How Bourbon is Made

Bourbon whiskey is an American distilled spirit that has become increasingly popular in recent years. But what exactly is bourbon, and what sets it apart from other types of whiskey? In this article, we'll explore the process of making bourbon and the requirements that it must meet to be called bourbon.

At its core, bourbon is a type of whiskey that is made from a grain mixture that is at least 51% corn. The other grains used in the mash bill can include wheat, rye, and malted barley. Bourbon must be distilled to no less than 80% alcohol by volume and aged in new charred oak barrels. The result is a distinctively flavored spirit that has become an American icon.

Understanding the bourbon-making process is important not only for those who enjoy drinking bourbon but also for those who want to learn more about American history and culture. Bourbon has a long and storied history and the process of making it is steeped in tradition. In the following sections, we'll explore the process of making bourbon in more detail and discuss the requirements that it must meet to be called bourbon.

The Bourbon-Making Process

Bourbon whiskey is a type of American whiskey made primarily from corn, but can also include other grains in its mash bill. The bourbon-making process is a precise and intricate process that involves several key steps.

Step 1: Mash Bill

The first step in making bourbon is selecting the grains for the mash bill. The mash bill is the recipe of grains used to make the bourbon. Corn must be the primary grain in the mash bill, making up at least 51% of the mixture. Other grains, such as rye, wheat, or barley, can be added to the mash bill to create different flavors and characteristics in the final product.

It's essential to select the right grains for the mash bill. The quality of the grains and the ratio of grains in the mash bill will have a significant impact on the final product's flavor and character. Once the grains have been selected, they are ground into a fine meal, mixed with water, and then cooked at a high temperature to create a mash.

Step 2: Fermentation

The second step in making bourbon is fermentation. Fermentation is a process where yeast converts the sugars in the mash into alcohol. The mash is cooled, and yeast is added to start the fermentation process. During fermentation, carbon dioxide is released, and alcohol is produced.

Some bourbon distillers use a sour mash process. This means that a portion of the previous day's mash is added to the new mash, creating a consistent flavor profile. The sour mash process is not required to make bourbon, but many distillers use it to ensure consistency.

The type of yeast used in fermentation also plays a crucial role in the final flavor of the bourbon. Different yeast strains can produce different flavor profiles, so the distiller must select the right strain for their desired outcome. The fermentation process takes about three to five days.

Step 3: Distillation

The final step in making bourbon is distillation. Distillation is a process where the alcohol is separated from the mash and concentrated to increase its alcohol content.

The mash is placed into a copper pot still and heated until it reaches the boiling point. As the alcohol evaporates, it rises through the still's neck, where it condenses and is collected. The first distillation is called the "low wine," and the second distillation is called the "high wine."

During distillation, it's important to control the temperature and timing precisely. The temperature and timing will affect the final product's flavor and alcohol content. The distiller must use their expertise to ensure that the right amount of alcohol is collected and that the flavor profile is consistent with their desired outcome.

There are two types of distillation processes used in bourbon-making: pot still distillation and column still distillation. Pot still distillation is the traditional method used in bourbon-making, where the mash is distilled in copper pot stills. Column still distillation is a more modern process that produces a more neutral spirit and is often used in blended whiskeys.

Step 4: Aging

The aging process is one of the most crucial steps in the bourbon-making process, as it gives bourbon its unique flavor and color. Bourbon must be aged in new, charred oak barrels for a minimum of two years to be considered "straight bourbon." The longer the bourbon is aged, the more complex its flavor profile becomes.

The type of oak barrel used in aging can also affect the flavor of the bourbon. American white oak is the most commonly used type of oak barrel in bourbon-making, as it imparts a distinctive vanilla and caramel flavor. French oak, on the other hand, is less commonly used but can give the bourbon a spicier flavor profile.

During the aging process, the bourbon also undergoes a process called "angel's share," where a small amount of the bourbon evaporates through the barrel. This loss of alcohol helps concentrate the flavor of the bourbon and gives it a smoother finish.

Step 5: Bottling

Once the bourbon has been aged to perfection, it is time for bottling. The alcohol content and proof of the bourbon is an important considerations during this step. By law, bourbon must be bottled at no less than 80 proofs (40% alcohol by volume). However, many bourbons are bottled at a higher proof, ranging from 90 to over 140 proof.

Different types of bourbons are also sold, such as single barrel, small batch, and blended bourbons. Single-barrel bourbons are made from a single barrel and bottled without any blending, while small-batch bourbons are made by blending the contents of several barrels to achieve a consistent flavor profile. Blended bourbons are made by blending different bourbons to achieve a desired flavor profile.

