Spirits Product Knowledge
THE SPIRIT MAKING PROCESS
A Spirit is a Drinkable Alcoholic Beverage.
A drinkable liquid containing 0.5 to 75.5% ethyl alcohol by volume is an alcoholic beverage. For the purpose
of taxation, federal and state governments have set standards as to what constitutes an alcoholic beverage.
Surprisingly, certain bitters and medicinal compounds, which often contain upward of 40% alcohol are not
taxed because they are not considered alcoholic beverages.
Spirits are fermented beverages heated to evaporate the alcohol, which is then condensed into the distilled
spirit. They are classified into seven broad categories depending upon the type of liquid from which they are
distilled. The categories are gin, vodka,rum, tequila, whiskey, liqueurs and cordials.
Spirits are produced by the distillation of a fermented base product. Distilling concentrates the alcohol and
eliminates some of the congeners. Congeners are impurities, that when fully developed give spirits distinct
characteristics, especially after the spirits have been matured in wood. Congeners are biologically active
chemicals and are often contained in alcoholic beverages, in addition to ethanol, the key biologically active
ingredient of alcohol.
When talking strength of an alcoholic beverage, use the term proof. In the United States, a 100 proof spirit is
one containing 50% alcohol by volume at 60 degrees Fahrenheit. For example, an 80 proof bottle of vodka is
40% alcohol. A proof gallon, or a gallon of spirit at proof strength, is the basis for most customs and excise
taxes. One proof gallon is equal to one bulk gallon or 128 fluid ounces at 100 proof.
The basic process for creating spirits is:
1. Milling - The raw material is ground into a coarse meal. The process breaks down the protective hull
covering the raw material and frees the starch.
2. Mashing - The starch is converted to sugar, which is then mixed with pure water and cooked. This
produces a mash.
3. Fermentation - The sugar is converted to alcohol and carbon dioxide by the addition of yeast. The
yeast multiplies producing carbon dioxide (which bubbles away) and a mixture of alcohol, particles and
congeners. Yeast is a living organism that feeds on sugar; the bi-product of this consumption is alcohol
and carbon dioxide (CO2). A simple formula for fermentation is: YEAST + SUGAR = ALCOHOL + C02.
4. Distillation - This process is where a liquid made of two or more parts is separated into smaller parts of
desired purity by the addition and subtraction of heat from the mixture. The vapors or liquids distilled
will be richer in content than any of their ingredients that have lower boiling points. Distilled spirits are
produced from fruit, sugar-cane, molasses, potatoes and cereals.
The alcohol, grain particles, water and congeners are heated. The alcohol vaporizes first, leaving the
water, grain particles and some of the congeners in the boiling vessel. The vaporized alcohol is then
cooled or condensed to form clear drops of distilled spirits.
5. Aging - Certain distilled spirits such as rum, brandy, and whiskey are matured in wooden casks where
they gradually develop a distinctive taste, aroma and color.
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6. Blending - Some spirits go through a blending process where two or more spirits of the same category
are combined. This process is distinctive from mixing since the blended spirit remains of the same
specific category as its components.
Spirits are consumed in many different ways:
Neat is when the spirit is served at room temperature without any additional ingredient.
Straight Up refers to an alcoholic drink that is shaken or stirred with ice, strained, and served in a
stemmed glass.
On the Rocks is when the spirit is served over ice cubes.
A Mixed Drink is an alcoholic beverage of two or more ingredients. Typically, a base spirit is combined
with other distilled spirits, mixers, sweetners, juices and water.
A Shooter is an alchoholic mixed drink that contains one ounce or more of spirits with or without a nonalcoholic mixer. They are generall drunk quickly, rather than sipped. For example:
Jäger Bomb which is Jagermeister and Red Bull.
Tootsie Roll is Absolut Vodka, coffee liqueur and orange juice.
Apocalypse Now is equal parts of Martini and Rossi Dry Vermouth, Jose Cuervo Tequila and St.
Brendan’s Irish Cream.
Earthquake is equal parts Plymouth Gin, Canadian Club and Pernod.
Voodoo is layering one half ounce Kamora, float Cruzan Rum Cream on top of that and finish with
one half ounce Bacardi 151.
Shots do not include a mix, only alcoholic ingredients. Shots can be any alcoholic spirit consumed on their
own like a shot of whiskey or tequila. The average shot glass holds approximately 1.5 oz. of alcohol.
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Brandy
PRODUCTION
If Whiskey is the Heart of the Distilled Spirits Business, then Brandy is its Soul.
Brandy derives it’s name from the Dutch word brandewijn which means burned wine. It is a liquor distilled from
wine or other fermented fruit juices and in most cases is 80 proof (40% alcohol). Brandy has been enjoyed for
centuries as a cocktail and cooking ingredient. Unless labeled otherwise, the term brandy always means grape
brandy because it is a distillate obtained from grape wine.
Fruit brandy is the term for all brandy that is made from fermenting fruit other than grapes. It should not be
confused with fruit-flavored brandy, which is grape brandy that has been flavored with the extract of another
fruit (such as DeKuyper Blackberry Brandy or DeKuyper Apricot Brandy).
Fruit brandy made from distilled apple cider in France is called Calvados and Kirschwasser, a fruit brandy from
Germany is made from cherries. Plum Brandy has many different names depending upon its origin. In France
it is called Mirabelle, in Germany it is called Quetsch and in Europe it is called Slivovitz. Fruit-flavored brandy
is generally distinctive in flavor since the fruit flavor has been obtained by adding an extract or concentrate of
the fruit along with some sweetening substances. The alcohol is provided by the brandy base produced from
grapes. The four basic steps are:
1. The fruit is fermented into wine.
2. The wine is then distilled into alcohol.
3. The aging process begins. This differentiates both the quality and variety of the brandy.
4. The final step in brandy production is to blend the liquor to taste.
When it comes to aging, a minimum of two years maturation in oak casks is required. Although the age is not
carried on the label, brandy is normally aged from three to eight years.
