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==Production== {{Multiple image | direction = vertical | width = 250 | image1 = Making malt whisky- from barley to bottle.webm | image2 = Glenfiddich Distillery stills.jpg | footer = The production of whisky from barley to bottle ''(top)'', swan necked copper stills in the [[Glenfiddich]] distillery ''(bottom)'' }}Although specific methods may vary among distilleries, whisky production broadly comprises four primary stages: grain preparation, [[fermentation]], distillation, and maturation (aging). This process is typically followed by the two additional stages of bottling and marketing.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=13 |language=en}}</ref> ===Grain preparation=== To initiate whisky production, grains are processed to convert their [[Starch|starches]] into fermentable sugars, which can then be subjected to fermentation and distillation. This process involves [[malting]], [[Mill (grinding)|milling]] and [[mashing]] the grains.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=14 |language=en}}</ref> ==== Malting ==== Malt production begins with the soaking of grains in water tanks for a period of three days. The soaked grains are then transferred to large containers where germination occurs, initiating the metabolic process that converts starches into sugars. This process is subsequently halted by drying the grains with hot air, a procedure also known as ''kilning'', at the end of which the product is [[malt]]. In the production of Scotch whisky, the air used for kilning is heated by burning [[peat]] bricks in a furnace, imparting the characteristic smoky flavour to the malt.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=14-15 |language=en}}</ref> ==== Milling ==== Following the malting process, the grains are transferred to a dressing machine, which separates the sprouts from the seeds. The grains are then conveyed to a mill for grinding.<ref>{{Cite book |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |language=en}}</ref> ==== Mashing ==== The extraction of sugars to be converted into alcohol is achieved through a process known as mashing. During mashing, the [[diastase]] [[enzyme]] is activated, which facilitates the conversion of starches and [[Dextrin|dextrins]] into sugars. The ground malt is introduced into a ''[[Mash tun|mashtun]]'', a large vat containing hot water, and is agitated for approximately thirty minutes or more. The water is then drained from the mashtun, which is subsequently refilled with hot water. This procedure is typically repeated between one and three times. Once complete, the resulting liquid, known as ''[[wort]]'', which contains the extracted sugars, is separated from the mash, cooled, and transferred to the ''washbacks'', or fermenting vats.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=16-17 |language=en}}</ref> === Fermentation === During fermentation, a specific strain of [[yeast]], ''[[Saccharomyces cerevisiae]]'' (commonly known as "brewer's yeast"), is introduced to the sugary wort, which provides the necessary nutrients for its [[asexual reproduction]]. The yeast metabolizes the sugars, producing [[Alcohol (chemistry)|alcohol]], [[carbon dioxide]], and [[Congener (beverages)|congeners]], which can influence the flavor profile of the whisky, either enhancing or suppressing desirable characteristics. The fermenting vats are maintained within a controlled temperature range, typically between {{convert|10|and|37.8|°C|°F|0}} which is optimal for yeast activity. Distillers ensure consistency by using the same yeast strain to achieve uniformity in the final whiskey product. Fermentation continues for two days or longer until the alcohol content of the liquid reaches between 5% and 10%. Once fermentation is complete, and the yeast ceases to be active, the resulting liquid is referred to as ''[[Wash (distilling)|wash]]'' or ''distiller's beer''.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=17-18 |language=en}}</ref> Even though the wash is alcoholic it is still organic, which makes it susceptible to contamination by microorganisms that cause rot. Consequently, it is promptly transferred to the still for boiling to mitigate this risk.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=18 |language=en}}</ref> ===Distillation=== The decision to transfer either the entire wash or only the most liquid portion into the still is at the discretion of the distiller, and each choice affects the flavor profile of the final product in distinct ways. Following the transfer of the wash, the still is heated to a temperature sufficient to evaporate the alcohol while remaining low enough to prevent the evaporation of water. Alcohol vapour ascends through the still and is directed to the condenser, which consists of copper tubes or plates, where it condenses back into a liquid form known as the ''[[distilled spirit]]''. This distilled spirit is meticulously monitored during its extraction. The initial and final portions of the distillate are deemed undesirable and are therefore redirected back into the still. Only the middle portion, considered the most desirable, is collected in the ''[[Spirit safe|spirits receiver]]''. At this stage, the distilled spirit is clear and has an ethanol content ranging from 70% to 80% ABV. It is typically diluted before being transferred to casks for maturation, though some distilleries sell it as is at 'cask strength'.