Category: distilling

How Grey Goose is Made
This September I visited Cognac, France to judge a competition for Grey Goose vodka. While there, I learned about the production process. I'm sorry I don't have pictures of all this to share- you like reading, right?

Grey Goose is made in two parts: in Picardy, in the north of France, where the wheat is grown and distilled; and Cognac, France, where the wheat spirit and water are filtered and bottled.

Picardy, France. Image from Wikipedia

The Wheat

Grey Goose is made from soft winter wheat grown in Picardy. In that region they grow tons of wheat for France (and you know how the French like baguettes). The temperature never goes below -5 degrees Celsius and in the summer not hotter than 25 or 35 degrees. Winter wheat is sewn in October and harvested in August, giving it 10 months to grow strong, as opposed to summer wheat that grows in 6 months and is more fragile.

The wheat is grown by many farms, then sold to and classified by a co-op. They use only that classified as "superior bread-making wheat" for Grey Goose. Soft wheat, as opposed to hard wheat, is better for distilling according to Maitre de Chai Francois Thibault. I takes about 1 kilo of wheat to make 1 bottle of vodka.

Milling and Fermentation

Interestingly, Grey Goose doesn't own their distillery, yet they have an exclusive contract with the distillery and they produce only Grey Goose there. The distillery is also located in Picardy, and it sounds like quite the huge operation. The entire distilling process is one continuous operation – wheat goes in and spirit comes out with the whole thing in motion.

The wheat, purchased from three different co-ops, enters the distillery, where it is cleaned and then milled. It is milled four times over the course of 24 hours. The husks, which won't ferment, are sold as cattle field. The flour goes through to fermentation.

To break the carbohydrates in the flour down into fermentable sugars, enzymes are added. They add one enzyme that cuts the starch into random sized pieces, then cool it, then add another enzyme that cuts those pieces into evenly sized fermentable sugars.

Why use enzymes? I asked Francois Thibault that question. He said that unlike barley, which can be prepared to transform into fermentable sugars by the malting process, wheat doesn't germinate (see geeky explanation by Ben in the comments). However, as with bourbon, malted barley could be added to the corn/wheat to help transform its starches into fermentable sugars. Thibault says though they could use malted barely, using enzymes is more stable, efficient, and cleaner; and no undesired microorganisms will be added during the process.

Now the wheat is ready for fermentation. They use a commercial (non-proprietary) yeast strain that is prepared elsewhere.

Fermentation takes place in a continuous manner – this is something I've not seen at other distilleries, though I think this technology is used elsewhere. Typically, the wheat/corn/whatever that is being fermented goes into a big vat, ferments completely, then the vat is emptied out. This is a batch process.

For Grey Goose, they use a continuous fermentation process over a series of six cascading tanks. Wheat and yeast goes in the first tank, then pours into each successive tank operating at a different phase in the fermentation process. At the end, the liquid is fully fermented in the form of a beer at 10% alcohol by volume. This takes about 30 hours. New wheat and yeast is constantly added to the first tank and beer is constantly pulled out of the last one.

Distilling

Then the beer is distilled into spirit. They use a five column distillation process. Despite the names given to each of thecolumn stills, they're more or less the same stills, just fine tuned with number of plates, pressure and temperature settings, etc., to do a certain job.
- The first column strips out the water and produces a spirit at 92% alcohol.
- The second column is tuned for "hydro-selection," meaning the spirit is watered back down before entering it, and it is redistilled to remove certain components.
- The third column is "rectification under pressure" and the fourth is "rectification under vacuum." Both of these strip out high and low oils.
- The last column is tuned for "demethanolisation."
The waste products of distillation are redistilled and sold off as industrial alcohol.

The entire process from when the wheat enters the distillery until it leaves takes four and a half to five days.

Filtration, Water, and Bottling

I didn't have the opportunity to visit the wheat fields and distillery in Picardy, but I did get to visit the bottling facility near Cognac.

The water used to bottle Grey Goose comes from a well 500 feet deep beneath the bottling plant. As the soil is full of limestone (just like in Kentucky), the resulting water is full of calcium.

