A

PROJECT REPORT

ON

“INVENTRY& DISCARD””

PREPARED BY – AMIT KAPRI DHMCT IIIRD YEAR

SUBMITTED TO - Mr. SUMIT JOSHI

AMRAPALI INSTITUTE OF HOTEL MANAGEMENT& CATERING TECHNOLOGY

HALDWANI (U.K)(2013-2014)

CERTIFICATE

This to certify that MR AMIT KAPRI Final Year student of Amrapali

Institute of Hotel Management & Catering Technology, Haldwani has duly

completed his project and research work on the topic “INVENTRY &

DISCARD” Under my guidance and supervision during the session 2013-

2014

Mr.SUMIT JOSHI

ACKNOWLEDGEMENT

I acknowledge the generous help and guidance extended to me by many

individuals who provided necessary information with their time and

contributions.

I would like to thank Mr. PRASHANT SHARMAfor extending worthful

and valuable information and advice and helping me at every step with

valuable advice and rich knowledge.

I am also thankful to Mr. PAWAN MEHRAfor providing information

and, providing books to related topics and my friends for their help and

support, in making this job done.

Date ……… GAURAV TEWARI

)

DHMCT 3RD YEAR

A.I.H.M.

FUNDAMENTALS

"A spirituous liquor distilled from a fermented mash of grains, usually rye, barley, oats,

wheat, or corn, and matured in wood casks, usually for 3 or more years. Inferior grades

are made from potatoes, beets, or other roots. Scotch whisky, usually blend, takes its

dry, somewhat smoky flavour from the barley malt, cured with peat, used in its

preparation. The somewhat similar Irish whiskey, for which no peat is used, has a full,

sweet taste. American whiskeys, classified as rye or as bourbon (a corn liquor), are

higher in flavour and deeper in colour than Scotch or Irish whiskeys. Canadian whiskey,

characteristically light, is produced from cereal grain only. First distilled in monasteries

in 11th century England, whiskey has been manufactured commercially since the 16th

century."

Well - that last part isn't completely true.When the first whisky was distilled exactly and

whether it originated in England, Ireland or Scotland is still in debate. The most popular

theory ,has Irish monks hopping across the Irish Sea to Scotland around 700 AD to

spread the gospel - and the secret of distillation - to the barbarians. Nowadays whisky is

produced allover the globe.You can find whisk(e)y distilleries in Scotland, Ireland,

Wales, France, Germany, Switzerland, Canada, the USA, Australia, New-Zealand,

India, Thailand and Japan

When you check a dictionary you'll find that 'whisk(e)y'is spelled either with or without

an 'e'. As far as I know,there's no logical explanation for this, but when a whisky is

produced in Ireland or the USA, it's usually spelled as 'whiskey'otherwise as 'whisky'.

Don't ask me why - itdoesn't make sense to me either. I guess this is just oneof those

inexplicable things in life one simply has to accept; like the success of rap music or

spontaneous combustion. The production of whisky became sort of an 'industry' in 18th

century Scotland.Apart from fondling their sheep and shaving their legs the Scottish

farmers had very little entertainment in those days. Shortly after the recipe for malt

whisky was published in 'Distillation For Dummies' dozens of distilleries were

establishedNobody likes to pay taxes. Hiding high in the Highlands many Scots

managed to elude the English tax collectors time after time. Only after the taxes

werereduced following the Excise Act of 1823 most distilleries were legalised.

Production practices gradually became more professional and the fame ofthe Scottish

whisky slowly but surely spilled over the borders into England. Still, the whisky

industry remained a largely local affair for many years.O.K. - Let's start with the basics.

Your average dictionary might describe ' WHISK(E)Y' something like:

Things changed considerably after a huge wine louse infection (Phylloxera) in the 19th

century wiped out the vineyards in France, and pretty much the entire brandy industry

along with it. The popularity of whisky grew quickly, both in England and overseas.

Scotch whisky production got another boost during the years of prohibition in the USA.

Decades of legal distilling hadn't dulled the Scottish smuggling instincts and the Scots

were happy to jump into the emerging American markets. When the prohibitionended,

'Scotch' had already earned its place on the American market.

How is whisky made? - Scotch Whisky - Scotland: Single malt

whisky 1. Ingredients Barley

Water

Yeast

2. The manufacturing steps Malting

Grinding

Brewing

fermentation

Distillation

Aging

Bottling

ILLUSTRATION OF THE WHISKY MAKING PROCESS

INGREDIENTS Barley The barley is at the base of all the process. The quality of the barley

has a great influence on the quality of the end product. The barley being used for the

production of whisky is carefully selected. It is after all the basic ingredient which will

determine the quality of the whisky which will be sold years later. This selection was

traditionally the job of the manager of the

distillery.

Most of the distilleries nowadays buy their malt in a malting plant (for economic

reasons), this selection is done less and less by the distillery manager but well by the

persons in charge at the malting plant. However, the maltings must respect precise

requirements from the distilleries, in order to let them produce their whiskey properly,

and on the same way year after year.

There is no legal obligation to use Scottish barley to produce Scotch whisky.

Even if some producers would like to go back to the tradition, like Bruichladdich does,

most of the distilleries are not concerned by the origin of their barley. The most

important thing is the highest sugar content and the lowest price. The combination of

those two elements is often the only criteria in the choice of a variety of barley. A great

deal of the barley used to produce Scotch whisky is coming from England or South

Africa. It is not excluded that GMO are used, but it is difficult to get evidences of that.

Anyway, this would perfectly conform with the productivity logic. If genetically

modified barley gives better harvests with a better sugar content...

Water Water is another of the most important ingredients in the making process of

whisky. The quality of the whisky depends on the quality and purity of the water. Water

in Scotland is famous for its great purity. The difference in taste between the whisky

coming from various distilleries is partly due to the quality of water used Water in the

Highlands is often peaty, which gives it a brownish colour. Substances, deriving from

peat, are carried by the river which water is used to make whisky, and contribute often

to the original taste of scotch whisky. original taste of scotch whisky But water is

certainly not the only determining factor in the taste of a malt whisky. The

manufacturing process is of course very important in the final taste of whisky. Water is

used in several steps during the distillation process. First of all, it is mixed to the

grinded malt in order to produce the wort. It is also used for cooling the alcohol leaving

the still. Last but not least, water is used to reduce the alcohol at bottling.

Yeast Yeast (brewer's yeast, often mixed with culture yeast) will start the fermentation

process. The role of yeast is capital. The choice of the yeast is part of manufacturing

secret of the distilleries.

THE MANUFACTURING STEPS

The making process of whisky takes at least 3 years. If a grain (malted or not) spirit

did not stay for at least 3 years in an oak cask, it does not deserve the name of whisky.

