Tag Archive for: Whisky

War and Whisky Part 1: The one-man Ukrainian cooperage

Whiskygeeks had the incredible opportunity to witness the craftsmanship of an artisan cooper Mr Arpad Laslo. He specialises in creating barrels from local Ukrainian oak. This one-man cooperage in Zakarpattia Oblast, Ukraine, supplies casks to local wineries and a whisky distillery in L’viv. It was fascinating to learn about the meticulous process involved.

The wood

The oak used in the barrels is seasoned in bolts for approximately 1-2 years. This seasoning is vital in stave production as various species of fungi will break down lignin and other flavours. This will subsequently lead to a better flavour profile when maturing spirits.

Photo 1: Bolts and Logs of Ukrainian white oak seasoning in the Cooper’s backyard

Almost all the oak used is Ukrainian white oak, but the exact oak species is hard to determine. In Ukraine, the main species of are Sessile Oak (Quercus petraea) and European Oak (Quercus robur). The occurrence of hybridisation between the two species further muddies the water regarding the determination of exactly what species it is. That said, folks usually lump Quercus robur and Quercus petraea together as European oak in the world of whisky.

Photo 2: Ukrainian White Oak Staves

The metal

The cooper utilises a collection of traditional tools, some of which are over a century old. These tools include axes, blades and other metal tools, to shape, carve and refine the wood. The old axe below has some Scandinavian origins.

Photo 3: An axe that is over a century old

In photo 4, the etched word ‘Wien” can be seen in the middle, giving away its Austrian origins. Coopers use this tool to shave the curved internal edge of the cask body such that the cask head can fit nicely into it. You can see this tool in action in photo 9!

Photo 4: An tool with Austrian origins

The cooper brings the staves together and uses metal bands to form a “skirt” shape, as seen in the photo below. However, in this state, the cooper cannot shape the staves or risk breaking them.

Photo 5: Staves made into a “skirt” held together by metal bands

The fire

Toasting or charring is necessary for cask making as this heat treatment leads to the caramelisation of some wood sugars and the creation of desirable flavours like vanillin. These congeners in the wood could contribute desirable flavours to the spirit later using maturation. In the photo below, Arpad is using spare pieces of oak to start a fire that becomes the heat source for the cask toasting process.

Photo 6: The toasting process (Photo Credits: Kateryna Panasiuk)

The water

During the toasting process, Arpad exposes the internal side of the cask to fire and occasional splashes of water. He usually uses less water for charring compared to toasting, so that the cask can reach higher temperatures in the former process.

Photo 7: Arpad adding water to the cask (Photo Credits: Kateryna Panasiuk)

This combination of water and heat makes the staves more malleable and easier to bend into shape without breaking. The gradual tightening of the ring around the staves slowly bends them into the desired shape. I had a go at it, where I turn a screw, and this would tighten the metal band on the bottom of the “skirt”.

Photo 8: The author having a go and shaping the cask

Once Arpad bends the cask into shape, he flips the cask for even toasting, ensuring optimal flavour development.

Photo 9: Arpad expertly shaves the toasted cask with the tool from Photo 4

Afterwards, the cooper meticulously shaves down the edges to fit the cask head and presents a beautifully crafted exterior. When the staves are in place, the cooper replaces these old placement rings with new shiny hoops.

Photo 10: Arpad branding his casks

Lastly, the cooper makes the final touch by stamping his signature on the cask with a heated metal stamp.

The Ukrainian terroir and wine

This talented individual not only runs a one-man cooperage but also grows, ferments and bottles their own homemade wine. After walking us through his coopering process, he treated us to a lovely traditional meal and wine.

Photo 11: A selection of wines made by Arpad, the Artisan cooper!

I am grateful for the opportunity to witness the artistry and passion that goes into creating these exceptional barrels. It was a true privilege to experience firsthand the skill and dedication of this artisan cooper.

Photo Credits for the first and eighth photos go to Kateryna Panasiuk, my friend, translator and host!

Slava Ukraini!
Heroyam Slava!