The water is filtered to remove the minerals using double reverse osmosis. Thibault emphasized that the machine can't make great water out of bad water, so they have to start with good stuff like they have. Furthermore Thibault says they don't filter it to 100% pure H20 – they do it to their specifications and leave in the rest for character.

The water is mixed with vodka to bottling proof and then filtered again, this time through pads of cellulose and carbon.

I was curious as to why they don't just bottle the vodka up in Picardy. Thibault says they didn't really consider it – he was based in Cognac (he was a cognac and other spirit maker) when Sidney Frank asked him to develop Grey Goose, and he knew the water in the region was good. He says it was a practical decision to grow the wheat and distill in Picardy and transport it Cognac rather than ship the water of Cognac to Picardy or to try to grow wheat in the Cognac region.

Finally, the bottles are also produced in France. At the bottling facility they only bottle Grey Goose, no other products.

The Glycerin Question

Grey Goose has long been the victim of rumors that it has something added to it to make it smoother. Darcy O'Neil tested Grey Goose for glycerol and found none. But other additives are allowed by US law (sugar, and I think citric acid, for example). So I asked Thibault directly if anything was added to Grey Goose after distillation besides water. He said "Absolutely nothing," and I believe him.
October 4, 2012
Distillery Visit: George Dickel

This spring I visited the George Dickel distillery, located in Cascade Hollow, Tennessee.

Dickel and Jack Daniel's are the two defining Tennessee whiskies: both employ the "Lincoln County Process" of running the new spirit through 10+ feet of charcoal before it is aged. Contrary to popular belief, this is not a requirement of Tennessee whisky, as Tennessee whisky is not its own category by US law. By putting "Tennessee" on the label it must be made in Tennessee, but beyond that Dickel and Daniel's meet all the requirements for bourbon.

In 1870, George Dickel founded the distillery, originally called Cascade Whisky, and it was renamed by his wife after Dickel died. Prohibition came early to Tennessee, so in 1911 the distillery moved to Kentucky, then closed during national Prohibition. Twenty years after Prohibition the distillery was rebuilt about half a mile from its original location.

The mashbill for Dickel bourbon is 84% corn, 8% rye, and 8% malted barley. All bourbon uses a majority of corn, malted barley to aid in fermentation, and a minority of either wheat or rye. At Dickel it is a pretty high percentage of corn for a sweeter tasting whiskey.

Most of the corn used for George Dickel is local, and the rye and barley comes from North Dakota. They distill here four days each week currently, so they have the capacity to make a lot more bourbon than they currently do.

The grains, which are cooked to make them easier to ferment, ferment with yeast for three or four days before they are distilled. The still is 42 inches in diameter and is three storeys tall. In a column still, the fermented mash (the grain solids and the liquids, unlike in scotch whisky where only the liquids are distilled) goes in near the top of the column. During distillation the alcohol comes out the top of the still and everything else goes out the bottom.

Most bourbons (but not Jack Daniel's) undergo a second distillation in either a "thumper" or "doubler." This second distillation acts like a pot still, so they say. Doublers are more common, and used here at George Dickel.

Originally Dickel distilled whiskey in the winter as they said it tasted best then. To mock that, the newly-distilled whisky is chilled to 40 degrees Fahrenheit before it is added to vats of sugar maple charcoal for the Lincoln County Process.

While at Jack Daniel's the whiskey is continuously dripped through a huge vat of charcoal and collected at the bottom, at Dickel the chilled distillate fills up the tank with the charcoal and sits together for about a week before it is drained. They have to refill the charcoal in each vat every 12-18 months.

The first distillation reaches 115 proof. The second distillation brings it up to 135 proof (160 is the legal limit). Though they can put whiskey in the barrel at up to 125 proof, at Dickel they store it at 115. The whiskey is aged in new American oak barrels with a char #4 on the staves and char #2 on the barrel heads.

As is common in American whiskey, the barrel warehouses (rickhouses) are not located right at the distillery, but are scattered about the hilltops nearby. This way they can take advantage of the cooling winds that blow through. Dickel has about 150,000 barrels of whiskey aging today.

