Production process of Whisky




Production process of Whisky
Production process of Whisky

Whisky:

  • It is a distilled alcoholic beverage obtained from fermentation of grains followed by distillation and ageing in white oak barrel for 3-4 years. 
  • Primarily, barley is used but other grains such as corn, wheat, oat & rye are also used.
  • Whisky may be malt or non-malt.
  • The concentration of ethanol in whisky is not less than 40%.
  • Whisky is usually colored with the addition of caramel (burned Sugar).
  •  Whisky production was first begun on Scotland.
  • But some believe that it started on Arabs & Greek.
  • Whisky production was supposed to be started first by Irish 1000 years ago.
  • But written records suggest that, it was after 1494.
  • Microbiology – Improved strains of Saccharomyces Cerevisiae.
  • Biosynthesis:   
    • Glucose —–> Pyruvate —–> Acetaldehyde —-> Ethanol

Steps in whiskey making:

  • Various steps involved in whisky production are:
    • Selection & Preparation of substrate
    • Malting
    • Mashing
    • Fermentation
    • Distillation
    • Ageing
    • Blending

Step I: Selection and Preparation of substrate:

  • Basic substrates used for whisky production are water & grains.
  • The water should be free from hazardous material, pesticides, toxic chemicals & heavy metals. 
  • But it should have high DO value.
  • The water containing lime is considered good for whisky production.
  • The basic ingredients for whisky include barley, oat, ray, malt etc. but it must be free from fungal infection.
  • Beside those substrate other things needed for whisky production are caramel mix (burnt sugar + others).
  • According to substrates used, whisky are of:
    • Straight whisky: No added ingredients i.e. non-blended
    • Blended whisky: Added with different ingredients and sherry (wine)
  • Barley—-> malted cooked at 100oC for 3hrs/150oC for 1 hr
  • Other grains —-> grounded without malting —-> cooked ta 100oC for 3hrs/150oC for 1 hr
  • Cooking liquify starch and break cellulose wall of grains.

Step II: Malting

  • Malting is essential for enzyme activity.
  • In Scottish whisky, barley germination heating is provided with hot air which is produced from peat burning.
  • Peat is soft carbon rich substance when plant matter decomposed in water.
  • It provides characteristics smoky flavor to Scottish whisky.
  • But, in other countries, hot air is produced by coal burning.

 Step III: Mashing

  • The malted barley is grounded and mixed with cereals and finally subjected to controlled heating with overall temperature 40-85oC for several days.
  • During heating alpha-amylase is converted into beta amylase.
  • After mashing it is filtered to obtain wort.
  • It is optimized for total sugar content (TSS)= 20-30%.

Step IV: Fermentation

  • Mash/wort (TSS=20-30%) —> pH adjusted (3.5-4.5) —-> close fermenter (mostly used)
  • Mash/wort (TSS=20-30%) —–> pH adjusted (3.5-4.5) —–> open tank fermenter (require more time, more chance of contamination, more chance of loss of ethanol.

Step V: Distillation

  • Now the ethanol is evaporated at 78-80o C.
  • In Scotland, distillation is carried out in copper plant or stain less steel.
  • Distillation is carried out to obtain 95% ethanol.
  • The ethanol should be free from congeners.
  • Congeners are the extra things that produces bad flavors such as aldehyde, ketones & other volatile substances.
  •  It is overcome by production of high % or concentrated ethanol.
  • Hard/High wine is produced.

Step VI: Maturation/ Ageing

  • The high Wine is diluted with addition of water to obtain the solution with alcohol content 50-65%.
  •  In the Scotland, the diluted ethanol is kept inside white oak barrel and mouth of the barrel is sealed and kept in cool & wet condition.
  • Whereas in American whisky, the ageing is done in warm and dry condition.
  •  During ageing, the congeners, esters, sugars, and alcohols react together to form special type of aroma.
  • Ageing is conducted minimum for 3-4 years & maximum up to 10-15 years.

Step VII: Blending

  • In blending, appropriate proportion of different whisky of previous batch is mixed with the aged whisky.
  •  At the same time, the appropriate proportion of Sherry port & other things are also mixed to develop flavors.
  • Finally, caramel mix is added in appropriate amount to develop a suitable color.
  • Finally, it is checked by testing with master blender.

Production process of Whisky