Further Reading

Conner, J. (2022) ‘Chapter 16 – Maturation’, in Whisky and Other Spirits. Third Edition. Elsevier Ltd, pp. 291–311. doi:10.1016/B978-0-12-822076-4.00013-9

Prida, A. and Puech, J.-L. (2006) ‘Influence of Geographical Origin and Botanical Species on the Content of Extractives in American, French, and East European Oak Woods’, Journal of agricultural and food chemistry, 54(21), pp. 8115–8126. doi:10.1021/jf0616098.

A Chat with Brendan McCarron from Glenmorangie

Brendan McCarron, Head of Maturing Whisky Stocks at The Glenmorangie Company

WhiskyGeeks is fortunate to get a chance to speak with Brendan McCarron, the Head of Maturing Whisky Stocks at the Glenmorangie Company, during our DFS event. As the heir apparent to whisky legend, Dr Bill Lumsen, Brendan has plenty to work on. He joins the company five years ago and started work with the whisky creation team alongside Dr Bill.

Brendan’s Whisky History

Brendan hails from Glasgow, Scotland. As a chemical engineering graduate, he started his career in the whisky industry in 2006 when he joined Diageo. After three years, Brendan began work as the distillery manager at Oban. Two years later, he left for “Peatland” – Islay, where he worked with Lagavulin, Caol Ila and of course, Port Ellen.

Port Ellen is a malting facility where Brendan got to work with the maltsers on different requirements. Making smoky malted barley was probably one of his favourite thing to do! The smoky malted barley was also the reason that Brendan got to know Dr Bill Lumsen. After ten years of working as a distillery manager, Brendan decided to change his direction and joined The Glenmorangie Company as part of their whisky creation team.

Brendan’s Unique Journey

Brendan has a fantastic whisky journey from the day he joined the industry in 2006. He is probably one of the very few people in Scotland who has worked on all aspects of whisky making. From designing a brand-new distillery (building it!) to malting, distilling and maturing whisky, Brendan has done it all. These experiences at the various distilleries and malting houses have shaped Brendan’s knowledge and expertise along the way. Additionally, he also went out of his way to acquire theoretical knowledge through his pursuit of books, courses and degrees. All of these add to his practical experience and give him a well-rounded education in whisky making.

Glenmorangie and its whiskies

Glenmorangie Whiskies (Picture Credit: Glenmorangie.com)

We had a short chat with Brendan on the different exciting whiskies that are coming shortly. We understood that there is a 25-year-old whisky released, but so far, we have yet to see it land in Singapore. It may be soon, but we do not know when.

The exciting part of the chat is, of course, the single cask #1399, that we tasted during the DFS tie-up event that we did on 22 June 2019. It is part of their latest project to launch exclusive single casks for specific countries. Making its debut as a travel retail exclusive bottle is naturally the best way for a brand to market a rare single cask bottling in Singapore considering the sheer volume of people passing through our airport!

Glenmorangie’s Affairs with Wood

Wood has always been the talk for Glenmorangie. We know that they used exceptional “designer” oak casks for some of their limited edition whiskies. We asked Brendan about these casks.

The creative team at the distillery involves itself in the creation of the oak casks from the start. Their research led them to the Ozark Mountains of Missouri, USA, where they found slow-growing wood that suits the spirit of Glenmorangie. To bring the effects of the slow-growth wood further, the team discovered the trees in the Mark Twain National Forest, where the oak trees grow slowly and develop the porous nature that the Glenmorangie team needs for its whiskies.

The Making of Artisan American White Oak Casks

An Oak Cask (Photo Credit: Glenmorangie.com)

The entire process of making these oak casks started with the identification of specific trees within the Mark Twain National Forest. These trees are cut and then air-dried for two years for maximum effects. Air-drying not only reduces astringency and improves the wood’s permeability; it also enhances the soft and rich flavours of the Glenmorangie whiskies.