Dickels rickhouses are all one storey structures. (Four Roses also uses one storey rickhouses but six storeys is the norm.) With one storey warehouses, there is less temperature differential between barrels aging at the top of the warehouse (those will be the hottest and get the most wood influence the fastest) and the bottom of the warehouse (where whiskey ages relatively slowly).

The angel's share, the amount of alcohol that evaporates from the barrels during storage, is 5 percent the first year and 3 percent each year after.

After aging, the whiskey is run though a paper filter to remove any charcoal bits before bottling.

Visiting George Dickel

Last year 17,000 visitors came through the distillery. The tour is free, but unfortunately there is no whiskey tasting as part of it. Visitors can buy bottles but can't drink them on site. For more information, visit Dickel.com.

June 8, 2012
A Visit to the Yamazaki Distillery in Japan

Yesterday I wrote about visiting the Hakushu distillery in Japan. Today I'll write about Suntory's other single-malt distillery, Yamazaki. It is located between Kyoto and Osaka, at the convergence of several rivers. I believe they said the distillery welcomes 100,000 visitors each year.

(Mount Fuji as seen from the train to Kyoto.)

The Yamazaki distillery was built in 1923 and launched its first whisky, the White Label, in 1929. That whisky is still made today.

The distillery location was chosen because of its water (as are most distilleries), also sought out by Sen no Rikyo, the inventor of the Japanese tea ceremony. One of his tea houses from the 1500s still stands nearby.

Like at Hakushu they import malted barley from Scotland, then grind it, mash it, ferment it, distill it, and age it on site. At Yamazaki they use a combination of wooden and stainless steel washbacks (fermentation vessels). They use the same yeasts as at Hakushu, but sometimes in different proportions.

They have six differently-shaped pairs of stills to make whiskies with many different flavor characteristics, further enhanced by aging in five different types of barrels.

Hogsheads (reassembled ex-bourbon barrels at a larger size), puncheons (large barrels made of new American oak), and Mizunara (Japanese oak) barrels are made at the cooperage in Japan at their grain distillery.

Spanish oak sherry butts are made for them in Spain, and ex-bourbon barrels are what they are.

Mizunara oak grows in the north of Japan, and sometimes in Hokkaido. I used to describe its flavor as similar to sandalwood incense, but on this visit I was tasting it more as a combination of sticky pine tree and cedar. Either way, it's got spice.

They still have a cask from 1924 in the warehouse (though they've swapped out the whisky) and you can see the Cadiz sherry stamp beneath the Yamazaki one.

We tasted whiskies aged in three types of oak: Mizunara, Spanish ex-sherry, and new American oak puncheons.

From the Yamazaki website, "White oak adds vanilla and coconut flavours during the aging process. Tannins and other polyphenols contained in Spanish oak casks leach into the whisky, imbuing it with a deeper reddish hue compared with white oak casks. Whiskies aged in Spanish oak casks typically have fruity, chocolate notes. Over long periods of aging the Japanese oak casks add a distinctively Eastern touch to the whisky, endowing it with sweet fragrances reminiscent of incense with a hint of citrus. This unique flavour has been gaining the Yamazaki brand new adherents around the world."

At Yamazaki they have six different still shapes, use five types of barrels, and barley at two peating levels. This adds up to 6x5x2 = 60 different whiskies produced at this distillery to be used in single malt and in blends.

Speaking of blends, the Hibiki blend is assembled at this distillery as well. (I think the lower-end blended whiskies that we don't get in the States are put together here too.) The blends have aged grain, column-distilled whiskies along with the single malts from the Hakushu and Yamazaki distilleries.

At the distillery, there is a tasting room where you can try a variety of distillery-only products like 100% sherry cask Yamazaki the 1980s and white dog.

They also have a library of their whisky experiments.

And an advertising museum. I wish they'd bring back Uncle Torys.

Now that we've talking about how they make Hakushu, Yamazaki, and Hibiki, I'll get into where and how to drink them in Japan over the next few posts.