Brandy is produced using one of three aging methods:
1. No Aging - Most fruit brandy is not aged before bottling.
2. Single Barrel Aging - Most brandy with a natural golden or brown color is aged in oak casks, however
some brandy has caramel color added to simulate the appearance of barrel aging.
3. Solera Process - A process of blending where the finished product is a mixture of ages. This process is
common in brandy from Spain.
Cognac - Few spirits can match the romance and worldwide reputation of Cognac, a type of brandy that
comes from the Cognac region of France. Cognac is rightfully famous, requiring a lengthy distillation and aging
process that yields a very distinctive spirit. This region has been divided into seven subdivisions that are
ranked in order of the quality of the Cognac made: Grande Champagne, Petite Champagne, Borderies, Fins
Bois, Bon Bois, Bois Ordinaires, and Bois Communs.
The official quality grades of cognac are the following:
V.S. (“Very Special”) or
(three stars) - A blend aged at least three years in wood.
V.S.O.P. (“Very Superior Old Pale”) - A blend aged at least five years in wood.
XO (“Extra Old”) - A blend aged at least six years but on average closer to 20 years. In 2016, the
minimum storage age of the youngest brandy used in an XO blend will be ten years.
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Cordial or Liqueur
PRODUCTION
Cordials and Liqueurs are Synonymous Terms.
The liqueur/cordial category is large and diverse. Products in this category encompass almost every flavor and
are used in popular shooters, as traditional after-dinner drinks, aperitifs, components of classic cocktails or
even as a flavorful enhancement to foods.
No matter which term you use, a cordial or liqueur must contain at least 2.5% sugar by weight. The sugar may
be beet, maple, cane, honey, corn or a combination. Most cordials and liqueurs contain between seventeen
and thirty percent alcohol by volume although some brands are over fifty percent.
These spirits begin with a base liquor, which could be anything from a neutral grain alcohol to brandy or
whiskey. Sugar is added along with a mixture of herbs, fruits or spices depending on the desired result. All
liqueurs are blends, even those with a primary flavor. Herbal liqueurs may contain dozens of different flavor
elements that a master blender manipulates to achieve the desired flavor profile.
Liqueurs are not usually aged for any great length of time (although their base spirit may be), but may undergo
resting stages during their production in order to allow the various flavors to blend.
There are three basic methods used for cordial production:
1. Percolation is similar to a traditional coffee pot process except the percolator is a large tank. Spirits are
placed at the bottom and fruit is either put into a basket-like container at the top of the tank or suspended
in cloth bags. The spirits at the bottom are then pumped to the top and sprayed over the fruit. The liquid
drips back to the bottom, and is re-percolated continuously until the flavor has been completely extracted
from the fruit.
2. Infusion is like brewing tea. Fruit flavors are extracted by infusion, where crushed fruit is steeped in
water, or maceration, where it is steeped in alcohol. Either process can take up to a year for the water
or alcohol to absorb almost all of the aroma, flavor and color of the fruit. Once the liquid is drawn off,
it’s stored in a tank for several days and then filtered. The fruit then undergoes distillation to extract
whatever flavor remains. This distillate may then be added to the original liquid to give it more character.
The final step before bottling calls for the addition of syrup made from sugar or another sweetening
agent to reach the desired sweetness level.
3. Distillation is the method where the leaves, peels, herbs, roots and flowers are placed in a still, covered
with a spirit and distilled. The distillate carries the flavor of the various ingredients. This is then reduced
with the addition of syrup and adjusted to bottling proof.
Cordials can be grouped into four broad categories:
1. Fruit - The most popular cordial group commonly labeled with the name of the fruit - such as blackberry,
peach or cherry.
2. Herbal - Typically a combination of many herbs, seeds, roots, and flowers. Many products in this group
are sold under distinctive trade names such as Benedictine, Chartreuse and Jagermeister.
3. Peels - Frequently given the name of the flavor from the rind of the citrus fruit. The most widely used is
the peel of the Curacao orange grown on the island of Curacao in the Dutch West Indies.
4. Crème - The sweetest cordial such as crème de menthe. Since the essence can be extracted in a
colorless form, although identical in flavor, they are available in green or white. These are called crèmes
because the high sugar content results in a consistency much like that of cream.
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American schnapps is an alcoholic beverage that is produced by mixing neutral grain spirit with fruit or
other flavors. This mixture is then bottled with added sugar to create a smooth, syrup-like drink. The alcohol
content can be anywhere from 30 to 100 proof.
Schnapps can be bought in a very wide variety of flavors, including aniseed, apricot, banana, blackberry,
black currant, butterscotch, cherry, cinnamon, coffee, lemon, mandarin orange, menthol, peach,
peppermint, root beer and sour apple.
The following chart outlines the most popular liqueurs available and includes dominant flavor and country of
origin.