Even worse, it does not have legally the right to be marketed under the name of whisky

To deserve the name of Scotch, the whisky has to stay for this minimum of 3 years on

the Scottish ground. Generally, the whiskies marketed as single malt aged for a

minimum of 8 to 10 years. Whisky, just like any other alcohol, is the result of natural

chemical alterations of sugar. To produce alcohol, we first need to produce sugar. Sugar

is potentially present in barley, which grows easily under the Sugar is potentially

present in barley, which grows easily under the Scottish latitudes. Many alcohols are

made from grapes, but the climate of Scotland is not suited for this kind of culture. But

the manufacturing process remains very similar to the one used in production of

alcohol based on other raw material.

Malting Malt is the result of the malting process. The barley is made wet and spread on

the malting floor to allow the germination process to start. A succession of chemical

reactions change the starch contained in the barley in sugar. Later sugar will change into

spirit. The malting art consist of finding the right moment to stop the germination

process: not too late but not too early. According to the season, malting takes between

8 and 21 days Constant attention has to be given to the process. Barley has to be turned

over regularly to ensure a constant moisture and temperature and to control the

germination of the barley grains. The end of the germination is triggered by drying the

germinating barley over a fire (kiln). This oven is often heated by peat. The smoke of

the peat fire in the kiln is determining is the taste of many a whisky. Germination is

stopped by drying the grains above an oven (kiln). The kiln on the picture is the one of

Laphroaig. A kiln was often fed with peat. It is the smoke of the peat fire which gives

some whiskies their particular flavour

The art of some distilleries is in the correct proportioning of peat used to dry the

malt. Springbank for instance produces 3 different malts: Springbank, Longrow and

Hazelburn (which will be available from 2006). One of the main differences between

those 3 products is the proportion of peat used for drying the malt. There are also some

other differences in the distillation process in the case of Springbank. Bruichladdich

also produces 3 different whiskies with different peat levels: Bruichladdich, Port

Charlotte and Octomore (the two latter's are recent productions, and will not be

marketed before several years).

Maltings Economic reasons obliged most of the distilleries to abandon their malting floors

during the 1960's Malting happens mainly at specialized plants, called maltings. This

maltings produce malt according to the requirements of their clients. The same malting

company produces thus several kinds of malt. There are however notable exceptions to

that rule: Balvenie, Laphroaig, Highland Park, Bowmore are some of the distilleries

which produce parts of their own malts. According to some sources, these distillery

would produce about 30% of their needs. Springbank produces 100% of their malt.

Maltings can be independent, or belong to big concerns, owning their malting plants, to

supply the distilleries of the group (like for instance the malting at Glen Ord) or for

local distilleries, like the Port Ellen Maltings on Islay

The latter is the result of an agreement signed by all the Islay distilleries who oblige

themselves to buy a certain amount of malt at the Port Ellen Maltings. This malting

plant is in full expansion, just like the distilleries of the island, and is progressively

occupying the territory of the (henceforth former) distillery of Port Ellen. The maltings

do not have the romantic aspect of (old) distilleries with their pagoda roofs...

Grinding When the malt is dry, it is grinded to make a kind of coarse flour which will be

used in the next operations. This flour is called grist Malt grinding is done with a malt

mill in the distillery itself. Nearly all the distilleries use the same kind of mill,

traditionally made in England, in Leeds, which is sometimes hard to accept for a real

Scot.

Brewing The grist will be mixed with hot water in the mash tun. Generally one volume

of grist is mixed up with 4 volumes of water. In this operation, 3 successive waters are

used, at a temperature between 63 and 95° A mash tun can contain up to 25000 litres

and has a double bottom with thin perforations to let the wort (sugared liquid resulting

of the brewing operation) flow out, retaining bigger parts which will be sold as cattle

food. In order to facilitate the process, mash tun have rotating blades. The waste is

called draff The first operation, taking about 1 hour, will change the starch in

fermenting sugars. The mix of water and grist looks like a kind of traditional porridge.

This sugared juice is called wort. The remainders will be brewed 3 to 4 times, in order

to get a maximum of wort The quality of the wort is controlled by the excise men,

because it determines the amount of spirit which will finally be produced. This is the

base of the taxation of the distillery. .

Fermentation The wash back In order to start the fermentation of the wort, yeast is added The

action of the yeast on the sugar of the wort will produce alcohol and carbon dioxide.

The wort starts bubbling, which will sometimes result in strong vibrations of the wash

back, despite its impressive size. Traditional wash backs are made of Oregon pinewood

or scottish larch. However, more and more stainless steel wash backs are used

nowadays, because they are easier to maintain The result of the fermentation is the same

in both kinds of wash backs. However, lots of distilleries pretend Oregon wood is much

better, and even hi-tech distilleries like Caol Ila do not believe in stainless steel wash

backs The picture above has been taken at the Glenkinchie distillery, The picture above

has been taken at the Glenkinchie distillery Laphroaig. The wash As result of the

fermentation of the wort, a kind of beer with a percentage of approximately 8%. Till

now, there are no substantial differences in the process of making whisky, and the

making of beer. From now the difference between the process will become obvious

Beer will be perfumed with hops, while whisky will be distilled alterations without.

Distillation The distillation is the process used to separate alcohol from water and other

substances contained in the wash. This is a classical operation, and it is the base of each

spirit round the world. It is used in perfumery too. Distillation is made in stills. The

principle is very easy: water evaporates at 100° while alcohol does from 80°. Alcohol

will thus be transformed in vapour and raises into the still before water itself begins

evaporating. Pot stills are used in Scotland.

The size of the stills is fixed by the law. This is due to historical reasons, related to

excise rights Edradour has the smallest legal stills of Scotland. If the stills were a bit

smaller, the distillery would lose its licence. Stills are in copper, because this material

has a great influence on the physical process of separation of the waters and the spirits

The quality of the dram we will enjoy a few years later depends partially on the copper

surface being in contact with the liquids during the distillation process. Other things are

important, like the shape, the height, the length of the lyne arm are also very important

in the making of the taste of the future whisky. If a distillery has to add or replace a

still, it will always try to get a still with the same capacity and the same shape, in order

to guarantee a constant quality to the whisky .Because of the extreme diversity of the

stills used throughout Scotland, it is not possible to display some pictures on this page. I

created a special page with pictures of various stills from several Scottish distilleries. To

get there, just click on the still icon on the left. By the way, this is a still of Glenfarclas

distillery.

Aging The distillation process is unique for each distillery using pot stills.

(Distilleries using Lomond stills - there are very few of them left now - can produce

several types of whisky.) This means that all the whiskies produced by a certain

distillery are treated on the same way, with the same malt, the same stills on the same

way by the same people... So, why can they be so different? from each other? The

answer to this question is in the aging process, the casks used, the nature of the

warehouse, the taste of the air (it seems that a whisky aged in casks stored in

warehouses close to the sea have a different taste from a whisky aged on some other

place). Glenmorangie Cellar 13 is a good example of that phenomenon. If the

surrounding air has a (little) influence on the taste of whisky, one must realize that

many distilleries bring their casks to some central place near Edinburgh for their aging.