November 18, 2011
A Visit to the Hakushu Distillery in Japan

I visited the Hakushu distillery owned by Suntory, located in the Yamanashi prefecture, about two hours by train from Tokyo in Japan. There is a new Hakushu single malt whisky on the US market.

As I mentioned in a previous post, Hakushu was built in 1973 and is located at a high elevation – 700 meters above sea level. (Scotland's highest distilleries are Dalwhinnie and Braeval, both about 355 meters.) On the train ride there, your ears are continually clogging as you change elevation. The distillery is on a large site to protect its water source, and doubles as a bird sanctuary.

The Yamazaki distillery used to grow at least some of its own grain up until around 1970, but now they import all their barley. It is grown and malted in Scotland and shipped to Japan. Suntory buys malted barley at two different peating levels; basically unpeated and at highly peated at at 25 ppm phenol content.

They grind the malted barley on site, then put it in the mash tun with hot water to expose the fermentable sugars and transfer it to the wooden washbacks for fermentation. They ferment it using both brewers' and distillers' yeast.

They have six pairs of stills at Hakushu; two of them the same shape and one not currently used. Thus they have four active still shapes producing different whiskies. As there is another whisky boom, they're currently distilling 24/7.

As Hakushu is at a very high elevation, the whisky ages more slowly with less wood influence on the spirit. Though they use five types of barrels at the other single malt distillery Yamakazi, at Hakushu they focus on two: ex-bourbon and hogshead. (Hogshead barrels are reconstructed bourbon barrels made a little larger, holding 230 liters rather than 180.) They do, however, age ex-sherry butts (Spanish oak, 480 liters), and puncheons (new American white oak, 480 liter).

They rechar some barrels after using them to age whisky about four times, but after they rechar they only use them one more time. Distillery General Manager Mike Miyamoto says that the whisky aged in rechar barrels is more astringent than with regular ex-bourbon barrels.

The smell of a recharred barrel is amazing! It's like campfire wood and sugars, even marshmallowish.

At Hakushu they use only racked warehouses, in earthquake-safe metal racks that go about 13 levels high.

Here they use peated and unpeated barley, four still shapes, and five types of casks (though they focus on two.) They say that between them (2x4x5) they make 40 different types of whisky at Hakushu.

Regardless, to make up the Hakushu single malt they primarily include three whiskies distilled on-site: unpeated malt distillate aged in hogshead barrels, unpeated malt distillate aged in sherry butts, and peated malt distillate aged in ex-bourbon barrels.

We sampled each component separately and then the Hakushu 12 and 18 year old blends. With three widely different distillates, Hakushu is almost more of a blended malt (vatted malt) than a single malt.

November 17, 2011
DonQ Rum Visit to Puerto Rico

This summer I visited the Destileria Serralles Puerto Rico, the home of DonQ Rum.

DonQ is distilled in the southern part of Puerto Rico, in Ponce. The distillery has been on the same site since 1865. As with most rum distilleries, it was once the site of a sugar refinery and the distillery was a small part of the overall operation. Puerto Rico stopped producing sugar in the 1980s and the distillery became the important business.

As with distilleries in the United States, during Prohibition Destileria Serralles was closed. After Prohibition ended, they rebuilt the distillery, this time with column stills to replace the previous pot stills. One of those distillation columns from 1934 is still in use today.

Making Rum

The molasses for DonQ is purchased on the open market; the low-sugar stuff from the Dominican Republic or thereabouts, and the high-test sugar-rich stuff from Gautemala. (I learned only recently that with improving technology and higher prices for sugar, they are stripping more sugar out of molasses so they need to suplement lower-quality molasses with special high-sugar stuff so that there is enough sugar in the liquid to ferment.)

The molasses is shipped into the port of Ponce and then transported to the distillery, where it is pasteurized to prevent any spontaneous fermentation.

It is then fermented in stainless steel fermenters with their own strain of yeast until it reaches 8-10 percent alcohol by volume. They distill two rums that are later blended; a "light" and "heavy" version. The lighter version ferments for a lesser time than the heavy.

The heavy rum is distilled in the original beer column (the first column of a multi-column still) from 1934. It looks just as old as it is.