Name
Alize
Amaretto
Anisette
Bailey’s Irish
Crème de Noyaux
B+B
Black Haus
Campari
Chambord
Cointreau
Crème de Cassis
Creme de Banana
Creme de Cocoa
Creme de Menthe
Curacao
Drambuie
Frangelico
Galliano
Grand Marnier
Grappa
Irish Mist
Jagermeister
Kahlua
Sloe Gin
Limoncello
Midori
Ouzo
Passoa
Remy Red
Sambuca
Southern Comfort
Tia Maria
Triple Sec
Vandermint
Yukon Jack
Flavor
Passion Fruit
Almond
Licorice
Whiskey & Cream
Almonds
Cognac
Blackberry
Aperitif
Raspberries
Sweet & Bitter Orange Peel
Black Currants
Banana
Chocolate
Mint
Orange Peel
Honey/Scotch
Hazelnuts
Vanilla
Oranges/Cognac
Slight Licorice
Honey/Whiskey
56 Herbs and Spices
Coffee
Sloe Berries (Plum)
Lemon
Melons
Licorice
Passion Fruit
Red Currant/Cognac
Licorice
Boubon/Peach/Caramel
Coffee
Oranges
Chocolate/Mint
Canadian Whisky
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Country
France
Italy
US
Ireland
US
France
Germany
Italy
France
France
US/France
Many
Many
Many
US
Scotland
Italy
Italy
France
Italy
Ireland
Germany
Mexico
US
Italy
Japan
Greece
France
France
Italy/Greece
US
Jamaica
US
Holland
Canada
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Gin
PRODUCTION
The United States is the World’s Largest Gin Market.
The distillation of juniper berries with spirits had its beginning in Holland. The drink was called Genevre, a
French word meaning juniper. The English merely shortened the name Genevre to gin.
Juniper berries are blended with botanicals such as herbs, seeds, berries and roots to create gin’s unique
flavor. The proportion of any of these botanicals is left to the producer and may contain licorice roots, lemon
and orange peels, cassia bark, caraway, coriander or fennel. The character and quality of the any gin will
depend greatly on the producer or distiller’s recipe formulation.
American gin is produced using one of two standard methods:
1. Distilling - Distilled gin is produced by extracting the neutral spirits from an alcoholic grain wash using a
columnar still. The highly concentrated spirit is then redistilled with juniper berries and other botanicals,
and may be mixed with similar distillates to achieve the desired final product.
There are two methods for producing distilled gin - direct distillation and redistillation:
In direct distillation, the fermented grain mash is pumped into the still. Then it is heated until the
spirit vapors pass through a gin head, a percolator basket filled with juniper, herbs and other natural
ingredients. It picks up the delicate flavoring agents as it passes through and then condenses into a high
proof gin. Water is added to bring the product down to its bottling strength usually 80 proof.
Redistillation is virtually the same as direct distillation except the fermented mash is first distilled into a
flavorless neutral spirit. This neutral spirit is placed in a second still containing a gin head packed with
the flavoring materials. The spirit is redistilled with the vapors passing through the gin head and absorbs
the flavors.
2. Compounding - Compound gin is a low-quality product made by simply mixing the base spirit with juniper
and botanical extracts. Mass-market gins are produced by soaking juniper berries and botanicals in the
base spirit and then redistilling the mixture.
Every gin producer has his own recipe and the skill of the blender is critical. To make a great gin, the producer
must start with a high quality neutral spirit free from any foreign flavor using the best grade of juniper and other
botanicals. It is a product so delicately flavored that the slightest variation or smallest trace of a foreign flavor
will throw off the entire batch.
Almost all leading gin brands are distilled and most use the word “dry” to describe the brand. It may read “Extra
Dry Gin,” “London Dry Gin,” or “English Dry Gin,” but they all express the same meaning: lacking in sweetness
and in any pronounced aromatic flavor or bouquet. London Dry Gin originally described gin only produced near
London, but it has become generic and is now used on American-made gins as well.
The best known gin drink is the martini made with gin and dry vermouth. The ratio of gin to vermouth started at
about two to one. Today most gin martinis are made with two and one half ounces of gin and just a hint of dry
vermouth. Winston Churchill, a British statesman, who devoted a great deal of thought and time to drinking,
was of the opinion that waving the vermouth bottle over the glass of gin was sufficient.
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Rum
PRODUCTION
Consumed by More People in the World than any other Liquor.
Rum is one of the few distilled alcoholic spirits without a specific standard. Proof, minimum aging, and even
naming standards all vary by country. There are, however, some consistent basics. Rums production begins
by fermenting sugarcane juice or sugarcane byproducts such as molasses. Molasses is the sweet, sticky
residue that remains after sugar cane juice is boiled and the crystallized sugar is extracted. Depending on the
recipe, the wash (sugar cane molasses mixed with water and yeast) is fermented for twenty four hours for light
rums or up to several weeks for heavy full flavored rums.
Distillation is then done either using column stills for or in small batches using pot stills. Finally, aging,
blending and bottling completes the process. Many countries require rum to be aged for at least one year and
commonly done in used bourbon casks, which makes the rum darker in color. It may also be done in stainless
steel tanks, which leaves the rum virtually colorless.
Rum types are determined by geography and the majority of the world’s rum production occurs in the
Caribbean and Latin America. Puerto Rican rums must come from Puerto Rico, Virgin Islands rum from the
Virgin Islands and Jamaican rums from Jamaica. The grades and variations used to describe rum depend on
the location that the rum was produced. Despite these variations the following terms are frequently used to
describe various types of rum:
Light Rum also referred to as silver or white rum has a very subtle flavor and is used primarily as a base
for cocktails. If it is aged in oak casks, it is usually filtered to remove any color. The majority of light rum
comes from Puerto Rico.
Gold Rum, also known as amber rum, is medium-bodied and usually spends several years in oak
casks. The dark color comes from the aging in the wooden barrels which also produces more flavor and
stronger taste than light rum.
Spiced Rum can be white, golden or dark rum infused with spices or fruit flavors. Some less expensive
brands are made from white rums and darkened with artificial caramel color. The spices that may be
added to create spiced rum are cinnamon, rosemary, absinthe/aniseed or pepper.
