How to Make Bourbon

Not only is this a challenging project - it is illegal in the U.S. so this is a simple explanation for the curious in mind. It is easy enough to drive to the liquor store and pick a nice clean and wonderful tasting bourbon - without breaking the law!

Instructions

Difficulty: Challenging

Things You’ll Need:

• corn, wheat, rye, barley
• spring water
• brewers yeast
• pot for cooking
• fermentation tank
• still
• barrels

1. Measure your grains, usually in the following ratio: corn 70%, rye 10%, malted barley 10%, and wheat 10%. Wheat makes the whiskey softer and suppler on the tongue.
2. The different grain types are separately ground and spring water is added.
3. The grain is usually cooked for approximately half an hour and the mixture called mash is cooled down afterwards.
4. After the mash has been cooled down to approximately 25 to 30°C, it can be added with a larger amount of yeast into a fermenter in which a beer with approximately 9-10% ABV develops.
5. During the alcoholic fermentation the yeast converts the sugar to alcohol and CO2. At the same time heat is produced. The fermentation usually lasts three days. An alcohol strength of approximately 9 to 10% is reached.
6. Now distillation takes place. the column stills achieves alcohol contents at the top of approximately 120 American Proof (60 Vol.% alcohol). If the columns are higher, the alcohol content can still be further raised.
7. The next step however is different and gives the Kentucky Straight Bourbon its special taste. The barrels are held, on one side still open, over a small fire. This procedure is called ‘toasting’ and leads to the wood sugar in the staves being caramelized. This reddish layer is later also visible when cutting a stave. The toasting procedure lasts about 12 min.
   
   After the toasting procedure the barrel is submitted to a still stronger fire treatment. It is burned out from the inside with large flames for 6 to 12 seconds. The barrel thus receives a thick charcoal layer on the inside.
8. Now the barrel is filled with the liquor and is stored on its side for a determined rate of time at a controlled temperature. Later it is removed and bottled into a multitude of different kind of containers and released for sale.
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Tips & Warnings

• If you are lucky enough to live close to a distillery - it is a fascinating process to see.
• The distillation of liquor is illegal in the U.S.