The light rum is distilled in the newer, multi-column stills.

After distillation, the rum is aged. The barrels used at DonQ are used twice before they buy them: the first time by the bourbon industry (as with most rums, tequilas, and scotch because barrels can only be used ounce for bourbon by law), but also another time for "light whiskey" which I take to mean blended whiskey like Seagram's.

Thus there should be less wood influence from these barrels than on other products. Furthermore, they reuse them about 20 times and never rechar them.

The rums are aged at a few different proofs, aged separately as light or heavy-style rums, and some is aged as a "medium" rum; a blend of the two. There are also some solera-aged rums in ex-sherry barrels, which are added to some of the blends.

Sustainability Practices

Roberto Serralles is a sixth-gernation Serralles family member who holds a PhD in environmental sciences. He is responsible for making this distillery more eco-friendly with the goal of making it waste-free. If given the chance to see him speak, I highly recommend it because he is engaging, authentic, enthusiastic, and making a real difference. Some of the innovations he has helped develop are already being copied by other distilleries.

The DonQ website has a great overview of the sustainability practices in place, though from what we learned on-site many of these are evolving from how they are described there.

The carbon dioxide released during the fermentation process used to be captured and sold to use to carbonate sodas, but a change in legal regulations has made this undoable in the short term.

The distilled molasses "beer" is only 8-10 percent alcohol, then is distilled up to 75 – 90 percent. That leaves a lot of excess water with organic material leftover – during the height of their production 350,000 gallons of wastewater per day.

The goal is to separate out the organic matter from the water so that you can reuse the water. First they use anaerobic digesters, in which bacteria eat the organic matter and release biogass. (I want to write a book about distillery waste and call it "Everybody Farts".) This biogass is burned to produce heat at the distillery and reduces the distillery's oil consumption by about 50 percent.

The next stage is aerobic decomposition, which further reduces the organic matter and produces brownish water. They used water this for irrigation, but as I understand it the water isn't ideal, so they are replacing this system with a new membrane filtration system that Roberto Serralles was pretty proud of.

That and other systems are in development, but some of the development has been delayed due to a significant business change. You'll learn why in tomorrow's post.

October 7, 2011
Jameson Irish Whiskey Distillery Visit
In early February I visited the Jameson Irish Whiskey distillery – actually two of them.

The original Jameson distillery is in Dublin, but it is no longer made there. In 1971 it moved to the Midleton distillery in Cork. The reason is because in the late 1960's Irish Distillers was formed, a merger of Jameson, Powers, and Cork distilleries.

In Dublin there is a visitors' center and restaurant. We went there first. I've got to admit, they did a really good job making a non-working distillery look working, using dioramas and original distillery parts but with fake ingredients pumping through them.

The next day we went to the new distillery in Cork. But actually it's the new-new distillery, located next to the old one.

Here we skipped the typical tour in favor of an in-depth one.

Jameson Fun Facts
- Triple-distilled, as opposed to most scotch's twice-distilled
- The old pot still here is gargantuan, probably one of the largest in the world. That is no longer used in favor of two wash stills half the size- that are still pretty huge.
- All of the pot-still whisky made here is made on the same four stills: two wash stills, 1 feints still, and one spirit still
- There are also several column stills as Jameson is blended whiskey.
- Redbreast (available in US) and Green Spot (not) are all pot-still whiskeys.
- They also make Middleton, Powers, and Paddy here, plus a couple other brands
- They distill Tullamore Dew here under contract
- Most Jameson uses ex-bourbon and ex-sherry casks. Some (Rarest Reserve) uses ex-port barrels
- Sherry butts are prepared by putting oloroso sherry (that has already aged the minimum of three years to be called sherry) into new casks for two years to prepare them.
- Their pot-still spirit is a combination of malted and unmalted barley. If it's all pot-still whiskey, it is called "Irish pot still." Bushmills is "Irish malt" as it uses all malted barley.
- They don't make a big deal about yeast strains here – use a "standard distilling yeast"
- We nosed 100% malted distillate vs. malt/unmalt blend. The malted smelled more fruity and esthery than the blend
- Due to the weather, there isn't a great temperature variation in the barrel warehouses, and only 2% angel's share per year
- Jameson and Jameson 12 have opposite ratios of pot to column distilled spirit in them, though they don't say the ratios.
- Jameson 18 tastes like green caramel apples
- Jameson Rarest Vintage Reserve tastes like the inside of banana peels, coconut flakes, pineapple gum arabic. It is the yumz.
- Only before 1800 was Irish whisky peated, and much of that would have been poteen rather than whisky. Around 1800 large-scale production became legal in Ireland and everyone moved to using coal rather than peat. So really in modern Irish whisky making there is no tradition of peating.
February 18, 2011
Four Roses Bourbon Distillery Visit