These tight-grained but porous wood are then made into casks. The casks will be heavily toasted and then lighted charred for the distillery’s needs. The cooperage then fills bourbon whisky in the casks for precisely four years. It is like clockwork. Once four years is up, the casks are ready for shipment to the Scottish Highlands. The whole process takes six years to complete. Such dedication to oak casks is impressive, and we salute the team for going through with this process.

Designer Wood Casks for Limited Edition Whiskies

Some of the designer wood casks hold the core range of the whiskies from Glenmorangie; others hold limited edition whiskies. One of the famous limited edition is the Glenmorangie Astar. Our team got the chance to taste the Astar at another event held at The Exciseman on 1st July, where Brendan gave a presentation to both trade and consumer alike. We will speak of that another time.

Due to the higher porosity of the cask, the whisky soaks better into the wood, extracting flavours that the distillery is after. The distillery also uses these designer casks only twice for maturation purposes. Brendan explained that the casks are no longer suitable after two uses, and they usually sell the majority of these casks. Some get left behind for experiments, and a small number of them go to Ardbeg.

Are Flat-Packing Barrels still a Cost-Saving Practise?

We asked Brendan some essential financial questions as well, that affects production. In the past, some distilleries broke up the ex-bourbon barrels they bought and flat pack them before shipping to Scotland. Once the vessel landed, the distilleries brought the staves to a cooperage and rebuilt the casks. The practice affected the quality of the casks, and the whiskies matured in such casks become a debatable topic.

According to Brendan, this practice is hardly used in Scotland’s distilleries today. The discovery that they do not save cost by doing so was one of the significant factors. However, the debate on the practice that MAY have affected production was probably the main factor that led to the abolishment.

The abolishment, unfortunately, led to a reduction of hogshead as most hogsheads are rebuilt from standard barrels. While this is a loss to the whisky industry, we must remember that cost is always a factor for end-consumers because higher cost equates to higher prices!

The Truth about Virgin Oak Casks

Some distilleries are making use of virgin oak casks to mature some of their whiskies. We even know of new distilleries that make use of virgin oak maturation to reduce the number of years needed to produce delicious whisky. Glenmorangie uses virgin oak casks as well, and we wanted to know what Brendan thinks about them. He thinks, that virgin oak casks may prove to be too strong an influence on Glenmorangie’s new make spirits. The virgin oak casks may hide the fruity notes of Glenmorangie and make it “un-Glenmorangie”. Brendan prefers to do finishes with virgin oak casks instead.

It is of interest to know that Glenmorangie does a lot of wood finishes to bring flavours to their whiskies. For example, the distillery finished the Lasanta in Oloroso and PX sherry cask, the Quinta Ruban in Ruby Port Pipes and the Nectar D’òr in Sauternes casks.

Factors that Affects the Choices of Cask Finishes

Brendan explained that they do not know all the elements of influences when the creative team chooses the cask finishes. They know for a fact that the spirit of Glenmorangie works well with Port and Sauternes casks finishes. Unfortunately, they do not know the reaction to all the casks in the world. Therefore, it is much of a trial and error for the team when they are choosing the cask finishes. By selecting items of interest which the team thinks would work with the spirit, they came up with various experiments of different finishing casks. The availability of the casks is also crucial, as they need enough casks to complete a new finishing experiment.

Brendan mentioned that the team also takes the opportunity when it comes knocking. If their suppliers offer casks which they have not tried before, they may take a few of the casks to create new experiments. Some experiments will succeed while others may not. Part of the fun is finding out if it works. For those of you who are curious, the casks that don’t work are not thrown away! The team reracks the “unworkable” casks into sherry or ex-bourbon casks to “reset” them. Usually, the age of the whisky will also help to rectify any issues that the team finds.

Brendan Wants YOU to Know This!

Brendan, the whisky expert

We thought that we have enough technical talk, so we asked Brendan what the one thing that he would like the whisky community to know is. The answer is not surprising. Brendan wants everyone to know that a single malt whisky comes from a SINGLE whisky distillery. It is one of the most misunderstood terms in the whisky industry. Many whisky drinkers confused single malt whisky and single cask whisky. Brendan shares his frustrations at how he always get that same question – “How is the whisky still a single malt whisky when you blend all these casks to create it?”