It it not clear to me if the whiskies aged that way are marketed as single malt or if they

will be used in blends In other words, the influence of the air on the taste of whisky;.

myth or reality? There is one thing for sure however, and that is that the role of quality

of the barley, the making process, and the nature and quality of the casks where it was

aged is very important. According to some specialists, this could be good for 95% of the

final quality of a malt whisky. To have the right to bear the name of whisky, a grain

spirit (malted or not) must be aged at least for 3 years in a oak cask. Unlike Cognac

which is stored in new casks, the Scottish always use second hand casks. The kinds of

casks The oak casks are classified by capacity, and the following casks exist:

The Scotch whisky industry uses mainly 3 kinds of casks:

The "barrel" : ±190 litres ,the "hogshead" :± 250 litres, the"butt" : ± 500 litres The

shape of the casks is mainly due to historic reasons, related to storage problems on

ships. Sherry was carried on Spanish gallions, storage problems on ships. Sherry was

carried on Spanish gallions, and the slender shape of the butts was the best for storing

on this kind of ships, while the Portuguese Port was stored in a more bulbous cask,

which was easier to carry on Portuguese merchant ships.

The "finishes"Often whisky is aged for a while in bourbon casks, and finishes his aging period

in some kind of other cask, in order to give is some new fragrances, before bottling.

Generally it stays for 6 to 12 months in another kind of cask. This explains the "wood

finish" mention on some bottling's. For instance, the 18 yo Glenmorangie finishes its

maturation in next casks, which is rather uncommon in Scotland. A whisky cask is

always a second hand cask. It generally contained bourbon (american whiskey made

from corn - (maize). Sherry is also very popular in the whisky industry. Other casks are

used too, like Port, Madeira and more rarely Claret (French red wine) or rum etc...

Glenmorangie is specialized in "wood finishes" and some of etc... Glenmorangie is

specialized in "wood finishes" and some of them are very expensive, probably because

of the rarity of the casks. However, there is a question about this wood finishes. If the

aim is to give some new and pleasant fragrances to the whisky, everybody knows (at

least in the whisky industry circles) that this method is used sometimes to hide some

distillation errors. Often, the casks are warmed up before transferring the whisky, in

order to accelerate the fragrance transfer. Such practices are not acceptable, because the

consumer has no way to know about this.

BOTTLING

Bottling is the last step before putting the whisky on the market. Unlike wine,

whisky does not mature anymore in the bottle. So a 12 years old whisky stays a 12 years

old even 12 years later, and does not become a 24 years old one... When bottling, some

residues are left in the whisky. The effect of this is that whisky looks "cloudy", and this

is not always appreciated by the consumer. That's why distilleries found out the"chill

filtering", which removes all this residues. The problem with chill filtering is that it also

removes parts of the fragrances and of the taste. With the current revival of single malt,

more and more bottlers (in dependant or official) bottle their whiskies without chill

filtering. And this makes single malt lovers very happy. During bottling, the alcohol

percentage is reduced. This is the other operation where the quality of water has a great

influence on the taste of whisky. The minimum percentage of alcohol for whisky is40%.

Most of the bottles are marketed at this percentage, because the excise rights are

calculated on the alcohol proportion in the excise rights are calculated on the alcohol

bottle. The excise rights are particularly high in Great Britain but in other countries they

are lower. That's why on the international market, whiskies are frequently bottled at

43°.For some technical reasons, the ideal percentage for bottling without chill filtering

seems to be 46°. Most of the non chill filtered whiskies are marketed at 46°. Often

whisky is not diluted when bottled. That's called cask strength bottling.

The World's Leading DrinkWhat is Scotch Whisky?

Scotch Whisky is a distillate made in Scotland from the elements of cereals. water and

yeast, all of which nature will in due course replace.

Is Scotch Whisky the world's leading drink?

Yes. It outsells every other noble spirit in world markets.

When consumers ask for a Scotch, what exactly do they mean?They usually mean a blended Scotch Whisky, that is a blend of as many as 50

individual Scotch Malt and Scotch Grain Whiskies. The wide range of single whiskies

available in Scotland ensures the continued high quality and consistency of brands of

blended Scotch Whisky and year in year out, enables blenders to ensure that all their

brands maintain their individual characteristics. Blended whiskies account for more

than 95 per cent of all Scotch Whisky sold in world markets.

What is a single whisky?

It is the product of a single distillery. Most distilleries produce Scotch Whisky primarily

for the purpose of blending, but many retain some of their production for sale as single

whiskies. A single Malt Whisky is the product of one Malt Whisky distillery and a

single Grain Whisky is the product of one Grain Whisky distillery.

(a) which has been produced at a distillery in Scotland from water and malted barley (to which only whole grains of other cereals may be added) all of which have been

(i) Processed at that distillery into a mash;

(ii) Converted to a fermentable substrate only by endogenous enzyme systems; and

(iii) Fermented only by the addition of yeast;

(b) Which has been distilled at an alcoholic strength by volume of less than 94.8 per

cent so that the distillate has an aroma and taste derived from the raw materials used in,

and the method of, its production;

(c) Which has been matured in an excise warehouse in Scotland in oak casks of a

capacity not exceeding 700 litres, the period of that maturation being not less than 3

years;

(d) Which retains the colour. aroma and taste derived from the raw materials used in,

and the method of, its production and maturation; and

(e) to which no substance other than water and spirit caramel has been added. The

Scotch Whisky Act 1988 prohibits inter alia the production in Scotland of whisky other

than Scotch Whisky.

The Scotch Whisky Act 1988 and European Community (EC) legislation both specify a

minimum alcoholic strength of 40 per cent by volume, which applies to all Scotch

Whisky bottled and/or put up for sale within or exported from the Community.

However, transitional arrangements allow whiskies which do not comply with the EC

Spirit Drinks Regulation, including those at an alcoholic strength lower than 40 per cent

by volume, to be bottled unti! 14th December 1990 provided that their preparation had

begun before 15th June 1990.

What is a Blended Scotch Whisky?

A Blended Scotch Whisky is a blend of a number of distillates each of which separately

is entitled to the description "Scotch Whisky".

The period for which any blended Scotch Whisky is regarded as having been matured is

that of the most recently distilled of the spirits contained in the blend.

.

What are spirits?

The term spirits describes the product of distillation, whatever the raw materials, or

whether it be in a pure state or contaminated by impurities normally present in any

distillate. Generally. the word refers to any volatile inflammable liquid obtained by

distillation.