This week I was in Kentucky for a quick visit to the Four Roses distillery. For some history on this brand, see this post a I wrote a few years ago. In short, Four Roses was only a bourbon in Japan for many years, and has recently come back to the US market. They use two mashbills (grain makeup) and five strains of yeast to make ten recipes of bourbon.

The ten recipes blended together ensure a consistent bourbon from batch to batch. Another way they help do this is by having single-story rickhouses. While other brands have several floors in their rickhouses with quite extreme temperature variations in them, at Four Roses they're only one floor high, six barrels tall, with a much less variation in temperature from top to bottom.

We did two tastings at the distillery. One was tasting all ten recipes of the white dog. They have quite the wide range of flavor, from fruity to spicy. The second was tasting several barrels all with the same recipe from different barrels. This was fascinating as there was a surprisingly large difference: one tasted like oloroso sherry, one like apricot socks, one like creamed corn.

Largely because they've been selling mostly in Japan, they use all non-GMO corn. Distillery Jim Rutledge says they don't really advertise that because he doesn't expect they'll be able to get enough non-GMO corn to continue doing so: everything is being replaced by the modified stuff.

Well I have to run to another event- more on this interesting brand another time.

December 8, 2010
More Fun With Distillery Waste

I am a big fan of distillery waste. Not bathing in it, but learning about it.

In most cases where a grain is distilled into whiskey or vodka, the spent grain (after all the sugar has been removed to be fermented) is sold off as animal feed. In Cognac (at Hennessy anyway) the spent lees (grape parts) are taken to an industrial distiller to get more alcohol out of them, and the "heavy sediments" of the grape juice go for cattle feed and for use in pharmaceutical products. In tequila production, the spent fibers from the agave pinas are sometimes put back on the fields as fertilizer, sometimes mixed with the heads and tails of distillation.

(There is a lot of leftover vegetation in tequila production.)

Many sugar cane distillers (either at the sugar factory for rum or at the distillery for rhum agricole) burn the spent sugar cane stalks to heat the steam engine that powers the distillery.

(Spent sugar cane to be burned at Rhum Clement distillery on Martinique.)

(Huge steam-powered gears at Rhum Clement distillery on Martinique.)

The heads and tails are the waste products of distillation, made up of alcohol, water, and undesirable flavor compounds that distillers don't want in their final products. These are also recycled. In scotch whisky, these are put back into the still for the next batch of distillation. (Somehow they never build up and overwhelm the spirit- weird.) Many companies sell the heads and tails to industrial distillers who make pure spirit, cosmetics, and other products. Some use this alcohol as fuel to heat their distilleries in winter.

(The condenser at Fettercairn.)

Speaking of heat, many (if not most) distilleries are mainly powered by hot water; heated either by an oil burner or by burning waste materials like the sugar cane stalks mentioned above. The hot water heats the stills to convert the liquids into steam. Cold water is also needed in the condensers of the still to convert the alcohol in steam form back into liquid form. Typically this cool water comes from a nearby stream or river. After it is used in the condenser it is now hot water, which isn't usually suitable for dumping back into the water stream from whence it came until it is cool. In some distilleries such as the one for Blue Ice Vodka, this hot water is used to lightly heat a warehouse in the winters.

What About the Water in the Still?

On my recent trip to the Isle of Jura, The Dalmore, and Fettercairn distilleries I learned about more industrial waste. This made me very happy.

