Scotch Whisky, How It Is Made

By Mark Paine


Scotch whisky requires a considerable amount of time to produce. It can be a tedious process that takes many years. On the other hand, when it's crafted the right way, the end product is one that is worth the long wait.

First, the barley is immersed in deep tanks of water for approximately 72 hours. The water causes the barley to start the germination process. Once germinated, the barley is transferred to the malting segment of the distillery where it is placed into drums also referred to as the malting floor.

The intention of the germination process is to transform the starch in the grains into fermentable sugar. The yeast will metabolize the sugars generating alcohol during the fermentation phase. Turning the barley frequently makes certain the temperature will remain consistent. Wooden spades called sheils are employed to turn the grains on a traditional malting floor. The grains will die-off if the temp gets above 71 degrees F. This would consequently stop the whole process since the starch won't be changed into fermentable sugars.

The grain is kiln dried to halt the germination process and the continuation of sugar consumption. Generally, a traditional kiln is a building standing two stories tall with the top perforated to allow all heat to escape. The bottom floor contains peat bricks which are burned. Throughout this procedure the grain is dried and soaks up the peat aroma and flavor. The pagoda roof style on a distillery is a very distinct element. Currently, the majority of the distilleries purchase malt from a malting company. On the other hand, there remain a limited number that will always be traditional and do everything by themselves.

The grain is milled into grist and combined with water in mash tubs. The mix is heated to 60 degrees. Throughout the mashing period the water is changed at least four times to clear away sediment. The result of this mashing is called wort. The wort needs to be cooled off before combining with yeast. This large container is not filled completely because wort froths due to co2. By the time two to three days have passed, all the yeast is wiped out because of the alcohol it produced. The final product of this cycle is referred to as wash. It contains 5 - 8 percent alcohol.

The stills where the wash is put are made from copper and are regulated to a special shape that allows for proper distillation to occur. Distillation is typically carried out two times, however, many companies do it 3 times or more. After the whole process is complete the distillate is then put into kegs made usually of oak, for a minimum of three years. Even so, many Scotch whiskies are aged for a lot longer.




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