Spirits for human consumption. or potable spirits, are the distillates of alcoholic liquids,

the alcohol in which has been formed by the fermentation of sugar as contained in

grapejuice, sugar-cane. etc., or in saccharified materials such as specially prepared

cereals, e.g. malted barley.

The History of Scotch Whisky

What is the origin of the name 'whisky'?

The term 'whisky' derives originally from the Gaelic 'uisge beatha', or 'usquebaugh',

meaning 'water of life'. Gaelic is that branch of Celtic spoken in the Highlands of

Scotland.

When was Scotch Whisky first distilled?

Whisky has been distilled in Scotland for hundreds of years. There is some evidence to

show that the art of distilling could have been brought to the country by Christian

missionary monks, but it has never been proved that Highland farmers did not

themselves discover how to distil spirits from their surplus barley.

The earliest historical reference to whisky comes much later. Mr J. Marshall Robb, in

his book 'Scotch Whisky', says: 'The oldest reference to whisky occurs in the Scottish

Exchequer Rolls for 1494, where there is an entry of 'eight bolls of malt to Friar John

Cor wherewith to make aquavitae'.'A boll was an old Scottish measure of not more than

six bushels. (One bushel is equivalent to 25.4 kilograms)

When King James IV was in Inverness during September 1506, his Treasurer's

Accounts had entries for the 15th and 17th of the month respectively: 'For aqua vite to

the King. . .' and 'For ane flacat of aqua vite to the King. . .'.lt is probable that the

aquavitae in this case was spirit for drinking.

The earliest reference to a distillery in the Acts of the Scottish Parliament appears to be

in 1690, when mention is made of the famous Ferintosh distillery owned by Duncan

Forbes of Culloden.

There is also a reference to distilling in a private house in the parish of Gamrie in

Banffshire in 1614. This occurs in the Register of the Privy Council, where a man

accused of the crime of breaking into a private house, combined with assault, was said

to have knocked over some 'aquavitie'.

One of the earliest references to 'uiskie' occurs in the funeral account of a Highland laird

about 1618.

An unpublished letter of February 1622, written by Sir Duncan Campbell of Glenorchy

to the Earl of Mar, reported that certain officers sent to Glenorchy by the King had been

given the best entertainment that the season and the country allowed. It stated: 'For they

want it not wine nor aquavite.' This 'aquavite' was no doubt locally distilled whisky.

Another writer affirms that aquavitae occasionally formed part of the rent paid for

Highland farms, at any rate in Perthshire, but no actual date is given for this practice.

The Importance of Blending

What is blending? What is its object?

A number of distilleries sell part of the whisky they distil for consumption as single or

unblended whiskies. By far the greater part of their production, however, is used to

contribute to the well-known blended brands that are sold all over the world.

Blending whisky is a considerable art acquired only after years of experience.

A blend will consist of anything from 15 to 50 different single whiskies, combined in

the proportions of a formula that is the secret of the blending company concerned.

Whiskies from different distilleries have a character of their own and, just as people of

different temperaments are often incompatible, so some whiskies cannot be blended

with certain others if a satisfactory result is to be achieved. The Malts and Grains in a

blend must be chosen to complement and enhance their respective flavours. Thus

blending is in no sense a dilution, but the combining of like with like, to produce a

whisky that brings out the best qualities of each of its constituent parts.

The objective of the blender is first to produce a whisky of a definite and recognisable

character. It is of the greatest importance that his blend should never vary from this

standard which his customers all over the world have come to expect. His second

objective is, therefore, to achieve consistency.

The blender must also decide when the different single whiskies are ready to be used in

his blend. They are brought from the warehouse where they have been maturing to the

blending establishment, where they are mixed together in a blending vat. They are

usually returned to cask and left to 'marry' for a period of months, before bottling. Some

companies prefer to vat their Malts and Grains separately and only bring the two

together before bottling.

The combining of Malt with Malt or Grain with Grain is known as vatting.

What is the percentage of Malt and Grain Whiskies in blended Scotch

Whisky?

There is no fixed percentage and the proportion differs from one blender to another. No

brand owner is willing to reveal the proportions of the different whiskies used, but the

blender determines the proportion according to the character of the blend. This

character is determined not only by the proportions of Malt and Grain Whisky which it

contains, but also by factors such as the ages of the individual whiskies and the manner

in which they combine to bring out the finest qualities in each other.

What is a de luxe blended Scotch Whisky?

It is a blend which contains a higher proportion of carefully selected older

and ,therefore, more expensive whiskies.

When there is an age label on a bottle of blended whisky does it refer

to the average age of the whiskies in that blend?

No. The law requires that when the age is declared on a label, it must refer to

theyoungest whisky in the blend. For example, if a blend is described as being eight

years old, the youngest whisky in that blend must have been matured for at least eight

years.

To how many countries is Scotch exported?In recent years Scotch has been exported to about 190 different markets all over the

world. The major markets are the European Community, USA and Japan .

How is the alcoholic strength of Scotch Whisky measured?In common with other EC countries, on 1st January, 1980 Britain adopted the system of

measurement recommended by the International Organisation of Legal Metrology, a

body with most major nations among its members. The OIML system measures

alcoholic strength as a percentage of alcohol by volume at a temperature of 20°C. It

replaced the Sikes system of measuring the proof strength of spirits, which had been

used in Britain for over 160 years .

What was meant by proof spirit?The Customs and Excise Act of 1952 defined spirits of proof strength as follows:

'Spirits shall be deemed to be at,proof if the volume of the ethyl alcohol contained

therein made up to the volume of the spirits with distilled water has a weight equal to

that of twelve-thirteenths of a volume of distilled water equal to the volume of the

spirits, the volume of each liquid being computed as at fifty-one degrees Fahrenheit'.

In other words. proof spirit meant that the spirit at a temperature of 51°F. weighed

exactly twelve- thirteenths of a volume of distilled water equal to the volume of the

spirit. It was, in fact. a mixture of spirit and water of a strength of 57.1% of spirit by

volume and 42.9% of water.

How was whisky tested for proof strength?Spirit of proof strength was the technical standard by which strength was measured until

1st January, 1980. Hundreds of years ago, spirit of this strength was proved when

whisky and gunpowder were mixed and ignited. If the gunpowder flashed, then there

was enough whisky in the mixture to permit ignition. Such whisky was held to have

been proved. If the spirit was weaker than this proof strength ignition did not take place.

In the 1740's. the Customs and Excise and the London distillers began to use Clark's

hydrometer, an instrument devised to measure spirit strength. A more accurate version

by Bartholomew Sikes was universally adopted under the Hydrometer Act,1818, and

remained in standard use until 1980.

At what strength is whisky sold (a) at home, (b) for export?All whisky is retailed at a minimum 40% volume of alcohol for the home market. A

strength of 43% volume is often found in export markets.