The reason why some bourbons are bottled at a higher proof than others is to appeal to different tastes. Higher-proof bourbons are typically preferred by bourbon enthusiasts who enjoy a stronger, more intense flavor, while lower-proof bourbons are often enjoyed by those who prefer a smoother, more mellow taste.

Requirements for Bourbon to be Called Bourbon

Bourbon whiskey is a distinctive type of whiskey that is regulated by specific legal requirements. For a whiskey to be labeled as "bourbon," it must meet certain criteria. The most fundamental requirement is that it must be produced in the United States. In addition to this, there are several other specific requirements that must be met for a whiskey to be labeled as bourbon.

One of the most important requirements for a whiskey to be labeled as bourbon is that it must be made from a grain mixture that is at least 51% corn. This grain mixture is known as the mash bill. Other grains, such as rye, barley, or wheat, may be used to make up the remaining 49% of the mash bill. However, to be labeled as bourbon, the mash bill must be at least 51% corn.

Another requirement for bourbon is that it must be aged in new, charred oak barrels. These barrels are an essential component of the bourbon-making process and are responsible for giving bourbon much of its distinctive flavor and aroma. The charring of the oak barrels also helps to filter out impurities and create a smoother, more refined taste.

To be labeled as "straight bourbon whiskey," the whiskey must be aged for a minimum of two years. If the bourbon has been aged for less than four years, the age must be listed on the label. In addition to these requirements, bourbon must also meet certain alcohol content requirements. Bourbon must be distilled to no more than 80% alcohol by volume (160 proof) and bottled at no less than 40% alcohol by volume (80 proof).

The Role of Kentucky in Bourbon Production

Kentucky has long been recognized as the birthplace of bourbon whiskey. The state's unique geography and climate have made it an ideal location for bourbon production, and today, Kentucky is home to some of the most iconic bourbon distilleries in the world.

Bourbon County, located in central Kentucky, is considered by many to be the birthplace of bourbon whiskey. This region was once a part of Virginia, but in 1785, it became a part of the newly-formed state of Kentucky. The fertile soil, abundant water sources, and temperate climate of Bourbon County made it an ideal location for growing the grains needed to make bourbon whiskey.

One of the key factors that have contributed to Kentucky's dominance in the bourbon industry is the region's abundant supply of limestone-filtered water. This type of water is ideal for bourbon production because it is rich in minerals and has a neutral pH. This helps to create a consistent flavor profile and a smooth, clean taste.

In addition to the abundant water sources, Kentucky's climate also plays an important role in bourbon production. The state's hot summers and cold winters cause the bourbon to expand and contract within the oak barrels, which helps to extract more flavor and aroma from the wood. This process, known as the "angel's share," is an essential part of the bourbon-making process and is responsible for creating the unique flavor and aroma of Kentucky bourbon.

Overall, Kentucky's unique combination of geography, climate, and natural resources has made it an essential player in the bourbon industry. Today, many of the world's most iconic bourbon brands are produced in the state, and Kentucky bourbon is celebrated and enjoyed by whiskey lovers around the globe.

Different Types of Bourbon

Bourbon whiskey comes in various types, each with its unique characteristics, flavor profiles, and production methods. Some of the most popular types of bourbon include small-batch bourbon, single-barrel bourbon, and blended bourbon.

Small-batch bourbon is produced by blending a small number of carefully selected barrels of bourbon, typically ranging from 10 to 100. The small batch production process allows distillers to create a consistent flavor profile while also showcasing the unique characteristics of each batch. Small-batch bourbons often have a more complex flavor profile than other types of bourbon, with notes of caramel, vanilla, and oak.

Single-barrel bourbon, on the other hand, is made from a single barrel of bourbon, which is hand-selected by the master distiller. Each barrel of bourbon has its unique flavor profile, and the goal of the distiller is to highlight the specific characteristics of that barrel. Single barrel bourbons often have a bold, intense flavor with notes of caramel, vanilla, and charred oak.

Blended bourbon is made by blending two or more barrels of bourbon together to create a consistent flavor profile. The blending process allows distillers to balance out any variations between different barrels, resulting in a smoother, more consistent flavor. Blended bourbons often have a milder flavor profile than other types of bourbon, with notes of caramel, vanilla, and oak.

Overall, each type of bourbon offers a unique flavor profile and production method, making it a popular choice for bourbon enthusiasts and casual drinkers alike.