The Whisky Production Process

Malting
First, top-quality barley is steeped in water and then allowed to germinate. During germination, the
grain slowly changes into malt where the starch in the grain is made ready to be converted into
sugars in the mash tun. Drying in a kiln stops the germination process. At the kilning stage, the
desired level of peating for each individual distillery is carried out.
Best quality barley is first steeped in water and then spread out on malting floors to germinate. It is turned
regularly to prevent the build up of heat. Traditionally, this was done by tossing the barley into the air with
wooden shovels in a malt barn adjacent to the kiln.

During this process enzymes are activated which convert the starch into sugar when mashing takes place. After
6 to 7 days of germination the barley, now called green malt, goes to the kiln for drying. This halts the
germination. The heat is kept below 70°C so that the enzymes are not destroyed. Peat may be added to the fire
to impart flavour from the smoke.

Mashing
The malted grain is crushed and mixed with hot water into the mash tun. The sugar is run off in
liquid form, called wort.
The dried malt is ground into a coarse flour or grist, which is mixed with hot water in the mash tun. The water is
added in 3 stages and gets hotter at each stage, starting around 67°C and rising to almost boiling point.

The quality of the pure Scottish water is important. The mash is stirred, helping to convert the starches to sugar.
After mashing, the sweet sugary liquid is known as wort. The spent grains - the draff - is processed into cattle
feed.

Fermentation
The wort is cooled and then pumped into fermentation vessels called washbacks where yeast is
added and the fermentation process starts. The yeast converts the sugar into alcohol. After 2 – 3
days fermentation is complete, leaving a liquid called wash which contains 8-9% alcohol by
volume.
The wort is cooled to 20°C and pumped into washbacks, where yeast is added and fermentation begins. The
living yeast feeds on the sugars, producing alcohol and small quantities of other compounds known as
congeners, which contribute to the flavour of the whisky. Carbon dioxide is also produced and the wash froths
violently. Revolving switchers cut the head to prevent it overflowing. After about 2 days the fermentation dies
down and the wash contains 6-8% alcohol by volume.

Distillation
The wash is distilled twice. The first wash distillation produces a liquid with a low level of alcohol
known as low wines, which is then re-distilled in the spirit still. During this second distillation only
the pure centre cut, which is about 65% alcohol by volume, is collected in the spirit receiver.
The wash is distilled twice - first in the wash still, to separate the alcohol from the water, yeast and residue called
pot ale - the solids of which are also saved for use in animal feeds.
The distillate from the wash still, known as low wines, and containing about 20% alcohol by volume, then goes to
the spirit still for the second distillation. The more volatile compounds which distil off first - the foreshots, and the
final runnings called feints where more oily compounds are vaporized, are both channelled off to be redistilled
when mixed with the low wines in the next batch.

Only the pure centre cut, or heart of the run, which is about 68% alcohol by volume is collected in the spirit
receiver.

Pot Stills
Curiously, the shape of the pot still significantly affects the character of each malt whisky.
In some mysterious way the shape of the pot still affects the character of the individual malt whisky, and each
distillery keeps its stills exactly the same over the years.

In distillation, the still is heated to just below the boiling point of water and the alcohol and other compounds
vaporize and pass over the neck of the still into either a condenser or a worm - a large copper coil immersed in
cold running water where the vapour is condensed into a liquid.

Spirit Safe
The entire product from the distillation is passed through the spirit safe to allow the stillman to
check the strength and quality of the spirit.
All the distillates pass through the spirit safe - whose locks were traditionally controlled by the Customs & Excise.
The stillman uses all his years of experience to test and judge the various distillates without being able to come
into physical contact with the spirit.

The newly distilled, colourless, fiery spirit reduced to maturing strength, 63% alcohol by volume, is filled into oak
casks which may have previously contained Scotch whisky, bourbon or sherry, and the maturation process
begins.

Maturation
The newly distilled, colourless spirit is filled in oak casks, while maturing the Whisky becomes
smoother and more flavoursome and draws its golden colour from the cask. By law the whisky
must be matured for a minimum of three years, but most single malts lie in the wood for 8 years or
more.
While maturing, the whisky becomes smoother, gains flavour, and draws its golden colour from the cask. A
proportion of the higher alcohols turn into esters and other complex compounds which subtly enhance each
whisky's distinctive characteristics.

By law all Scotch whisky must be matured for at least 3 years, but most single malts lie in the wood for 8, 10, 12,
15 years or longer. Customs & Excise allow for a maximum of 2% of the whisky to evaporate from the cask each
year - the Angels' Share. Unlike wine, whisky does not mature further once it is in the bottle.

THE ART OF BLENDING

While the distinctive single malts produced by individual distilleries are becoming increasingly popular, blending
creates over 90% of the Scotch whisky enjoyed throughout the world.

By nosing samples in tulip-shaped glasses the blender selects from a wide palate - from the numerous Highland
and Speyside malts to the strongly flavoured and peaty Island malts, and the softer and lighter Lowland malts.
These malts are combined with grain whiskies - usually 60-80% grain whiskies to 20-40% malt whiskies, and are
then left to 'marry' in casks before being bottled as one of the world-renowned blended whiskies.

A blend of a range of malt whiskies, with no grain whisky included, is known as a vatted malt.

The way we make Scotch whisky has evolved over several centuries, but the history of Scotch whisky embraces
a much wider heritage; that of Scotland and its people.
The Perfect Dram
Each bottle of single malt whisky is the product of a single distillery.