How soon after it is distilled is whisky usually sold?The normal practice is for the blender to buy the whisky as soon as it is distilled. It is

then kept under bond in warehouses at the distillery to mature until the blender requires

it. By law whisky must mature for a minimum of three years. although in practice the

minimum age is much greater. After blending, Scotch Whisky is usually returned to

cask and left for a further period of several months to allow the constituent whiskies to

'marry'. It is then bottled for sale.

 

How does the rate of duty on Scotch Whisky compare with that on

other alcoholic liquors?The Excise Duty paid on mature spirits is the same regardless of whether they are

produced in this country or abroad. Scotch Whisky is not protected in any way against

competition from spirits produced overseas, even those from the countries which

themselves discriminate against imports of Scotch Whisky.

At the same time Scotch Whisky is now much more heavily taxed than most competing

drinks. Scotch Whisky is therefore discriminated against when competing in the UK

market against imported wines.

The only reduction in the Excise Duty since the last century was that made in 1973.

when the rate was lowered to compensate for the extra taxation which resulted from the

introduction of Value Added Tax. By contrast, during the last few years more than once

there have been reductions in the duty on high strength wines such as Sherry and Port,

on sparkling wines, on beer and on British wines which are made largely from imported

grape juice.

How many brands of Scotch Whisky are there?There are about 100 well-known brands on the home market and many more are

exported, but it would be impossible to count every brand of Scotch Whisky marketed.

Many of them are sold only locally or to private clubs and individuals.

What are the best blends?This is entirely a matter of taste. All the well-known brands on the market are blended

by experts of many years' experience, and consumers can be confident that in choosing

their favourite they are drinking a whisky consistently blended to bring out the best

characteristics of the Malt and Grain Whiskies of which it is composed.

How old should the best Scotch Whisky be?It is not possible to lay down any precise age as being the best for a particular whisky.

Generally speaking, Malt Whiskies require longer to mature fully than Grain Whiskies.

The law insists that Scotch Whisky shall be at least three years old, and many overseas

countries have similar provisos varying from three to five years. It is the practice of the

trade to mature for substantially longer than the legal minimum. Malt Whiskies are

normally matured for up to 15 years and sometimes even longer. When an age is quoted

for a blended whisky, it is the age of the youngest single Malt or Grain Whisky in the

blend, no matter how small the amount. It is never an average.

Does Scotch Whisky in a bottle lose its strength with age?Once bottled, whisky does not lose its strength.

Does Scotch Whisky improve in a bottle which is kept sealed?No. There is no change in a whisky once it has been bottled and securely sealed. As

oxygen in the air cannot get to the whisky there is no further maturing.

What causes Whisky to lose its brightness?If the whisky is reduced to a low temperature or stored in very cold conditions it may

become cloudy. but this cloudiness will disappear when the whisky is brought back to a

normal temperature. It has been found that when whisky is actually chilled to

temperatures below freezing-point the cloud formed becomes a deposit and if this is

filtered off. the whisky will then retain its brightness under all conditions of

temperature. Unfortunately. the removal of the deposit produced by very low

temperatures also entails the removal of some of the flavour.

At what temperature is whisky best served?This is entirely a matter of personal choice and no rules, such as chilling for certain

wines, can be laid down. In the United Kingdom it is usually served at room

temperature, but in some overseas countries the convention has grown up of putting ice

in the glass.

What is the best shape of a whisky glass?A tumbler-shaped glass or goblet is probably the most convenient shape. but whisky

does not require any specific shape to enhance its delights and no rigid convention has

grown up in this connection.

What is the measure at which Scotch Whisky is generally sold across

the counter?

What information must by law be given on the label of a bottle of

Scotch Whisky sold in the home market?The liquid measure of the contents, e.g. 70cl and the strength. e.g. 40% vol. must be

stated on the label, together with the name and address of the bottler.

Does it spoil or improve the flavour of Scotch Whisky to put ice into it as a

drink?This is entirely a matter of personal taste. Similarly to mix soda water or other soft

drinks with Scotch Whisky is a question of individual choice.

Why do some people turn a new bottle of Scotch Whisky upside down

before opening?This is quite unnecessary and can do nothing to improve the whisky, which does not

need to be turned upside down or shaken. It is quite erroneous to think that the essential

constituents settle at the bo~~t,tom. The blended whisky is all one weight and is

therefore the same at top or bottom. The habit of cocktail shaking may be the reason

why one occasionally sees a bottle turned upside down.

Is it injurious to drink whisky with oysters or other shellfish?No. This is an ancient superstition for which there is no foundation. A personal

experiment will furnish the proof.

What is the alcoholic strength of Scotch Whisky?When distilled it is usually reduced for filling into casks at a strength of 68.5 per cent of

alcohol by volume.

The minimum bottling strength is 40 per cent volume. 43 per cent volume is often found

in export markets, with occasional upward variations.

What is a single whisky?A single whisky is the product of one particular distillery.

What is meant by saccharify?To saccharify means to convert to sugar. In whisky distilling it refers to the process

which takes place during the malting and mash-tun stages by which enzymes in the

malt, referred to as diastase, turn the starch in the cereals into sugar ready for the

fermenting action of the yeast.

What is wort?Wort is the liquid drawn off the mash- tun in which the malted and unmalted cereals

have been mashed with warm water Wort contains all the sugars of the malt and certain

secondary constituents. After cooling, it is passed to the fermenting vats.

In Malt distilleries the cereals are all malted; in Grain distilleries a proportion only is

malted, the remainder being unmalted. In some cases, Grain distilleries do not separate

off wort, passing the complete mash to the fermentation vessels.

What is Wash?The wort or mash technically becomes wash as soon as yeast is added to start

fermentation However, the term is usually used to refer to the liquid at the end of the

fermentation. It IS the wash which forms the raw material of the first distillation in the

Pot Still process and of the only distillation in the Patent Still process

What is the Pot Still distillation?Malt Whisky is distilled twice - although a few distilleries may undertake a third

distillation - in Pot Stills which resemble huge copper kettles. The spirit is driven off

from the fermented liquid as a vapour and is then condensed back to a liquid.

In the first distillation the fermented liquid, or wash, is put into the Wash Still. which is

heated either directly by fire or by steam-heated coils. At this stage the wash contains

yeast, crude alcohol, some unfermentable matter and the by-products of fermentation.

During the process of boiling the wash, changes take place in its constituents which are

vital to the flavour and character of the whisky.

As the wash boils, vapours pass up the neck of the still and then pass through a water-

cooled condenser or a worm, a coiled copper pipe of decreasing diameter enclosed in a

water jacket through which cold water circulates. This condenses the vapours and the

resulting distillate, known as low wines, is collected for re- distilling. The liquor

remaining in the Wash Still is known as pot ale or burnt ale and is usually treated and

converted into distillers' solubles for animal feed.

