Tag: distillery tour

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
A Trip to Italy with Pallini Limoncello

I am one lucky son-of-a-gun. This September I visited Rome and the Amalfi Coast with Pallini Limoncello. Though we began the trip in Rome and went to the Amalfi Coast later, I'll explain the process of making limoncello in the proper order.

The Lemons of the Amalfi Coast

The lemons for Pallini are sfusato ("elongated") lemons, so-named for their tapered shape. They are also sometimes called feminine lemons because each side looks like a nipple. These are slightly different from Sorrento lemons that are more football-shaped.

These lemons are low in acid; very sweet. In fact we had an unsweetened lemonade made with them. It was tart, but still drinkable. Even the pith isn't that bitter- we had a 'salad' made with these lemons soaked in balsamic vinegar and salt – and you could eat the whole thing – fruit, pith, and rind.

But for limoncello purposes, they're interested in the skin of the lemons only. The skins of sfusato lemons are highly aromatic and rich in essential oils.

These lemons grow along the Amalfi Coast in a most improbable way. Actually, the whole coast doesn't make much sense – it is all incredibly steep and rocky, with sharp inclines from the mountains down to the ocean. Picture the drive along Highway 1 in California if people had build houses all the way down to the ocean.

Carved into the cliffs are terraced gardens on which they grow lemons, along with eggplants, grapes, tomatoes, olives, and everything else you can think of. It's a surprisingly productive area given that the base is just rocks.

But the cliff-side growing arrangement means lots and lots of sunshine for these plants. The lemons grow so big and so productively that if these were just normal trees growing on their own, the branches would almost surely snap beneath the weight of the fruit.

Thus the farmers have developed a system to support the lemon tree branches, a pergola made of chestnut wood. This forms a lemon tree umbrella of sorts, with hundreds of huge lemons dangling from above.

(Bonus cat picture!)

The terraced lemon groves present some difficulties in harvesting, as you'd imagine. The lemons are all picked by hand as they ripen, then must be carried uphill to the next road that can be pretty far when you've got a heavy crate of lemons on your back.

Processing Lemons

After the lemons are harvested, they're transported by truck along the windy (and terrifying to those of us scared of heights) road to the processing center. We visited the one Pallini uses: Castier Agrumi De Riso.

When the lemons come in to the factory, they are first washed and then sorted. The very best lemons are sold in crates to stores and restaurants. The rest are peeled to make limoncello.

To do this, they use a machine that peels two lemons at a time. It is hand-loaded and seems to frequently jam – no wonder with sticky, oily peels involved. In this video, you can see the machine working.

The peels that come out are then vacuum-sealed into bags and sent to Pallini to use.

Making Limoncello

Pallini's distillery (it's not actually a distillery as they don't distill there but a rectification plant; still I'll call it a distillery for the sake of clarity) is where they make limoncello from the lemon peels.

Though once there were 30 distilleries in Rome, Pallini is the only one left. Originally, the distillery was located a few hundred yards from the Pantheon in central Rome but now it is in an industrial park-type area a good 30-40 minutes drive from the city center.

To make the limoncello, first they soak the peels in high-proof alcohol (I think around 96%) to extract their flavor. Though they didn't tell us the exact time, I inferred the extraction takes less than a couple of days.

Then they blend this concentrated lemon alcohol with more neutral alcohol (that is distilled from Italian sugar beet molasses), water, and a sugar syrup (made from crystallized sugar beet sugar). To make the flavor pop, they also add essential oils from the same lemons.

Somewhere in the process, they homogenize the ingredients so they retain a fresh flavor and do not separate or oxidize. We tasted several other brands of limoncello and most had a slightly musty flavor of oxidation compared to Pallini.

Other Products

Pallini also makes a Raspicello (useful as a Chambord substitute, or perhaps in a Bramble?) and a Peachcello (for the Bellini). These are actually made by distilling the berries and peaches, and adding fruit juice or fresh berries back in at bottling time. The production seemed pretty interesting but we didn't go into it in detail.

Pallini makes around 150 products, which you'd never guess given the size of the distillery. The most famous one, however, is Sambuca Romana. They created this brand but sold it to Diageo in the 1980s. They still produce it for Diageo though. It's actually a pretty interesting product on its own; a blend of distillates from three kinds of anise, elderflower, angelica, and other herbs and spices.

Anyway, that's it for my Pallini trip. Limoncello is an incredibly straight-forward liqueur made from very special lemons grown in an absolutely stunning place.

October 13, 2011
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
An Auchentoshan Distillery Visit

On the last day of my trip to Scotland with Bowmore, we went to another distillery, Auchentoshan. This distillery is located just outside of Glasgow, on a former estate.

Auchentoshan is in the Lowland region of Scotland, one of just five single-malt-producing distilleries there. It’s also unique as the only scotch distillery that triple distills all of its whisky. This gives it a lighter flavor profile than most single malts, and a thinner body/mouthfeel. This makes it both an entry-level whisky for drinkers new to the category, and one that can be easily mixed into cocktails.

Scotch whisky distilleries usually (always?) have stills in pairs for two distillations; a smaller one for the second. Rather than adding a third still at the end of the process, Auchentoshan has an ‘intermediate still’ between the other two.

(I couldn't fit all three stills in the picture. They do exist, though.)

The spirit is distilled to a high alcohol percentage before the final distillation that will make the cut of the heads and tails. (Previous to that, they're mostly concentrating alcohol. The final distillation/cut will pick out the desired flavor elements for the whisky by discarding portions of the distillate.) According to Auchentoshan's distiller Jeremy Stephens, the higher level of alcohol sitting in the still forces the volatile aromatics in the alcohol to rise to the top first, rather than the heavier, oilier compounds that they want to avoid in this whisky.

After a trip through the distillery, we took a spin through the one of the aging warehouses then went for a tasting.

The Auchentoshan line includes the Classic, which bears no age statement but holds scotch most between five and eight years old, all aged in ex-bourbon casks. The twelve year old contains about 25% whisky aged in ex-sherry casks. We sampled the 18 and 21-year-old expressions as well, along with a 1988 Bordeaux finished bottle that I really liked. The Three Wood is matured in ex-bourbon, ex-oloroso sherry, and ex-Pedro Ximenez casks.

And then it was on to the blending room… see the next post.

May 3, 2010