For some reason nobody talks about the leftover water from distillation. Distillation is really just separating alcohol from water in order to concentrate the alcohol. Concentrate alcohol in beer and you get (unaged) whisky or vodka. Concentrate it in wine and you get brandy. The heads and tails contain alcohol and this is valuable so it gets recycled, but there is still the water left in the still.

(Stills at Fettercairn.)

At Fettercairn, Jura's master distiller Willie Tait explained it: After the first distillation, the leftover water also contains yeast bodies from fermentation. This water/yeast mix is called "pot ale," and it can be boiled down into a high-protein syrup used as cattle feed or as fertilizer.

After the second distillation the leftovers are mostly water with a high copper content with some congeners. Tait said this mixture is called the "spent lees," which is confusing because in cognac this means something different. I also failed to write down how this water is recycled if it is at all, so I have more fun facts about distillery waste to learn!

June 23, 2010
Fettercairn Distillery Visit- Single Malt Scotch Whisky Distillery Tour

Last week I visited the Isle
of Jura, The Dalmore, and Fettercairn distilleries in Scotland. These
brands are all owned by White &
Mackay. This post is about visiting the Fettercairn distillery.

(Fettercairn marked with red pin. Map made with Google Maps)

From The Dalmore distillery we went on yet another gorgeous drive over two mountain ranges to reach Fettercairn, a distillery named after the town where it is located. As you can see on the map below, after you come down from the mountains where much of the vegetation is heather (brown at this time of year) like low scrub bushes, you hit the eastern farmlands with rich soils and plenty of water coming off the hills.

The Fettercairn distillery is about a five-minute walk from the center of Fettercairn with its one pub and stone arch commemorating a pit stop from Queen Victoria. It is surrounded by fields and there are cattle grazing across from the distillery.

The distillery is full of much original equipment from 1824 with a few technological improvements. They no longer do floor maltings (I think only five or six distilleries still do) but otherwise things look pretty old-fashioned here.

(Fettercairn Distillery. Cows in foreground.)

The mash tun is an old copper-topped one with mechanically-driven (see below) stirrers inside. The drainage at the bottom of these older mash tuns is different from newer models, so to compensate the barley must be ground to a courser level.

(Above: Copper-topped mash tun. Below: Inside the mash tun.)

The distillery also has wooden washbacks where fermentation happens. Most wooden washbacks I've seen are made from Doug Fir pine from Oregon.

(Wooden washback)

Unlike at The Dalmore distillery that uses the brown-colored peat-rich river water, Fettercairn uses water from an underground spring for mashing, fermentation, and reducing to barrel proof. It is crystal clear and rich with minerals- you can taste a sort of metallic-granite flavor and it is very drying in the mouth, almost a tannic feeling.

(Stills at Fettercairn)

Fettercairn has two pairs of stills and the still for the second distillation (the "spirit still") has a pretty unique feature.

On yesterday's post about The Dalmore I noted that the still has a reflux box (don't know the technical name for it) in which cold water runs around the top of the neck of the still to encourage only the heavy flavor molecules to cross over.

At Fettercairn they do this in a different way: during the part of the distillation when they're getting the heart of the spirit (the part that will actually be put in barrels rather than recycled), cold water runs down the outside of the neck of the still. I've never seen anything like this on a still before.

It's hard to capture in pictures, so I took this short video. I think this is supercool, but I'm a nerd.

After the whisky is distilled and put into barrels it is stored in traditional dunnage warehouses- old, earthen floor warehouses in which barrels are stacked no more than three-high. There are thick walls and in this case a slate roof. The walls are super moldy and reminded me a lot of the aging warehouses in Cognac.

In these dunnage warehouses (about 12 of them for Fettercairn, all local), there is not a great deal of temperature difference between the top and bottom row. This is quite different from a racked warehouse (think of the tall bourbon warehouses), in which casks are stacked several stories high and temperature, evaporation, and rate of aging vary greatly in different parts of the warehouse.

Now for the bad news: Fettercairn is not available in the US. Even in Scotland its pretty rare to find it as a single-malt. They released a new bottling called Fior that's really tasty and they can't keep it on the shelves. They also sell some 30-year-old and 40-year-old expressions but who can afford such things?