Dark Rum, also known by the rum’s particular color as brown rum, black rum, or red rum, is a grade
darker than gold rum and is generally aged longer, in heavily charred barrels. Dark rum has a much
stronger flavor than light or gold rum, and hints of spices can be detected, along with a strong molasses
or caramel overtone. It is used to provide substance in rum drinks, as well as color.
Añejo is aged rum from different vintages or batches that are mixed together to insure a continuity of
flavor in brands from year to year. Some aged rum will give age statements stating the youngest rum in
the blend.
Flavored Rum starts with a base of white rum and natural essential flavors or extracts are added. No
sugar is ever added. The most expensive flavored rums use essences of fruit much like a perfume
would, except in larger quantities. Flavored rum frequently has an alcohol content ten to twenty proof
lower than straight rum.
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Tequila
PRODUCTION
Tequila is made from the Sap of the Blue Agave.
Tequila is a distilled beverage made from the blue
agave plant primarily in the area surrounding the city
of Tequila, Mexico. The agave plant, which is planted,
tended and harvested by hand, takes approximately
eight to twelve years to mature. Once it is mature, the
leaves are chopped away from its core or piña (Spanish
for pineapple) that have an average weight of 40 to 70
pounds. Some pina weigh up to 200 pounds!
Before the blue agave heads are allowed into the
factories, a sample is taken from each lot to verify that
the sugar content of the fruit is right to ensure that a high
quality spirit will be produced. This sugar content varies
from region to region in the state of Jalisco, Mexico. The
higher the agave sugar level, the better its tequila.
After a particular lot of weber blue agaves has been verified and its entry authorized, the agave heads are split
in half and slowly cooked in ovens until an appropriate tenderness has been reached. Records are kept to
maintain perfect cooking instructions to produce highly dark brown pinas with an intense sweet flavor.
The piñas are then shredded and the juices pressed out and placed in fermenting tanks where yeast is added.
Every distiller keeps his own yeast a closely guarded secret. During fermenting, the yeast acts on the sugars of
the agave plant converting them into alcohol.
Following two to five days fermentation, the juices are distilled twice in either traditional copper or stainless
steel stills or continuous distillation towers. The first distillation produces ordinario - a cloudy or milky liquid - the
second distillation produces a clear, silver tequila. The tequila is then diluted and bottled or pumped into barrels
to begin the aging process. Fifteen pounds of agave piña are needed to produce one liter of tequila.
The Tequila region of Mexico is the only place Tequila can be produced and there are strict government
regulations. It is produced in two categories defined by the percentage of juices from the blue agave:
100% Agave Tequila must be made with 100% blue agave juices. In 100% Agave Tequila the base
ingredient is more vegetal than grain spirit and often more complex.
Tequila Mixto (Mixed) contains a minimum of 51% blue agave. The remaining 49% is made up of
sugars, typically cane sugar. The additional products allowed in Mixto Tequilas are caramel color, oak
extract flavoring, glycerin and sugar based syrup. This Tequila has no restrictions on where it can be
bottled.
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The two categories of tequila are then labeled as one of the following five types of tequila:
Blanco (white) or Plato (silver) is the blue agave spirit in its purest form. It is clear and typically un-aged,
where the true flavors and the intensity of the agave are present, as well as the natural sweetness. It can
be bottled directly after distillation or stored in stainless steel tanks to settle for up to four weeks.
Oro or Gold is typically a mixto, where colorants and flavorings have been added prior to bottling. These
young tequilas are less expensive and used in many bars and restaurants for margaritas. There are
exceptions when Gold Tequila can also be the result of blending a Silver Tequila with a Reposado and/or
Añejo Tequila, while keeping the 100% Agave classification.
Reposado or Rested is aged in wood barrels or storage tanks from two to eleven months. The spirit
takes on a golden hue and the taste becomes a good balance between the agave and wood flavors.
Many different types of wood barrels are used for aging, with the most common being American or
French oak. Some tequila is aged in used bourbon/whiskey, cognac, or wine barrels, and will inherit
unique flavors from the previous product.
Añejo or Aged is stored in barrels or containers with a maximum capacity of six hundred liters for at least
one year. This aging process darkens the tequila to an amber color, and the flavor is smoother, richer
and more complex.
Extra Anejo is any tequila aged more than three years following the same rules as an Añejo. This
extended amount of aging, gives the tequila a much darker, mahogany color that is so rich it becomes
difficult to distinguish it from other quality aged spirits. After the aging process, the alcohol content must
be diluted by adding distilled water. Extra Añejo’s are extremely smooth and complex.
Traditional tequila practices and processes seem to violate the rules that demand speed, efficiency and
volume. In a world where so much has become computerized and mechanized, tequila seems like a
throwback to how things were done years ago. Growing agave is more of an art than a science; the simple
touch of a hand on a spiky leaf speaks volumes to those who know the language.
It is a misconception that some tequilas contain a worm in the bottle. Only certain mezcals contain a worm and
that began as a marketing gimmick. The worm is actually the larval form of the hypopta agavis moth that lives
on the agave plant. Finding one in the plant during processing indicates an infestation and, correspondingly,
a lower quality product. However, this misconception continues, and even with all the effort and marketing to
represent tequila as a premium liquor there are some opportunist producers for the shooters market who blur
these boundaries.
In Mexico, the most traditional way to drink tequila is straight, without lime and salt. Outside Mexico, a single
shot of tequila is often served with salt and a slice of lime.
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Vodka
PRODUCTION
Made by the Distillation of Fermented Grains, Potatoes or Fruits.
There is an ongoing disagreement among Russians, Poles and Swedes as to which country was the first to
distill vodka. Most historical references credit Russia; alternative accounts only reinforce the uncertainty of the
matter. Whichever country it happened in first, the word Vodka (from the Russian word for water ‘voda’) was
originally used to describe grain distillates that were used for medicinal purposes. Vodka gradually came to be
the accepted term for beverage spirit, regardless of its origin.