The low wines are distilled again in the Spirit Still, similar in appearance and

construction to the Wash Still but smaller because the bulk of liquid to be dealt with is

less. Three fractions are obtained from the distillation in the Spirit Still. The first is

termed foreshots, the second constitutes the potable spirit, and the third is called feints.

The foreshots and feints are returned to the process and redistilled in the Spirit Still with

the succeeding charge of low wines. The residue in the still. called spent lees, is run to

waste.

In the case of the Spirit Still, the design of the still, the height of the head (or top) of the

still and the angle of the wide-diameter pipe or Lyne arm, connecting the head to the

condensing unit, are all very important and have an effect on the distillate.

The Pot Still has changed little in general design over the centuries.

What is the worm?The worm and its surrounding bath of cold running water, or worm-tub, form together

the condenser unit of the Pot Still process of manufacture. The worm itself is a coiled

copper tube of decreasing diameter attached by the Iyne arm to the head of the Pot Still

and kept continuously cold by running water. In it the vapours from the still condense.

Fed by the still, it in turn feeds the receiving vessel with the condensed distillate.

The worm is being replaced gradually by the more modern tubular condenser.

What are low wines?This is the name given to the product of the first distillation in the Pot Still process of

manufacture. It is the distillate derived from the wash and contains all the alcohol and

secondary constituents and some water. It forms the raw material of the second

distillation, which is carried out in the Spirit Still. The feints and foreshots are added to

the low wines when the Spirit Still is charged.

What are foreshots?Foreshots is the term applied to the first fraction of the distillate received during the

distillation of the low wines in the Spirit Still used in the Pot Still process of

manufacture. They form the first raw runnings of this second distillation and their

collection is terminated by the judgment of the stillman. The following fraction of the

distillate is the potable spirit.

The foreshots are returned to the still, together with the feints.

.

Scotch Whisky and HealthIs alcohol good for health?

Yes. Research carried out in several countries has shown that drinking in moderation

can be beneficial. This has been endorsed in a report by the British Medical Association

which states that up to 30 grams of alcohol a day - the equivalent of four single

whiskies - can help protect against heart disease. Alcohol can also help relieve stress

and promote appetite and sleep. especially among the elderly. At the same time the

Scotch Whisky Industry recognises that misuse of alcohol can not only damage health

in a number of ways. but may cause domestic and financial problems.

Bourbon Whisky

A Short History Of Kentucky Bourbon

Although Bourbon can be produced anywhere in the United States, it is typically

produced in Kentucky; and it is indigenous to America. So indigenous that, in 1965,

Congress passed a resolution making Bourbon whisky a distinctive national product, a

unique American product.

The proclamation, as welcome as it was, did nothing more than affirm the over 200 year

history of Bourbon whisky. It has been part of this nation's history, and dates to

Colonial times.

Early Beginnings

Large numbers of Scotch-Irish fled England in the early 1700's for various reasons;

some to practice a religion independent of the Anglican Church, others to avoid

retribution for debts, and a number to escape poverty and difficult farming conditions.

Many settled in the vast regions of Virginia and Pennsylvania, parts of which eventually

became the state of Kentucky.

Initially, a large tract of land that would later become Kentucky was set aside by

America's first Congress and named Bourbon County, honoring France's rulers, the

House of Bourbon, in homage to the French who had provided valuable assistance in

the Colonial struggle against the British. But frontiersmen needed motivation to venture

west of Williamsburg and Philadelphia and to colonize the area. And, during the late

1700's, America needed a sturdy mechanism to nurture the independence her freedom

fighters had won. The motive became land ownership.

Thomas Jefferson encouraged expansion and property ownership in this newly annexed

territory. While Governor of Virginia, he offered 60 free acres in Bourbon County to

any man, provided he would plant corn, a native American crop that flourished in the

region's rich limestone shelf. The area also had abundant reserves of spring water, a

naturally pure supply that had filtered through limestone deposits and was low in iron

and other minerals that affect the taste and quality of water. A number of people seized

the opportunity and moved-westward settling in Bourbon County.

What Is Done With Barrels That Cannot Be Reused?The used barrels are sold to distilleries in Ireland and Scotland. Some distilleries seem

to have specific clients for their barrels while others just claim to sell in Ireland or

Scotland. Some American distilleries are owned by large concerns which have distilling

interests in both Ireland and Scotland and their barrels generally go to them.

Filling and Dumping

Filling of the barrels is done mechanically and only takes about a minute or less. The

barrel hole is then stoppered with a bung which is pounded in to the level of the stave.

Most of the distilleries use poplar wood for the bung.

The barrels are continuously sampled during the aging period and are not "dumped"

until fully matured (according to each distilleries standards). The dumping takes place

on long troughs. The barrels ride on the trough (see illustration), the bungs are removed

and the barrel rotated until the hole is on the bottom and the whisky pours out. Along

with the whisky, a considerable amount of charred wood is removed as well. The char is

loosened over the years of movement of the whisky in and out and by the physical

moving of the barrels, either for rotation and/or for removal from the warehouse.

Following dumping, the contents of the barrels are mixed together. This is where the

selection of the barrels for dumping is critical since the barrels in the warehouse do not

mature at the same rate. The distillery may dump 1,000 or more barrels per day and the

product from day to day must remain consistent. Following mixing, the whisky is sent

to the bottling line.

Tennessee Whisky or Tennessee Sour MashCharcoal filtration is the distinguishing production technique of Tennessee whisky.

Tennessee filtering is unique in two respects:

Done before wood maturation.

It is such an exhaustive process.

Others may do some filtering but often after wood aging and never through a filter 10

feet deep!!

There is considerable leaching out of fusel oils; thus these are not oily tasting whiskies

(relative to Kentucky Bourbon) but some feel that they may lose some flavor

characteristics during the filtering.

The charred sugar maple may also add some flavors of its own. For example, some find

a faint but distinctive smokiness in Jack Daniel's.

Between the two Tennessee distilleries, Jack Daniel's is a little heavier with a slight,

pleasant oiliness of body. George Dickel whiskies are lighter and very aromatic, with

the typical vanilla bouquet of the barrel. Tennessee whiskies in general are regarded as a

little drier than are Kentucky Bourbons.

Jack Daniel's Black Label is 90 proof, Green Label is 86.4 proof. Both are between 4

and 5 years old but neither carry an age statement.

Jack Daniel's makes Lem Motlow's Tennessee Sour Mash. It is one year old, 90 proof

and is intended for the Tennessee and Georgia markets. They also make Gentleman

Jack; a high end product which is given a second filtration, following maturation.

With George Dickel, the black is 86.8 and the ivory label = 90 proof. Both are more

than four years old with no age statement.

The two distilleries are less than 10 miles apart; Daniel's in Lynchburg, and Dickel in

Tullahoma.

