymes that are produced during the malting process. The resulting liquid, called wort, is separated from the grains and is then ready for fermentation.

3. Fermentation: The wort is mixed with and heated in washback. The yeast converts the sugars i
   n the mash into alcohol. This process is called fermentation. It lasts between 48 and 74 hours. The result is a strong and rather tart beer called the wash.
4. Distillation:  The distillation of the wash is the next step. The goal is the same whether batch distillation is done in a pot still or continuously in a column still: to remove the wash’s alcohol spirit. The wash is then distilled to increase the alcohol content.  It involves heating a mixture of liquids to a temperature at which one or more of the liquids will vaporize, and then condensing the vapors back into a liquid form. Most Whiskey is distilled twice. The first time in a wash still, the second time in a spirit.
5. The Cut: A spirit safe is used in pot still distilleries to allow distillers to evaluate the spirit. The first and last “runs” of the second distillation are not pure enough to be used. They will return to redistill with the “low wines” from the first distillation. The middle section of distillation is the desired and usable part. The “cut” is what it’s called. The “cut” is drinkable and has some of the characteristics of the finished whisky. However, there was no depth of flavor or color.

   

6. Filling the Cask: The new make will have its strength reduced to 63 or 64% ABV. The spirit is then transferred from the holding tank into an oak cask.
   In Scotland it’s filled into used casks; in the US is filled in new ones.
7. Maturation: it’s also called aging. The low wine is then aged in oak barrels. The length of time the whiskey is aged can vary, but it is typically at least three years for single malt whiskey. The aging process helps to develop the flavor and color of the whiskey.
8. Bottling: Once the whiskey has been aged for the desired amount of time, it is ready to be bottled. It is typically diluted with water to reduce the alcohol content to around 40% or 43% alcohol by volume before being bottled. However, cask-strength bottlings are released at the strength they came out of the cask, between 53-65% ABV.