Although vodka began as a rye-based liquor, as it gained popularity the potato became the ingredient of
choice. The potato was much more common and although the vodka did not taste as good, it was much easier
to distill than other grains. As vodka made the switch from a family made liquor to one that was produced on
a grand scale by large distilleries, the potato was discarded and grain was embraced. Today most brands of
vodka are distilled from grains such as rye, wheat, barley and most commonly corn, however, potato, fruits and
other vegetables can be used.
All vodkas begin with grain or vegetable in a mash tub fitted with agitators that break down the ingredients as
the tub rotates. If using starch based ingredients such as potatoes or corn, the first step is to gelatinize the
starch by heating it until it forms a paste. Ground malt meal is added to promote the conversion of starches into
maltose, a kind of sugar. To prevent the growth of bacteria, the mash is sterilized by boiling, then cooled and
poured into large stainless-steel vats. Yeast is added and the vats are closed. Over the next two to four days,
enzymes in the yeast convert the sugars in the mash into ethyl alcohol to produce a wash.
Distillation is the critical step that produces vodka from wash and should happen before the wash exceeds
15% alcohol. Heating and condensing the wash and then collecting the alcohol rich vapors as they are
released separates the more volatile component, alcohol, from the less volatile component, water, and creates
vodka. It is not unusual for some vodkas to be distilled three or four times or more, with each re-condensation
from the previous achieving a higher alcohol concentration.
The choice of pot or column still for distillation has a fundamental effect on the final character of the vodka
being produced. All vodka comes out of the still as a clear, colorless spirit, but vodka from a pot still (also used
for cognac and scotch whisky) will contain some of the delicate aromatics, congeners and flavor elements of
the crop from which it was produced. Pot stills are relatively inefficient and the spirit from the first distillation
is usually redistilled to increase the proof. Vodka from a more efficient column still is usually a neutral,
characterless spirit.
To create vodka that is fit for consumption, the methanol content must be reduced to no more than 0.5g per
litre of alcohol. Unlike other spirits, all impurities are removed from vodka. Most vodkas will contain around
thirty milligrams of congeners per litre, as opposed to whiskies and cognacs which may contain up to twenty
six hundred. Concentrating and purifying vodka is done through a process known as rectification that also
removes the flavors characteristic of the base ingredient.
The vodka must be blended with demineralized water to reduce it to about 55% alcohol by volume. Complete
neutrality must be achieved through filtration using charcoal because it is the most effective in removing
oily contaminants. The vodka is pumped through several consecutive columns of charcoal or, in the case of
cheaper vodkas, simply seeped into charcoal filled tanks.
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Two charcoal based vodka-making processes are specifically recognized:
1. Neutral spirits flow continuously through tanks containing at least 1.5 pounds of charcoal for each gallon
of spirit, so that the spirits are in intimate contact with the charcoal for eight hours or more. It is also
required that after every 40 hours of operation at least 10% of the charcoal be replaced.
2. Spirits are maintained in constant movement by mechanical means in contact for not less than eight
hours with at least six pounds of new charcoal for every 100 gallons of spirits.
The government also permits a third process of purifying or refining the spirit by any other method that
results in an equal product without distinctive character, aroma or taste. Absolut and Vox have mastered the
distillation process so that no charcoal filtering is necessary. One of Absolut Vodka’s directors said “Charcoal
is for barbecues” “We rely on our distinctive distillation methods to produce a pure product that still bear’s
character.”
Each brand’s filtration process remains a trade secret and is used as a marketing device. Smirnoff, for
example, proudly proclaim that each drop of their vodka passes through seven tons of activated charcoal.
Except for a few minor styles, vodka is never put in wooden casks or aged for any extended period of time.
Vodka is not legally required to have anything else added to it after water. Unlike nearly all other spirits, vodka
is ready for immediate consumption.
Distilleries that produce flavored vodka start with a base of vodka and typically steep the flavoring ingredients
into the spirit for several weeks. A more industrial process, involves spreading herbal ingredients across a
steel sieve or net inside a tank. The spirit in the tank is filtered past the net every eight hours or so for several
days.
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Whiskey
PRODUCTION
Making Great Whiskey is an Art.
The word whiskey comes from the Gaelic phrase uisce beatha, loosely translated as, “the water of life.” Many
people use the words whiskey and whisky interchangeably. Both refer to alcoholic drinks made from fermented
grain mash; however, whiskey refers to American and Irish variations while whisky typically refers to Scottish
and Canadian types.
Here is a quick way to remember how some of the world’s biggest producers spell their products:
•Countries that have E’s in their names (UnitEd StatEs and IrEland) spell it whiskEy (whiskeys)
•Countries without E’s in their names (Canada, Scotland, and Japan) spell it whisky (whiskies)
Whiskey is derived from distilled grains that are aged in oak casks. Different grains are used for different
varieties, including barley, malted barley, rye, malted rye, wheat and corn.
The United States government defines and recognizes 29 different types of whiskey. The average consumer is
most familiar with five types: Rye, Bourbon, Scotch, Canadian and Irish. For American whiskey in the United
States federal regulations require the following blended mash percentages:
• Bourbon whiskey - at least 51% corn.
• Corn whiskey - at least 80% corn.
• Malt whiskey - at least 51% malted barley.
• Rye whiskey - at least 51% rye.
• Rye malt whiskey - at least 51% malted rye.
• Wheat whiskey - at least 51% wheat.
American whiskey must be distilled to no more than 80% alcohol by
volume and cannot have any added coloring or flavoring. It must then
be aged in new charred-oak containers, except for corn whiskey which
does not have to be aged. If corn whiskey is aged, it must be in uncharred oak barrels and usually is six months or less.
