Malted barley, yeast and water are used to make Scotch malt whiskey. The first production stage is of course the malting of the barley, which is initially steeped in huge tanks of water for a few days before it is spread out on the floors of the ready malting house for germination. In order to control the germination process, the barley will be turned three times a day. This will prevent heat from developing and mold forming.
Peat, which is a natural fuel cut found in the Scottish moors, is used in the dying process to fire kilns. Other more modern fuels are also used. Smoke resulted from the fire then drifts gently vertically through a mesh floor to gradually dry out the barley. The peat reek then imparts a highly distinctive aroma that contributes to the true character of the spirit. When it is dried, the malt is absolutely crisp.
The malted barley is now ground and later mixed with high temperature water in a separate vessel. This process helps convert the unwanted starch in the malted barley into a sugary liquid called ‘wort’, which is then transferred to a vat for fermentation, where yeast will be added and the sugary wort converted into crude alcohol. This process is known as wash.
The next crucial process involves the highly distinctive copper pot stills, in which distillation quickly separates the much-needed alcohol from the wash. There are two stages of distillation, the first taking place in a bigger wash still and the other in a considerably smaller spirit still.
The still-man then increases the temperature within the still and steadily, the liquid is heated, with the alcohol in the wash vaporising. These vapors rise and pass over the head of the wash still, before they are reverted to liquid by condensers.
The newly acquired liquid is collected in a separate receiver before it is passed into the next spirit still, in which the process is then repeated. A lot more control has to be taken in the next distillation, where the spirit gradually flows through the so-called spirit safe, for the still-man to observe, measure and assess the spirit.
To be legally defined as Scotch whiskey, the new spirit must go through at least 3 years of maturation. In reality, most Scotch whiskey does mature for a lot longer, from five to over thirty years or longer. During this time, the cool and clean air of Scotland steals through the oak of the great casks and of course charms their fine contents, further contributing to the golden and smooth character of each and every distillery’s distinctive creation.