Bourbon Whisky Brand DescriptionsBourbon Heritage Sampler Pack: Group of 5 American whiskies including I.W.

Harper (15-year-old Kentucky straight bourbon, 80 proof), George Dickel Special

Barrel Reserve (10-year-old Tennessee whiskey, 86 proof), Old Charter Proprietor's

Reserve (13-year-old Kentucky straight bourbon, 90 proof), Old Fitzgerald Very

Special (12-year-old Kentucky straight bourbon, 90 proof) and W.L. Weller Centennial

(10-year-old Kentucky straight bourbon, 100 proof). These are considered super

premium bourbons.

Baker's Bourbon: A small batch Kentucky bourbon. Baker's Bourbon uses a special

strain of jug yeast that has been in Baker's family for over sixty years. This provides

Baker's with a smooth texture and consistent taste from batch to batch. Baker's has a

cognac-like quality and is made for sipping. Aged 7 years in new oak casks. Deep

amber/tawny color. Aromas of vanilla, caramel and cherries. Flavors of roasted nuts,

ripe fruit and vanilla. Sweet, medium-long finish with hints of banana. Kindred Spirits

gives it a **** (highly recommended) rating. 107 proof.

Basil Hayden's Bourbon: A small batch bourbon made in Kentucky using larger

percentages of rye and barley in its mash. A hint of peppermint is added. A light-bodied

bourbon, aged for eight years. 'Spirit Journal' says it is 'lovely... with simple notes of

spice and apple.' 'Wine Enthusiast' gives it a silver medal'. Brief, dry finish.

Blanton Single Barrel Bourbon: Leestown, makers of Ancient Age, produces a limited

reserve Bourbon whiskey, and its makers understand that efficiency and maturity don't

necessarily coexist in the world of fine spirits. The product takes its own time to mature,

which can be costly. Unlike other Bourbons, Blanton's is a Single Barrel Bourbon, aged

and bottled unblended. It is not mixed with Bourbon from other barrels, or of other

ages. The product emanates from one barrel, each one made of -charred new American

oak. And its age could be as old as ten, even 12 years, it just depends with each barrel.

Single Barrel Bourbon by Blanton's variable aging period accounts for its consistently

smooth taste, from one year to another, from one bottle to the next. At Blanton, each

barrel is monitored for the optimum time at which the liquid has matured. Then, and no

sooner or later, is the Bourbon ripe for bottling.

That leaves the bulk of responsibility to the Blanton master distiller, who marries his

skills with those of nature. It is he who decides the exact moment at which the Bourbon

has extracted enough flavor from the barrels. It is he who determines exactly how

smooth and mellow the Bourbon is to ensure the Blanton pedigree.

Six Significant Steps Toward Making Single Barrel Bourbon By Blanton

The production process of Single Barrel Bourbon by Blanton explain why this limited

reserve is a luxury in the world of fine spirits. Born of essential elements - clean water

and corn - Blanton maintains the highest procedures and standards in the whiskey

industry. Here are the important steps in the process.

1. Cooking . Corn, rye and barley malt are the principal grains of Blanton. Their

quality is inspected, and they are ground through a hammer mill into meal. Then

they are treated to convert the solid mass of starch into a more soluble

substance, which can become sugar, and subsequently, alcohol.

2. Corn is then cooked in Kentucky limestone water, within pressure cookers to

break down cellulose walls that separate the starch granules in the corn. The

starch absorbs the water and becomes a gelatin-like substance. Once the corn is

cooked, smaller batches of the other grains are added, as a seasoning for the

Bourbon.

3. Mashing . A mashing machine homogenizes the thick, gooey liquid, called

"beer." The beer, in turn, is recycled several times.

4. Fermentation . Yeast is added to begin fermentation, and the sugars are

converted to alcohol over a period of three to four days.

5. Distillation . This process extracts alcohol from the beer. The fermented beer

("wash" in the case of Scotch whiskies) is continuously distilled. That is, it

passes slowly through perforated plates of a large steel column or still. As the

beer descends through the plates, it is continuously boiled by rising vapor. When

it reaches the bottom of the column, the alcohol has burned off, and water and

solids remain. It is during this time that important flavoring agents are formed.

The liquid is transferred to large tanks in the cistern room and pumped into

barrels, each holding 53 gallons.

6. Maturation, or Aging . This is the mellowing of the Bourbon in charred new

oak barrels. The Bourbon has no aging statement. There's no set rule beyond that

to determine the Bourbon's precise point of maturity, which is why the role of

the master distiller is so important.

Glossary of Whisky TermsAge, Aging - The period of storage, in barrels, after distillation and before bottling; the

mellowing, maturing and developing of a distinctive character while a - whiskey is "on

wood." Minimum aging requirement for Bourbon is two years.

American Blended Whiskey: A blend of which at least 20% is 100 proof straight

whiskey. The rest of the blend may include other whiskey and/or grain neutral spirits. A

small amount of sherry may also be added.

Beer, or Distiller's Beer, also known as Fermented Wort - An alcoholic mixture made

by fermenting finely ground grain, which is then distilled.

Blend - The mixture of various percentages of straight whiskeys; or of straight

whiskeys with neutral spirits. Under present law, a blended whiskey must contain at

least 20 percent by volume of 100-proof straight whiskey. The resulting mixture must

proof at not less than eighty.

Blended Bourbon Whiskey - Must be at least 51 percent by volume straight Bourbon

whiskey; the rest grain neutral spirits.

Blended Canadian Whisky: A blend of grain whiskies.

Blended Corn Whiskey - Whiskey and grain neutral spirits, at least 51percent straight

corn whiskey.

Blended Scotch Whisky; Blended Irish Whiskey: A blend of malt and grain whiskies.

Bonded Bourbon Whiskey: Bonding dates to the early days of bottling when a law

(1894) permitted distillers to warehouse packaged whisky without paying tax until it

was released for sale. The strength standard was 100 proof and this is still referred to as

bottled in bond.

Bourbon 'n Branch - Bourbon 'n Spring Water. Traditionally a way of ordering one's

preferred beverage in the South.

Bourbon Whiskey: Made in the United States from a fermented mash containing at

least 51% corn. It must be produced at no more than 160 proof, stored in new charred

oak barrels at no more than 125 degrees, and bottled at no less than 80 proof.

Char - The result of burning the interior of whiskey barrels used for aging spirits. The

char imparts color and nurtures development of caramel and vanillin flavors,

characteristic of Bourbon.

Fermentation - The conversion of sugar into alcohol prior to distillation.

Grain Whisky: Produced from a grain mixture containing corn, rye, and/or wheat as

well as malted barley. This is whisky in the United States and Canada; in Scotland and

Ireland, it is called grain whisky (or whiskey).

