THE WHISKY MAKING PROCESS: A COMPREHENSIVE GUIDE

Introduction

The creation of Scotch whisky is a meticulous process that has been refined over centuries. It is a journey from humble raw materials to a complex and nuanced spirit. This guide will walk you through each stage of the whisky making process, from malting the barley to bottling the final product.

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1. Malting: Awakening the Barley

Objective: To convert the starches in the barley into soluble sugars that can be fermented.

Raw Material: High-quality barley

The Process:

1. Steeping:

• The barley is soaked in water for 2-3 days.
• This triggers the germination process.

2. Germination:

• The damp barley is spread out on a malting floor.
• It is turned regularly to ensure even germination and prevent heat buildup.
• This process takes 4-6 days.
• During germination, enzymes are produced that will break down the starches.

3. Kilning (Drying):

• The germination process is halted by drying the barley in a kiln.
• The temperature and duration of kilning affect the final flavor profile.

The Peating Process (for peated whiskies):

• If a peated whisky is being made, peat is burned in the kiln.
• The smoke from the peat is absorbed by the barley, imparting smoky, medicinal, and maritime flavors.
• The duration of peat smoke exposure determines the PPM (Parts Per Million) of phenols in the malt.

Modern Malting:

• Most distilleries now buy their malt from commercial maltsters.
• Only a handful of distilleries (e.g., Springbank, Bowmore, Laphroaig) still do their own floor malting.

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2. Milling: Grinding the Grist

Objective: To grind the malted barley into a coarse flour called "grist."

The Process:

• The malt is passed through a mill.

• The grist is a mixture of three components:

  • Husks (20%): The outer shell of the barley, which forms a filter bed during mashing.
  • Grits (70%): The starchy middle part of the grain.
  • Flour (10%): Fine powder.

• The ratio of these components is crucial for efficient sugar extraction.

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3. Mashing: Sugar Extraction

Objective: To extract the soluble sugars from the grist.

The Process:

• The grist is mixed with hot water in a large vessel called a "mash tun."

• The water is added in three stages, at increasing temperatures:

  • First Water (approx. 64°C): Extracts the majority of the sugars.
  • Second Water (approx. 75°C): Extracts the remaining sugars.
  • Third Water (approx. 85°C): Used as the first water for the next mash.

• The hot water activates the enzymes from the malting process, which convert the starches into fermentable sugars.

• The resulting sugary liquid is called "wort."

• The wort is drained from the bottom of the mash tun, through the filter bed of husks.

• The leftover solids are called "draff," which is sold as cattle feed.

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4. Fermentation: Creating the Alcohol

Objective: To convert the sugars in the wort into alcohol.

The Process:

• The wort is cooled and pumped into large fermentation vessels called "washbacks."
• Washbacks can be made of wood (traditionally) or stainless steel.
• Yeast is added to the wort.
• The yeast consumes the sugars and produces alcohol and carbon dioxide.
• This process takes 48-96 hours.
• The resulting liquid is called "wash," and it is essentially a strong beer with an ABV of 7-10%.

Factors Affecting Flavor:

• Fermentation time: Longer fermentation can create more complex, fruity flavors.
• Yeast strain: Different yeast strains produce different flavor compounds.
• Washback material: Wooden washbacks can harbor bacteria that contribute to flavor.

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5. Distillation: Concentrating the Spirit

Objective: To separate and concentrate the alcohol and flavor compounds from the wash.

The Still:

• Scotch whisky is distilled in copper pot stills.
• Copper is essential as it removes sulfur compounds and helps to create a smoother spirit.
• The shape and size of the still have a significant impact on the character of the spirit:
  • Tall, slender stills: Produce a lighter, more delicate spirit (e.g., Glenmorangie).
  • Short, wide stills: Produce a richer, oilier spirit (e.g., Macallan).

The Process (Double Distillation):

1. First Distillation (in the Wash Still):

• The wash is heated in the wash still.
• Alcohol has a lower boiling point than water, so it evaporates first.
• The vapor rises up the still, is cooled, and condenses back into a liquid.
• This liquid is called "low wines" and has an ABV of 20-25%.

2. Second Distillation (in the Spirit Still):

• The low wines are heated in the spirit still.

• The resulting spirit is divided into three parts, known as the "cut":

  • Foreshots (Heads): The first part of the run, high in volatile compounds and not suitable for consumption. These are re-distilled.
  • Heart of the Run (Middle Cut): The desirable part of the spirit, which will become whisky. This is collected.
  • Feints (Tails): The last part of the run, high in oily, unpleasant compounds. These are re-distilled with the next batch of low wines.

• The "cut points" (when the distiller starts and stops collecting the heart) are crucial for determining the character of the new make spirit.

Triple Distillation:

• Some distilleries (e.g., Auchentoshan, Hazelburn) triple-distill their whisky, which produces an even lighter, smoother spirit.

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