Production of scotch
November 25th, 2008
It is a long, tedious process that takes lots of time, sometimes it can take years. But when it is processed with professional correctness the product that results is well worth the wait.
The process commences with Barley placed in deep tanks of water for approximately three days while the germination process takes place. Once that has been achieved the barley is taken to the malting floor of the distillery where it is placed in drums.
The entire purpose of the germination process is to convert the starch in the grains into fermentable sugars. This will feed the yeast in the fermentation stage. Turning the barley frequently ensures the temperature will remain consistent. Sheils, another name for a wooden shovel, are used to turn the grains, on a traditional malting floor. The grains will die if the temperature reaches above 22 degrees, and will the stop the entire process as the starch will not be converted to sugar.
The grain is then taken to a kiln to halt the process of sugar consumption and dry up any moisture. A kiln is a two storey building with a perforated top to allow heat to get away. On the lower floor are heated peat bricks where the grain is dried and acquires a peat like aroma. With regard to a distillery and its functions the building usually has a pagoda type roof, and the malt therein must not be heated above 70 degrees or it will be destroyed.
Most of the distilleries in this day and age buy all their malt from a centralized malting company. However there are still a select few that remain traditional and do it all themselves.
As the process continues the grain is milled into grist and along with water is heated to sixty degrees in mash tubs. Sediment is removed during the mashing period by changing the water no less than four times, and the bi-product of this process is called wort. It has then to be cooled in what is called a wash back before mixing with yeast. This next process consists of a large container which is never filled to the top because of much frothing from the wort due to carbon dioxide. Within two to three days the alcohol has killed all the yeast, and the end product of this cycle is called wash and contains five to eight percent alcohol.
The wash is then placed in copper stills regulated to a certain shape that allows for
satisfactory distillation to take place. The use of the stills usually takes place twice in most distilleries, but some companies do the process three times or more. When all this has been completed the end product is placed in casks usually made of oak for a length of time eight to twelve years minimum.
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