At least 51% Rye = Rye Whiskey
At least 51% Corn = Bourbon Whiskey
Swap two parts corn for two parts rye
and you change rye whiskey into
bourbon whiskey!
If the aging is over two years, the whiskey is then additionally
designated as straight. For example, 51% rye whiskey aged more than two years would be called straight rye
whiskey. If the whiskey is less than 51% of any one type of grain it will just be called straight whiskey without
naming a grain.
The four steps in whiskey making are:
1. Mashing - Since alcohol is derived from sugar, the natural starch content of the grain must first be
converted to grain sugar. To accomplish this, the grain is ground, cooked and then mixed with barley
malt. Barley malt is barley that has been allowed to sprout. It is then dried, ground into a meal, and
mixed with the cooked mash of corn and rye. At this point, the enzymes of the malt take over and
convert the grain starches to maltose or grain sugars.
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2. Fermentation – A huge tank, called a fermenter, is filled with the converted mash and yeast, which is a
living organism. The yeast feeds on the grain sugars and produces an alcoholic whiskey known to the
trade as distiller’s beer. The fermentation process takes from two to four days.
3. Distilling - There are two types of stills: the pot still and the continuous or column still. The pot still is
like a huge kettle, the top of which tapers off into a spiraling pipe. Heat beneath the pot vaporizes the
liquid and as the vapors rise through the cooling spiral, they are condensed and run off as new whiskey.
This will result in alcohol at about 40 to 60% purity with plenty of flavor. If this distillate were put through
the pot still again, it would increase in purity to around 70 to 85% and lose a bit of its flavor. The pot
still cannot produce a high proof whiskey, but it is used for certain whiskeys in the United States and is
universally used to make Scotch malt whisky.
The continuous still is standard equipment of virtually all U.S. distillers and can deliver whiskey at nearly
any proof. It looks like a tall cylinder, usually rising two or three stories through the distillery and the
inside is fitted with numerous baffle plates. Distilling is accomplished by pumping the preheated liquid
mash to the top and permitting it to splash down through the baffle plates, while at the same time steam
at the bottom of the still is rising through the baffle plates. In constant contact with the mash, the steam
distills and redistills the liquid as it rises, and finally passes on through the top of the still where it is
cooled and condensed as new whiskey. The liquids drop to the bottom of the still and are drawn off.
Pot Still
Continuous Still
4. Aging - New whiskey that flows from a still is colorless and harsh. Only time can change its nature to
the mellow, amber beverage that is eventually bottled as straight whiskey or used as a base for blended
whiskey. In the course of aging, no one knows exactly what happens inside the barrel, but whiskey
makers have never found any substitute for time. Within the barrel, oak gives the whiskey color, the
char (carbon) absorbs impurities, and time alone mellows the congeners that give whiskey its flavor and
bouquet. The inside of barrels are typically charred with a flame for a minute or less, which creates a
black charred layer.
One of the important things to remember about whiskey is that the product never ages in the bottle, only in the
barrel. The barrel is of the utmost importance in whiskey production because, chemically, that is what changes
the whiskey. Therefore, the age of whiskey is defined as the time between distillation and bottling. Since
aging does not continue in the bottle, an older bottle of whiskey that was aged the same as a newer bottle
is of no better quality. Also, during each year of aging, about three percent of the whiskey in the barrel is lost
to evaporation or to leaching into the barrel itself. This whiskey that disappears before bottling is called the
angel’s share.
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BLENDED AMERICAN
It is All About “Lightness”.
Blended American whiskey is produced by the distillate of a fermented grain mash which is aged and then
blended. The purpose of blending is to create a balanced, light-bodied whiskey, with richness in taste and
individual character.
To produce a balanced blended whiskey, the distiller combines a variety of whiskey and grain neutral spirits
that comple¬ment each other to develop flavor characteristic that will be consistent time and time again. It
is important to note that grain neutral spirits have lighter flavor intensity and therefore are used in greater
proportion.
Sometimes a blending agent such as sherry is added and the result is a blended whiskey that is lighter in
body than any straight or blend of straight whiskeys. This blending agent is limited by law to two and one half
percent of the total volume however it is unusual to use even this amount. Scotland, Ireland, Canada and the
United States are common countries of origin for blends.
In the United States, government regulations specify that blends must:
1. Contain at least 20% of straight whiskey on a proof gallon basis.
2. Contain separately or in combination whiskey or neutral spirits.
3. Be bottled at not less than 80 proof.
Distillers blend their whiskey to conform to the taste preference of the majority of consumers. Having arrived
at a formula, blending experts can precisely maintain the uniformity of a brand year after year. They will also
continue to improve the brand and keep it in step with consumer tastes, because consumer preferences are
always changing.
As many as 75 different straight whiskeys and grain neutral spirits go into the premium blend brands. Once
blended, the whiskeys and spirits are not merely stirred but are allowed to rest together for a considerable
period of time. This is commonly known as the marrying period. For this final aging, the blend is sometimes
stored in whiskey barrels.
AMERICAN RYE
Experiencing a Small Revival in the United States.
Spicier and leaner than bourbon, rye was the most popular whiskey in the country before Prohibition. Made
from a mash of fermented rye grain, often including barley, corn and other grains, rye whiskey has a more
assertive flavor than bourbon, and its taste inspired the creation of some of the most classic cocktails such
as the Manhattan. The whiskey must be put into charred new oak barrels at not more than 125 proof and is
distilled to no more than 160 proof. Rye whiskey that has been aged for at least two years may be further
designated as straight as in straight rye whiskey.