To set the record straight, Brendan shares that a single malt whisky can be a “blend” of 15 casks from the SAME distillery. As long as the whisky is made from malted barley and is not blended with whisky from another distillery, it is a single malt whisky.

What You Can Do If You Want to Work for a Whisky Distillery

Most of our younger folks here would probably be keen to work for a whisky distillery. We ask Brendan what we need to do if we want to work for a distillery. Here is his advice.

Get a science-related degree if you want to be on the distilling team. Chemical engineering or chemistry is a good start. Otherwise, biochemistry is helpful too. There are, however, many ways to get involved. You can still work in the industry even if you have a business degree. You can join the distillery in sales or marketing with it. Nonetheless, you will still need the passion and love for whisky before you can comfortably stay in the industry.

Do not despair if you do not have any of those. Brendan said that having experience is equally vital if you are not Scottish and want to work in Scotland. He started in pharmaceutical and the knowledge he gained there translated into his next job with Diageo. Working in a brewery also helps because that involves two stages of the whisky distillation. Ultimately, the potential candidate needs to be open and adaptable. When you combine the passion for whisky and your openness to adapt, you will be able to make headway into the career that you want. Start with a job that you can do and learn from there. You will never know where that will take you!

 

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    Nantou Distillery (Omar whisky) visit!

    Nantou distillery has been making Omar, a Taiwanese whisky, since 2008. The distillery tours there are quite like those of Scotland. The tour guide makes the experience more intimate, more personalised and less commercial. Nantou distillery’s willingness to experiment makes them unique, especially to whisky geeks like myself! I know many of you are more interested in the whisky; so I will leave the technical production details to later in the article!

    Omar Whisky

    Nantou winery makes different fruit wines and liqueurs which can be used to season casks for unique cask finishes. Omar whisky has released whisky finished in casks of Lychee Liqueur, Plum liqueur, Black-Queen Wine and Orange liqueur.

    Batch 4 Lychee Liqueur Cask Finish

    This Lychee liqueur finish has a balanced Lychee note that does not overpower the whisky. I enjoyed the tropical fruit notes of pineapple and mango alongside notes of pear drops!

    Batch 1 Orange Liqueur Cask Finish

    This dram is for the orange lover with notes of orange puree, orange zest, and orange flower water alongside some lovely notes of vanilla and honey from its prior maturation.

    I am particularly fond of their bourbon cask strength, both peated and unpeated! But do not fret about the age statements. Due to a higher average temperature, maturation speeds are a lot faster than Scotland. A 3-year-old whisky at Nantou would taste similar to an 8 to 12-year-old whisky matured in Scotland. The 8-year-old cask strength is a special release; it feels like a 15-20-year-old scotch.

    Omar 8yo 2009 Cask Strength

    This 8yo is very soft and demure, giving notes of old oak, vanilla, pears and mandarin oranges!

    Omar 3yo 2014 Peated Cask Strength

    The 3-year-old peated cask strength displayed a high calibre of maturation, with the right balance of peat smoke. Water will draw out more smoke for people who love that note! This delicious yet affordable single cask would be good smoky daily dram!

    Omar 10yo 2008 PX Sherry Cask

    For sherry bomb lovers, this is an absolute sherry nuke or WMD! This is the result of 8 years in sherry hogshead before finishing in a PX cask for two years. This dram holds notes of Christmas cake, cinnamon, chocolate, plums and dried fruit!

    Barley

    TTL buys barley in bulk from multiple maltsters. Most of the unpeated barley is from maltsters in England, while most of the peated barley at 35ppm is from maltsters based in Scotland. The moisture content is also similar to specifications required in Scottish distilleries, around 4%.

