The Whiskey Production Process

The Whisky Production Process

DARe-me Consulting Engineers offer building services design for all types of whisky production facilities. From distilleries to maturation facilities, our team offer full M&E design in accordance with regulations and industry standards. 

The Whisky Production Process

There are 6 main stages involved in the production of whisky: malting, mashing, fermentation, distillation, maturation and bottling. 

Stage 1: Malting

Barley is one of the key ingredients in malt whisky and must be treated in a specific way to extract its sugars. During this stage, the barley is steeped in water and is able to germinate. The germination process concludes when the barley is dried in a kiln. For a smoky flavour, smoke can be introduced directly into the kiln.


While barley is the most common type of grain to be malted by distillers, rye and wheat can also be used to add unique flavours to a whisky. 

Stage 2: Mashing

Following the malting process, the dried barley is ready for mashing. Before fermentation, the sugars within the grain need to be extracted. The grains being used are ground up, and now identified as grist, are combined with hot water in a mash tun or tub. These large containers have rotating rakes that continuously agitate the mix.


During the mashing process, enzymes convert starches to sugars. Once the sugar has been extracted, the liquid – now referred to as wort – is ready to move on the next stage and be turned into alcohol.

Stage 3: Fermentation

During fermentation, the wort is moved to a large wooden container called a washback. Here, yeast is added. Mixing the wort with yeast converts the sugar into alcohol, referred to as the ‘wash’. This process takes between 48-96 hours and can produce a diverse range of flavours depending on fermentation time and the type of yeast strain. The resulting liquid has approximately 7-10% ABV before being distilled.

Stage 4: Distillation

Distillation increases the alcohol content of the liquid and removes toxic alcohol and other undesirable components.

The wash goes through stills, typically the ‘wash still’ and the ‘spirit still’. The stills are typically made of copper, helping strip spirits of undesired smells and flavours.


The liquid is heated and refined to allow the process to be conducted again. Most whiskies go through distillation twice, but some go through this process three times. A high-quality spirit is produced at the end of this stage. 

Stage 5: Maturation

A key element of the production process is aging. Almost all whiskies are aged in wooden containers called casks, typically made from oak. These give the whisky its colour and other characteristics. Casks are stored in warehouses for the whisky to mature.


Some whiskies have a minimum required age before they can be bottled. For example, Scotch Whisky is aged in oak casks for at least three years.

Stage 6: Bottling

The final stage of the process involves bottling up the whisky. Once it has matured, whisky is bottled at a minimum of 40% ABV. Whisky can be chill-filtered to prevent it becoming cloud when ice is added. 

Whisky Production Facility Design

When designing a whisky production facility, buildings must comply with The Dangerous Substances and Explosive Atmosphere Regulations (DSEAR) 2002. As the processing of grains, distillation and storing alcohol all pose risk of explosion, it is extremely important to identify and control these hazards to prevent any serious incidents occurring. Those failing to comply with DSEAR guidelines can face serious consequences.


As a result, it is vital to ensure your production facility controls the risks to safety from fire, explosions, and substances corrosive to metals. 

Summary

The production of whisky is a six-stage process. While it can vary dependent on the style of whisky being produced and the location it is being made, it generally remains the same. Though a drawn-out process, this is essential to achieve the desired taste, colour and smell within the end product.


With a wealth of experience in this industry, we offer our services for whisky production facilities of all sizes in compliance with DSEAR. From risk assessments and hazardous area classification to engineering design solutions, our designs keep your building as safe as possible and compliant with regulations. Get in touch with a member of our team today to find out more. 

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