The most common Bourbon recipes consist of a mixture of at least 51 percent corn, barley malt and rye or wheat. Each distiller takes great care in selecting the grains, making choices based on quality, ripeness and moisture content. These grains are ground into a meal and mixed in intervals with the iron-free limestone water. The mixture is then "mashed" or cooked. During this process the mash produces starch, which upon further cooking become maltose, or grain sugar. A strain of yeast added to the mixture converts the sugar to alcohol, beginning fermentation.

The yeast feeds upon the mixture of water and grain, called sour mash, in huge tubs. The strains of yeast used in fermenting mash in the various Bourbon distilleries make one brand of Bourbon different from another and are closely guarded secrets in the industry. The yeast is believed to affect the body, aroma and taste of the Bourbon as much as the aging process. Many strains have been passed from generation to generation in family-owned distilleries and are still used today. Fermentation takes place in large tubs, some with a capacity of up to 50,000 gallons. In the early days of Bourbon making, tubs made of cypress wood were used to hold the mash. Although some distilleries still use cypress, stainless steel tubs are now common. After three to four days of fermenting, the mash is then transferred into another container for distilling. The resulting crystal clear liquid is distilled or separated from the mash. At this point, the mixture is eight to nine percent alcohol, making it 16 to 18 proof.

Bourbon is aged in NEW white oak barrels, unlike the used barrels of other whiskey types. This new wood means that the Bourbon draws a great deal of color and flavor from the barrel, with vanilla and caramel predominant characteristics. Think of the new barrels as big sugar cubes that impart that sweet woody flavor and aroma to the Bourbon. To make a Bourbon barrel wood is cut into staves which are super heated and bent into ovular form. The barrel is then "toasted" by sending it through a small fire for about 12 minutes to caramelize the sugar in the wood. Next, it is applied to a larger fire for 6 to 12 seconds to burn out the inside and produce a charcoal layer. The charring must cover the barrel evenly so the whiskey has a consistent flavor. The new, white oak barrels are filled to capacity with the high wine, ready for several years of aging. During the aging process, the whiskey is said to"breathe" in the barrel. The climate in Kentucky in the summer gets very hot, and cold in the winter. This means that with the rapid expansion and contraction of the spirit into and out of the wood, maturing happens at a quicker rate than for example in the cool, damp climates of Scotland or Ireland. As the liquid ages in the barrel, variations in temperature as the seasons change force it to expand and contract through the caramelized layer of charred wood inside the barrel, "mellowing" it and giving it the distinctive Bourbon flavor and appearance. The liquid moves 3/4 of an inch in and out of the 1 inch thick white oak, this is why it is important to use only NEW barrels. Bourbon aging must take place for a minimum of two years. If aged less than four years, labeling must include age. Most Bourbons are aged from four to eight years. Some are aged 12, 18, and even 24 years.

Most warehouses are built on hilltops or in a staggered format in open fields. They contain several stories of "racks" for housing the barrels and usually allow a certain amount of airflow. Because temperature changes often affect barrels stored on the top story more quickly, some distillers rotate the barrels as they age to even out the process. Temperature changes cause pure water in the Bourbon to evaporate, so the barrels when opened commonly contain much less liquid than when they were filled. Bourbon loses about three percent of its volume for each year of aging, but contains between 10 and 20 percent more alcohol. Because no two barrels of Bourbon have been subjected to the exact changes in temperature, variations in alcohol content and character result. Most distillers blend Bourbon from the various barrels to ensure a uniform and distinctive final product. Select single barrel Bourbons are becoming more popular.
The wood used in our Kentucky Bourbon whiskey barrels is American grown white oak. Helping to support American families. The stave mills that make these sturdy barrels employ Kentucky workers.

A true Kentucky artisan, the Master Distiller is the crucial element in the Bourbon making process. If there is one thing that seems to characterize Bourbon Master Distillers, it is dedication to their craft. It takes decades to learn the fine art of distilling, and as a result, Master Distillers are a rare breed who have learned their trade through long apprenticeships. Some are second or third generation, with knowledge handed down from father to son. Each brand of Bourbon has its own recipe, closely guarded by the Master Distiller. Master Distillers are involved from the beginning, carefully selecting grains and keeping a close eye on fermentation. It is said that a good distiller can tell just how long the mash has been fermenting by the shape of the bubbles. The Master Distiller plays other key roles; selecting barrels, monitoring temperatures and finally, determining when the Bourbon is aged to perfection.