    Milling & Mashing

    The barley is milled into grist with the standard ratio of 70% grist, 20% barley husk and 10% flour. Distilleries maintain specific ratios to assist in the filtration of wort and to prevent choking in the pipes. The grist is sent to a German semi-lauter mash tun with a charge of 120000L. Hot water is added three times; the first and second streams form the wort. The third stream, called the sparge, picks up the remaining sugars, but it is low in sugar. The sparge is not mixed with the first 2 streams, but to maximise sugar recovery. This is done by reusing the sparge for the first stream to be added to the next batch of grist.

    Fermentation

    The wort goes into one of the stainless steel washbacks to undergo fermentation, turning it into a strong beer called wash. In this stage, the yeast will start eating the sugar in the wort and produce carbon dioxide and alcohol. For Omar whisky, this fermentation process takes an average of 72 hours using French distiller’s yeast. This is slightly longer than the 48 hours of fermentation in most modern Scottish distilleries. The wash from Omar is around 7-8% alcohol by volume (abv).

    Distillation

    Pot stills

    The wash goes into one of 2 wash stills to be distilled into low wines. This distillation removes the barley solids leaving mostly ethanol, water and aromatic compounds. The low wines are pipped into the spirit still for its second distillation to reduce water content. Nantou Distillery currently has 2 Wash Stills and 2 Spirit Stills. One spirit still is different, as it, strangely enough, has a window. The stills are of varying sizes, one at 7000L, two at 5000L and the last one at 2000L.

    Cut of the Heart

    There are three components in the spirit still distillate. The head comes first at a high abv, followed by the heart, which is what goes into the barrels, and lastly comes the tail which has a lower abv. The cut of the heart affects the new make spirit and how the whisky tastes. If the cut starts at a higher abv, the new make spirit gets lighter, fruity notes, but also more undesirable flavours from the heads. If the cut ends too low, it gets heavier flavours but risk lowering the final abv.

    The master distiller decides how to balance these two points. For Omar, the cut of the heart is somewhere between 73% and 64%. This means that the stillmen sends distillate above 73% (heads) and below 64% (tails) into a tank to be redistilled. The heart that is within the range will go into barrels for maturation. Due to Taiwan’s legislation, Nantou Distillery reduces the strength of their new make spirit to just below 60% abv before filling in casks.

    Maturation

    Cask Management

    Nantou distillery receives the sherry and bourbon casks whole so that the cask maintains its inherent quality. Nantou distillery uses ex-bourbon casks up to 3 times. As for Sherry casks, there is no fixed numerical limit. Craftsmen will keep utilising the sherry cask until they deem it to be too exhausted to provide flavour. According to the tour guide, the sherry casks usually provides stronger flavours in Nantou’s climate, therefore using refill would give a more balanced dram.

     

    3rd and 4th fill Bourbon casks are usually used for seasoning with wines or liqueurs. This is extraordinarily creative, because a 3rd or 4th fill cask may not provide as much cask influence, but they can act as a sponge to soak up the previous liquid. This means that such a seasoned cask would deliver the flavours of the previous content without over-oaking the product. These seasoned casks are used for the various Omar whisky finishes.

    Warehouse

    Most of Nantou distillery’s warehouses are racked for easy access to the individual cask. Amongst the racked warehouses, Nantou distillery also has a specially designed warehouse with space for future tasting events. This warehouse has an architecture heavily influenced by the sherry bodegas in Spain. The casks stacked up to three high and is a mimic of the solera system in a sherry bodega. Though the ceiling is lower, the arcs near the ceiling are similar to Bodegas in Spain. As a comparison, these are some pictures of the bodegas I visited in Jerez de la Frontera. On the left is Bodega Diez Merito, on the right is Bodega Fundador.

     

    Distillery Expansion

    Omar is looking to expand its production capacity by adding 3 more pairs of wash and spirit stills! The distillery is also undergoing renovation to accommodate larger tour crowds. In addition, Omar is continuing to experiment with new and different finishes! It is an exciting time ahead for Omar whisky and Nantou distillery is a must go on your Taiwan trip!

     

    Special thanks to Nantou Distillery, Chairman Chung, and Ben for this enjoyable experience!