<ref>{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=18-21 |language=en}}</ref> A [[still]] for making whisky is usually made of [[copper]], since it removes [[sulfur]]-based compounds from the alcohol that would make it unpleasant to drink. Modern stills are made of stainless steel with copper innards (piping, for example, will be lined with copper along with copper plate inlays along still walls). The simplest standard [[distillation]] apparatus is commonly known as a [[pot still]], consisting of a single heated chamber and a vessel to collect purified alcohol. [[Column still]]s are frequently used in the production of [[grain whisky]] and are the most commonly used type of still in the production of [[Bourbon whiskey|bourbon]] and other American whiskeys. Column stills behave like a series of single pot stills, formed in a long vertical tube. Whereas a single pot still charged with wine might yield a vapour enriched to 40–60% alcohol, a column still can achieve a vapour alcohol content of 95.6%; an [[azeotrope|azeotropic]] mixture of alcohol and water. ===Maturation (Aging)=== Whiskies do not mature in the bottle, only in the [[barrel|cask]], so the "age" of a whisky is only the time between distillation and bottling. This reflects how much the cask has interacted with the whisky, changing its chemical makeup and taste. Whiskies that have been bottled for many years may have a rarity value, but are not "older" and not necessarily "better" than a more recent whisky that matured in wood for a similar time. After a decade or two, additional aging in a barrel does not necessarily improve a whisky,<ref>{{Cite web |last=Stone |first=Jason |date=18 July 2012 |title=Whiskey 101 |url=https://www.whiskeystill.net/blogs/whiskey-still-co-blog/6356446-whiskey-101 |access-date=14 July 2017 |publisher=The Whiskey Still Company}}</ref> and excessive aging will even affect it negatively.<ref name=":0">{{Cite book |last=Kosar |first=Kevin R. |url=https://press.uchicago.edu/ucp/books/book/distributed/W/bo10546280.html |title=Whiskey: A Global History |publisher=Reaktion Books |series=Edible |pages=24 |language=en}}</ref> The minimum aging period required for whisky varies by country. In the United States, the minimum aging requirement is typically 2 years, while in Scotland, Ireland, and Canada, it is generally 3 years.<ref name=":0" /> While aging in wooden casks, especially [[American oak]] and [[Quercus robur|French oak]] casks, whisky undergoes six processes that contribute to its colour and final flavour: [[extraction (chemistry)|extraction]], [[evaporation]], [[oxidation]], [[concentration]], [[filtration]], and [[colour]]ation.<ref>Nickles, Jane, 2015 Certified Specialist of Spirits Study Guide, Society of Wine Educators, p. 23 (2015).</ref> Extraction in particular results in whisky acquiring a number of compounds, including [[Aldehyde|aldehydes]] and [[Acid|acids]] such as [[vanillin]], [[vanillic acid]], and [[syringaldehyde]].<ref>Jeffery, John D.E., Aging of Whiskey Spirits in Barrels of Non-Traditional Volume, Master's Thesis, Michigan State University, p. 30 (2012).</ref> The casks used for aging [[bourbon whiskey]] are required to be new (and [[Charring|charred]]); after being used for this purpose, these casks are typically exported for use in the aging of other whiskies elsewhere. Distillers will sometimes age their whiskey in barrels previously used to age other spirits, such as [[Port wine|port]], [[rum]] or [[sherry]], to impart particular flavours. The size of the barrel also has an effect on the flavour development of the whisky, smaller barrels will contribute more to the whisky due to the higher wood surface to whisky ratio.<ref name=":0" /> During maturation, up to {{convert|45|litre|USgal|disp=or}} of whisky may evaporate from the cask over a 4 year period. This portion is called the ''[[angel's share]]'' by distillers.<ref name=":0" /> ===Packaging=== Most whiskies are sold at or near an alcoholic strength of 40% [[Alcohol by volume|abv]], which is the statutory minimum in some countries<ref name=cfr5.22/> – although the strength can vary, and cask-strength whisky may have as much as twice that alcohol percentage. Enthusiasts often prefer cask strength whisky for its concentrated flavors and customizable dilution experience. ===Exports=== The UK exports more whisky than the rest of the world combined.<ref>{{Cite web |title=The Observatory of Economic Complexity |url=https://oec.world/en/profile/hs/whiskies |access-date=2023-11-12 |website=oec.world |language=en}}</ref><ref>{{Cite web |title=Global whiskey export leaders, by country 2022 |url=https://www.statista.com/statistics/1040492/global-whiskey-export-leader-by-country/ |access-date=2023-11-12 |website=Statista |language=en}}</ref> In 2022, whisky exports from Scotland were valued at £6.25 billion, making up a quarter of all UK food and drink export revenues.<ref>{{Cite web |last=Scotch Whisky Association |title=Facts & Figures |url=https://www.scotch-whisky.org.uk/insights/facts-figures/ |access-date=11 September 2023}}</ref> In 2012, the US was the largest market for Scotch whisky (£655 million), followed by France (£535 million).<ref name="Scottgov">{{Cite web |date=27 March 2012 |title=Record high for food and drink |url=http://www.scotland.gov.uk/News/Releases/2012/03/foodanddrinkexports270312 |access-date=17 January 2014 |publisher=Government of Scotland}}</ref> It is also one of the UK's overall top five manufacturing export earners and it supports around 42,000 jobs.<ref>{{Cite web |last=Scotch Whisky Association |title=Facts & Figures |url=https://www.scotch-whisky.org.uk/insights/facts-figures/ |access-date=11 September 2023}}</ref> Principal whisky producing areas include [[Strathspey, Scotland|Speyside]] and the [[Islay|Isle of Islay]], where there are nine distilleries providing a major source of employment. In many places, the industry is closely linked to [[tourism]], with many distilleries also functioning as attractions worth £30 million [[Gross value added|GVA]] each year.<ref>{{Cite web |last=The Whisky Barrel |date=12 September 2011 |title=Scotch Whisky Exports & Visitor Numbers Soar |url=http://www.thewhiskybarrel.com/blog/post/scotch-whisky-exports-soar |url-status=dead |archive-url=https://web.archive.org/web/20131019085548/http://www.thewhiskybarrel.com/blog/post/scotch-whisky-exports-soar |archive-date=19 October 2013 |access-date=12 June 2013}}</ref> In 2011, 70% of Canadian whisky was exported, with about 60% going to the US, and the rest mostly to Europe and Asia.<ref name="CBC business">{{Cite news |last=Stastna, Kazi |date=25 May 2013 |title=Growing appetite for American whisky straining supply |publisher=CBC News |url=http://www.cbc.ca/news/business/growing-appetite-for-american-whisky-straining-supply-1.1382836 |access-date=17 January 2014}}</ref> 15 million cases of Canadian whisky were sold in the US in 2011.<ref name="CBC business" />
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