The production of Scotch whisky takes time, a lot of time. It is a tedious process that can take years. However when it is done correctly, the product is one worth waiting for.
Barley is placed in deep tanks of water for approximately three days. As the moisture increases it promotes the germination process. After the germination process, the barley is then moved to the malting segment of the distillery where it will go into drums sometimes known as the malting floor.
The entire purpose of germination is to convert the starch in the grains into fermentable sugars that will feed the yeast during the fermentation stage. As the temperature has to remain consistent the barley is turned frequently while this is taking place with a wooden shovel, usually referred to as a sheil on a traditional malting floor. If the temperature rises above 22 degrees the grains will die and the entire process halt because the starch won’t be converted into sugar.
The grain then goes to the kiln, halting any further sugar consumption and drying up any moisture. It is usually a building two stories high with a perforated top that allows heat to escape. On the lower floor of it peat bricks are heated to dry the grain and consequently it acquires a peat like odour one of the most notable characteristics of a distillery is a pagoda type roof. A further matter of interest to take note of is that the malt will be damaged and unusable if heated above 70 degrees.
Centralised malting companies supply most distilleries with their malt these days, but there are still a small number who prefer to remain traditional and do it 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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