Bourbon is made through a detailed process starting with a mash of grains, primarily corn (at least 51%), mixed with rye, malted barley, or other grains. This mash is cooked and then fermented with yeast, which converts the sugars into alcohol, creating a "distiller's beer." The fermented mash is distilled, usually in a column still followed by a pot still called a doubler, producing a clear spirit called "white dog." This spirit is then aged in new, charred white oak barrels, which impart distinctive flavors and color to the bourbon. The aging process, which takes place in warehouses, can vary in length, but straight bourbon must be aged at least two years. The charring of the barrels is essential as it creates carbon that filters out undesirable flavors and imparts vanilla, caramel, and woody notes to the final bourbon. Key aspects of bourbon production include:
- Mash bill with minimum 51% corn
- Fermentation with proprietary yeast strains
- Distillation at no more than 80% ABV
- Aging in new charred white oak barrels
- Minimum two years aging for straight bourbon
This process results in the distinct taste profile of bourbon that combines sweetness, spice, oak, and vanilla notes.