Rye is known for imparting what many call a spicy or fruity flavor to the whiskey. Due to its distinctive flavor,
American rye whiskey is sometimes referred to as America’s equivalent of an Islay whisky which is a Scotch
whisky made on Islay, an island off the west coast of Scotland.
Since bourbon is distilled from at least 51% corn, it is noticeably sweeter, and tends to be fuller bodied than
rye. As bourbon gained popularity, bartenders increasingly substituted it for rye in cocktails like whiskey sours,
manhattans and old fashioneds, which were initially made only with rye. All other things being equal, the
character of the cocktail will be drier with rye.
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BOURBON
A Distinctive Product of the United States.
Bourbon is a type of American whiskey made primarily from corn. It’s character is largely determined by
the grain proportion used, the mashing techniques, the fermentation environment, the strain of yeast used,
distillation equipment and finally, the maturation process that takes place in the barrels.
Government regulations stipulate that in order to be called bourbon, a whiskey must conform to the following:
1. The mashing formula must have at least 51% corn grain.
2. It must be distilled at a proof no higher than 160 degrees and no lower than 80 degrees.
3. It must enter the new charred oak barrel for at least two years aging at not more than 125 proof.
4. It must be bottled at 80 proof or more.
What matters is not only the length of the aging, but the quality of the white oak in the barrel, the processing of
the wood, the skill of the cooper and the depth of the char. These are important because the bourbon will be
resting in these barrels usually from four to twelve years or longer.
Temperature and humidity controls are critical during this aging process because one improperly cured stave
can ruin the entire contents of the barrel. It is believed that the caramel layer which forms in the oak during
the charring process, is more important than the char itself and it is from this caramel that the colorless new
whiskey acquires its bright amber color.
The action of the wood sugars, the char, and the breathing of the whiskey through the staves all contribute to
the mysterious transformation that slowly mellows the raw new whiskey to the smooth fine-textured product
that finds its way into the bottle.
Sour mash whiskey is made from a yeast mash soured with lactic culture for a minimum of six hours; however,
there is nothing sour about sour mash whiskey. The distiller uses part of a previous day’s mash, instead of
fresh mash and fresh yeast to start and assist in the fermentation process. Each batch is related to a previous
batch. The sour mash process is used for the production of nearly all bourbon and Tennessee whiskey.
Straight bourbon is not a blend, has been aged less than four years and must be labeled with the age. There
is a classification called a “blend of straight bourbon” which is when you put two straight whiskeys together.
Bourbon that has an age stated on its label must be labeled with the age of the youngest whiskey in the bottle
(not counting the age of any added neutral grain spirits).
Bottled-in-bond is straight whiskey produced and bottled in accordance with the Bottling-In-Bond Act, a federal
law dating back to 1897. A straight whiskey under this law must conform to all the requirements and standards
applying to any straight whiskey and the whiskey must be:
1. At least four years old (most are older).
2. Bottled at 100 proof.
3. Produced in a single distillery, by the same distiller, and be the product of a single season and year.
The bottled-in-bond designation in itself is no guarantee of quality, however most distillers select only the best
whiskeys for this bottling.
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CANADIAN
Mashed, Distilled and Aged in Canada.
Canadian Whisky owes its quality to two factors that have influenced the country greatly - the rich Canadian
soil and the traditions of its people, British and French Canadians were familiar with the whiskies from the
Scottish Highlands and Cognac from France which resulted in a distinctive whisky with delicate flavor and light
body.
It is a common misconception that Canadian whiskies are primarily made using rye grain. Although many
Canadian whiskies are labelled as rye whisky, the use of rye grain is not dictated by law, and whisky products
of all grain types are often referred to as and may be labelled as “rye whisky”. Under Canadian law, the term
“Canadian rye whisky” is simply synonymous with “Canadian whisky” and the primary mash ingredient in most
Canadian whisky is corn.
The United State’s definition of Canadian whisky is “a blended mixture of distilled spirits produced in Canada
in compliance with the laws of Canada and containing no distilled spirits less than two years old.” Canadian
rye, barley, and a small amount of wheat are used. Since these grains have been developed to withstand the
rigors of the Canadian climate, they are slightly different and may contribute a certain degree of distinction to
Canadian whisky.
Canadian blends are not a blend of straight whiskies and neutral spirits as blends are in the United States.
Their lightest spirits, distilled at 185 proof would legally be defined as whisky rather than as neutral spirits in
the United States.
Aging is typically done by putting the whisky into wooden casks or barrels which may be charred on the inside.
During the aging process, a number of slow chemical reactions occur which evaporate the volatile components
and the wood mellows the whisky. Certain wood sugars and tannin are extracted from the wood, and it is
these extracts that give the whisky its golden coloring. If needed, up to nine percent of flavoring such as
caramel, vanilla and sherry can be added.
No Canadian whisky may be sold until it has been aged in wood for at least two years. You will find no age
listing on the labels of Canadian whisky, however, the product is at least four years and some are six, eight
and even 12 years old. When sufficiently aged, various batches of whisky are married. The resulting product is
tasted and tested for quality. Once approved, the whisky is filtered many times, bottled, labeled and packaged.
Although the definition of Canadian whisky does not mention proof, a United States regulation requires that all
whiskies on the American market must be at least 80 proof or higher. Canadian whisky bottled at 70 proof is
the same as the United States 80 proof.
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IRISH
Made almost Exclusively of Irish Products.
Irish whiskey is unique in that when you pick up a bottle of Jameson, for instance, everything you hold in your
hand comes from Ireland except the cork in the bottle. It is made primarily from barley and it takes an acre to
make 100 cases of whiskey.