We tasted several barrel samples and they were really wild- a 2004 ex-bourbon had a salty finish and a bourbon grain taste. A 1997 sherry refill cask sample tasted fruity-savory with flavors of sundried tomato and cranberry. The 1974 and 1973 ex-American oak hogsheads were insane floral explosions of lilac, jasmine, rose, and other candied flower flavors.

I assume that most all Fettercairn goes into blends, as most whisky goes toward blends even if it is from a notable single-malt. I do wish they sold this single-malt in the states because:

1. It tastes good.

2. Unicorns!

June 17, 2010
The Dalmore Distillery Visit- A Single Malt Scotch Whisky Distillery Tour

Last week I visited the Isle of Jura, The Dalmore, and Fettercairn distilleries in Scotland. These brands are all owned by White & Mackay. This post is about visiting The Dalmore distillery.

(The Dalmore distillery indicated by red dot. Map from Google Maps.)

From Jura, we took a boat to the mainland and then drove diagonally northeast to reach The Dalmore. It was a long and gorgeous drive into the Highlands that took the better part of a day.

(The Dalmore distillery)

There are many things that make up the final flavor profile of a single-malt scotch, including the variety of barley, the peating levels of it, the water used in the mashing and fermentation, the size and shape of the stills, the size and type of barrels used to age it, where the barrels are aged, and of course the length of aging of the whisky.

The water for The Dalmore comes from Loch Morie, and inland lake. The water then runs through a river to the distillery that is located on another body of water, the Cromarty Firth. As the water travels through a whole lot of peat on the way, by the time it reaches the distillery it is brown in color. This water, not filtered, is used in the mashing and fermentation, and to dilute the whisky to barrel proof for aging.

You can see how it might add to the flavor of the whisky.

(Peat-filled brown water flowing into The Dalmore distillery.)

In the previous post I talked about Jura's tall stills that produce a light and fruity spirit full of high esther notes like pear. At The Dalmore the stills are quite differently shaped and this impacts the spirit.

Photography wasn't allowed in the still room so you'll have to make due with my artistic renderings below.

The stills for the first distillation almost look decapitated- they just stop with a flat top and the lynne arm is not a gentle curve from the top, but a tube sticking out from a foot or two below it.

(Artistic rendering of stills at The Dalmore. Not to scale.)

The still for the second distillation isn't quite as ugly, but it's even more interesting. I think this is the first time I've seen a water-filled reflux section on a still in Scotland. On the tubular pipe near the top of the still is a section that is rinsed with cool water inside.

This makes it difficult for light elements to reach the top of the still, leaving the more robust heavy molecules to cross over to the condenser. You get a spirit that's a lot less light and esthery, very much unlike Jura we'd visited the day before.

Thus The Dalmore comes off the still as a big bold heavy liquid before it goes into wood. It is then the job of the Master Blender, Richard Patterson in this case, to tame the spirit as it ages and shape it into the final product.

I thought that the role of the Master Blender was simply to take what was given to him- a bunch of scotch in barrels- and mix it together, but it is much more than that, at least at The Dalmore.

Patterson chooses the types of barrels (going to Jerez to pick out the sherry ones personally) in which the spirit will be aged, decides on the flavor profile he's seeking for a particular bottling, manages the aging process and checks up on the spirit to see how it is doing as it develops, and puts the blends together. It is product development, wood management, and blending.

Keep in mind that this is still just for a single-malt scotch whisky, a blend of whiskies from the same distillery. A vatted malt or a blend would involve whiskies from other distilleries and grain (column distilled) whisky also. Patterson does this for the Whyte & Mackay blended scotch whisky that is not available in the US.

On this trip I learned a great deal about the different roles of the master distiller and the master blender, and how some spirits need gentle nudging as they age to get them to the right final flavor profile, and others need an aggressive and more hands-on approach to bring them into line. Funny enough, the lighter, softer spirit is made on an island and the full-bodied bruiser comes from the Highlands.

June 16, 2010