Malt - Dried, sprouted grain, usually barley, introduced into a watery mixture with the

ground-up grain, to turn starch into fermentable sugar.

Malt Whisky: Whisky made entirely from malted barley. In Scotland and Ireland, these

would be their straight whiskies.

Mash - The starchy material that becomes distillate after it has been subjected to the

action of water, heat, stirring and fermentation.

Moonshine: Distilled spirits produced in an unlicensed, unregulated still and without

payment of taxes, and hence, illegal. Seldom aged, and produced from anything that

will ferment.

Neutral Spirit: Any spirit distilled at 190 proof or higher; should contain no noticeable

aroma, flavor or character.

Prohibition: National Prohibition in the U.S. ran from roughly January, 1919 through

December, 1933. During that period, beverage alcohol could not be legally produced,

transported or sold. Limited exceptions were for medical purposes. Widespread

defiance of Prohibition led to the growth of popularity in the U.S. of Scotch and

Canadian Whisky, which were imported illegally.

Proof - A statement of alcoholic strength. The proof number is twice the percentage of

alcohol by volume. Example: a Bourbon marked 100 proof contains 50 percent alcohol.

The remainder is water.

Single Barrel Bourbon Whiskey: A bottling of bourbon whiskey from a single barrel.

Small Batch Bourbon Whiskeys: Marrying together bourbon whiskey from a small

number of specially selected barrels. Because bourbon ages differently at different

locations in the rack house, the marrying together of whiskey from selected barrels

assures the consistency of their unique flavor and character.

Sour Mash: A process developed by Dr. James C. Crow about 1840 to provide

uniformity in bourbon production. A portion of the previous day's mash is added to new

mash to ensure consistent quality and character.

Spent Beer - The distiller's beer after the alcohol has been removed; also called slop or

stillage. Formerly used wet to feed stock, now dried and marketed as cattle feed.

Still: An apparatus, usually made of copper, in which the distiller's beer is purified by

means of heating the liquid to at least 176 degrees Fahrenheit, but less than 212 degrees

Fahrenheit. Because alcohol boils at a temperature lower than water, the alcohol can be

evaporated, collected, and condensed.

Straight Whiskey: Whiskey distilled at not more than 160 proof, aged at least 2 years in

new charred oak barrels and bottled no less than 80 proof. Straight whiskey includes

mixtures of straight whiskeys of the same type produced in the same state.

Tennessee Whiskey: Straight whiskey distilled in Tennessee from a fermented mash

containing at least 51% corn, then filtered through maple charcoal before aging.

"Tennessee Whiskey" is recognized as a distinct whiskey type. It is not bourbon

whiskey.

Whiskey - The most general name of all, never found alone on bottles. A label which

carries any other term - Straight, Blended, Bourbon, etc. must, of course, fulfill the

requirements for whiskey as well as for the other terms it carries. According to the

Federal Government, whiskey is "an alcoholic distillate from a fermented mash of grain

distilled at less than 190 proof in such a manner that the distillate will have the taste,

aroma, and characteristics generally attributed to whiskey, and withdrawn from the

cistern room of the distillery at not more than 110 proof and not less than 80 proof and

is further reduced before bottling to not less than 80 proof."

White Dog: Unaged distillate, just as it comes from the still, is colorless. Also known as

"green whiskey" or "high wine."

Notes on Distilleries Visits:

Makers Mark (Loretto, KY)

Grain Mixture:

Corn = 70%

Wheat = 16%

Barley Malt = 14%

Aged 4 to 8 years; bottled according to taste. When they feel it is ready, it is bottled.

Therefore, there are no age statements on Makers Mark. Three tasters are used to make

the decision. The average is usually about 5.5 to 6 years.

The sealing wax has a plastic base and is heated to 130 degrees F. The workers are

expected to dip 23 bottles (750 ml) per minute.

In 1811, there were over 2,000 distilleries in KY, today 9.

MM uses cypress fermentation vats with a capacity of 9,658 gallons. They have 8 of

them.

Distillation:

Low wine = 120 proof

Doubler = 130 proof

Jim Beam (Clermont, KY)

56 warehouses

20,000 bbls each

Currently at 96% of capacity.

Incoming grain (corn, rye, barley malt) trucks are sampled in 7 locations.

Another term for sour mash is backset.

Sour mash is used because:

It saves on the use of water.

It provides nutrients which may not be in the water.

It helps the fermentation.

Jim Beam uses 41% backset for fermentation.

The process is to add the backset, then the corn, then the premalt. They heat by steam to

sterilize the mash and ?? the starch. The mixture is then cooled and rye is added (they

want to avoid high temperatures with the rye). Following the rye the malted barley is

added which converts the starches to sugar. It is then cooled rapidly and sent to stainless

steel fermentation tanks.

It will ferment for 3 to 4 days (3-4 day beer). The fermentation is controlled by

temperature.

Yeast. Referred to as "jug" yeast. They use the same yeast as used 200 years ago. Take

a 20 gallon milk can, add hops extract and inoculate with a previous yeast mixture and

transfer to a yeast tank. They use a 3,000 gallon tank weekly. The yeast is then mixed

with the cooled mash as it goes into the fermenter. Only Jim Beam and Heaven Hill do

this; the others add the yeast to the fermenter after the mash has been added. The result

is beer and is stored in what they call a "beer well."

The first distillation, in 5 story column stills, is called "low wine" and is 125 proof. This

is distilled a second time in the "doubler" at 135 proof. The first distillation is done with

steam and it extracts the various constituents indiscriminately; thus the use of a doubler.

Char: grade #3 to 4 on staves and grade #3 on top/bottom of barrel.

JB distills 700 barrels per day. They have three men in the 1,000 barrel club. This

means that they have filled 1,000 or more barrels in one day.

Use poplar bungs.

All their water comes from the Jim Beam lake which has a capacity of 68 million

gallons. They also have the use of another lake with a 28 million gallon capacity. Both

lakes have limestone substrates. This contributes to the sweetness of the bourbon.

JB probably use more malt than some others. Grand Dad, for example, has more small

grains than does Jim Beam bourbon.

Jack Daniel's (Lynchburg, TN)

20,000 bbs/warehouse.

Distill at 140 proof; age at 110 proof.

4 years old.

Charcoal Filtering: The charcoal has a life of 8-12 weeks and then must be replaced.

The charcoal is made from hard maple trees that grow in the area. They are called maple

ricks and are burned for 2.5 hours. They must be continuously tended during the

burning and soaked down with hoses from time to time to control the burn. It takes 24

hours for the whisky to filter through the new charcoal. The charcoal vats are 8 feet in

diameter and 10 feet deep.

Use grade #3 burn on barrels.

80% corn; 12% rye; 8% barley.

Filtered twice; once again following aging. The details of the second filtering are a trade

secret.

ml/liter) can lose .5 proof.