There are two types of Irish whiskey – malt whiskey distilled in a traditional manner in pot stills and grain
whiskey made in modern distilleries using tall distillation columns called patent stills. Over 90% of all whiskey
consumed is a blend of pure malt whiskey and grain whiskey. As a rule of thumb the more expensive the
whiskey the higher the percentage of malt.
The Irish whiskey process:
1. The Irish barley malt is dried over coal fires, not peat, which is one of the major differences from Scotch.
2. Choice Irish grains are fermented it into very strong beer, about 9% alcohol.
3. The beer is then distilled into whiskey similar to grape-growing countries such as France where wine is
distilled into brandy. Irish whiskey (apart from the spelling whisk(e)y) differs from Scotch whisky in that
normally Irish whiskey is distilled three times. Up to half of the barley used in distilling Irish whiskey is
malted; the other half is un-malted.
4. At bottling time, the whiskey in the casks is blended to meet taste and quality standards. Every cask
has a written “case history,” and is blended to the taster’s palate. Minute differences from one barrel to
another are important in the final blending. Each brand has its own formula, a closely guarded secret
that ensures uniformity from one bottle to another and from year to year.
Key regulations defining Irish whiskey and its production by the Irish Whiskey Act of 1980 are:
1. Irish whiskey must be distilled and aged in the Republic of Ireland or in Northern Ireland.
2. The contained spirits must be distilled to an alcohol by volume level of less than 94.8% from a yeastfermented mash of cereal grains in such a way that the distillate has an aroma and flavor derived from
the materials used.
3. The product must be aged for at least three years in wooden casks.
4. If the spirits comprise a blend of two or more such distillates, the product is referred to as a “blended”
Irish whiskey.
Although Scotland sustains approximately 90 distilleries, Ireland has only four main distilleries and a couple
of independants such as Tulllamore Dew. Economic difficulties in the last few centuries have led to a great
number of mergers and closures. Currently those distilleries operating in Ireland are:
1. New Midleton Distillery (Jameson, Powers, Paddy, Midleton, Redbreast, and others),
2. Old Bushmills Distillery (Bushmills, Black Bush, 1608)
3. Cooley Distillery (Connemara, Michael Collins, Tyrconnell, and others)
4. Kilbeggan Distillery, which began distilling again in 2007.
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SCOTCH
Three Types of Whisky: Malt, Grain and Blended.
The first whisky was distilled in the Highlands of Scotland around 1505 and was called usquebaugh in Gaelic.
This word was later contracted to uisge and later translated to English as “whisky”. The Scots appear to have
been the first to discover value in aging whisky. It was the appearance of blends around 1850, which enabled
Scottish distillers to move their product into every market of the world.
Malt Whisky in Scotch begins with selected barley that is allowed to sprout, then removed to a drying kiln and
spread out on huge screens above peat fires (Scotch acquires its “smoky” taste from the heat and smoke of
burning peat). After the malt is dried, it is ground to a meal. Then it goes to a mash tun which is a dedicated
vessel for mashing. The sweet liquor called wort is passed to a tun room for fermenting and distillation. Skilled
blenders, blend as many as thirty different malt whiskies with grain whiskies to produce the final product.
Scotch whisky must be produced from water and cereal grains, distilled and aged in oak casks for at least
three years in Scotland.
A Single Malt Scotch Whisky is the product of one specific distillery and has not been mixed with whisky from
any other distilleries. Highland, Lowland and Islay are the main malt whisky producing regions of northeast
Scotland. Each of these regions has its own distinctive style of malt whisky. Although it is not possible for two
malts to be identical even if the distilleries are next to each other, you can usually tell which particular region
of Scotland a particular whisky is made.
The “Six Classic Malts,” said to represent the six whisky producing regions of Scotland:
OBAN
A 14-year-old combining the sophistication of the West Highlands with a touch of
the peaty style of the Islands. It is rich and full-bodied with a mellow fruity finish.
(Sweet)
GLENKINCHIE A 12-year-old soft, sweetly aromatic malt from the Lowlands ‘Garden of Scotland’.
It has a fresh, grassy sweetness balanced with a warming, dryish finish.
(Ladies whisky)
CRAGGANMORE A 12-year-old sophisticated Speyside with the most complex aroma of any malt.
Astonishingly fragrant with sweetish notes and a smoky maltiness on the finish.
(Medium)
TALISKER
A 10-year-old and the only malt produced on Skye. Its seaweedy, smoky nose and
sweet maltiness is perfectly complimented by its spicy, long finish.
A bit smoked.
DALWHINNIE A 15-year-old gentle, delicate malt from the wild and windswept Central Highlands.
It is subtle, smooth delicately smody malt with a heathery honey finish.
LAGAVULIN
A 16-year-old distinctive and powerful Islay malt.
(This is smoked.)
It is deeply smoky and peaty with a velvety, complex finish.
Grain Whisky is very different from malt whisky. Grain whisky is the foundation of every blended Scotch
whisky. These distilleries closely resemble big factories and are located primarily in the Lowlands of Scotland.
Grain whisky distilleries use a continuous distillation process from a mash of cereals. This mash always
includes some malted barley, but other unmalted cereals like corn and wheat are allowed because they
are considerably cheaper than malted barley. The Scotch grain whiskey is a flavored spirit and reaches
maturation after four or five years. There are seven operating grain distilleries in Scotland.
Blended Scotch Whisky is lighter style of Scotch from unmalted barley, corn, rice and single malt whiskies
and forms the backbone of the Scotch industry. A blended scotch whisky may contain a combination of
whiskies from over 40 or 50 different malt and grain distilleries. The normal ratio of malt to grain is 60% grain
and 40% malt. The percentage of malt used will determine the quality and smoothness of taste and character.
Each whisky used in the blending process will normally have been matured for about five years. Examples of
blended Scotch whisky are Cutty Sark and Dewar’s.
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