Grain to Glass
Discover the people, places, and stories
behind every step of our most adventurous
whiskey production ever.
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Our Story
After over 80 years of experience in Bourbon-making, we started the Grain
to Glass Project to develop uniquely different whiskeys. And that
starts before a seed is even planted.
Greatest of Grains
For decades, Beck's Hybrids has specialized in developing customized seeds that generate increased harvest yields.
The Evolution
of Grain
The most important
ingredient that
we use to
create our bourbon survived
mass extinctions and evolved to
consist of 10,000 species. Scroll to learn more about
this versatile plant.
30,000 Years Ago
The earliest detected
domestication of wild grains in
the Fertile Crescent. They are
einkorn wheat, emmer wheat,
and barley.[1]
1,000 Years Ago
Native Americans from South
and Central America migrate
North, bringing maize with them.
The cultivation of maize in North
America leads to the creation
of new varieties of corn
across the country.[2]
600 Years Ago
Europeans begin using grains
to distill whiskey. The first
confirmed written record
of whisky comes from
Ireland in 1405.[3]
70 Years Ago
New technology and science allow farmers to experiment
in order to maximize yields and produce the most efficient crops.
This period, known as the Green Revolution, lead to the creation
of several new varieties of grains.[4]
Selecting the Grain
Exceptional grains come from passionate farmers and the Petersons are no exception. They take tremendous pride in their craft.
In the Blink of an Eye
Finding the perfect farming partner was essential to this project. They must monitor everything from soil temperature to wind direction during growing season and make precise adjustments to ensure success.
The Harvest
The SoilOnce the soil maintains our optimal temperature of around 60 degrees, it's time to plant our corn. Crops are usually planted between mid April and the end of May.
The Harvest
The CornCorn used for whiskey production is harvested when the stalks are brown and the kernels are dry.
The Harvest
The FarmersThe dedicated team at Peterson Farms works around the clock to ensure everything runs smoothly.
The Harvest
The YieldDetermining the optimal harvest date is crucial when selecting grains for whiskey production. If the kernels aren't dry enough, they can't be used in a mashbill.
The Process
The Bernheim facility is home to our 70-foot column stills where we regularly distill every major type of American whiskey.
The Process
The Grain Once we’ve created a mashbill from the grain, we start the mashing process. We brew small, 35-barrel batches in Kentucky limestone water.
The Process
Fermentation Now that the mash is created, it goes into a fermenter where we add our own proprietary strain of yeast, which converts sugar to alcohol.
The Process
Distillation After fermentation, the liquid gets run through our 70-foot-tall beer columns before going through a second distillation process, which brings the proof up to about 138. This distillate is known as "White Dog".
The Process
The Whiskey From there we put the liquid into a new, charred, American Oak barrel, where it will develop its character for the next 4 – 27+ years.
Our Mashbills
We developed three original mashbills to create a High-Wheat Bourbon,
a High-Rye Bourbon, and a High-Rye Rye Whiskey.
Rye Bourbon
For our first mashbill recipe, we utilized the corn from the Peterson's farm and introduce a higher rye content than you find in our traditional Bourbon mashbill.
Bourbon
This is a similar recipe to the wheated Bourbon, only we replaced the wheat with rye instead. It's an interesting way to compare not just the distillate, but also the finished product.
Rye Whiskey
For this recipe, we wanted to introduce an even higher rye content than you find in our usual rye whiskeys, like Pikesville or Rittenhouse.
The Cooperage
Barrels give whiskey all of its color, and much of its flavor and aroma. The char filters and flavors. The oak develops the whiskey’s character.
Barrel Making
The SourcingAll our whiskey barrels are made with new American Oak. We work closely with cooperages to determine the best seasoning and drying specs for our specific needs.
Barrel Making
Barrel RaisingA barrel raiser must properly, and evenly, arrange about 30 oak staves around a steel ring to form the barrel. Uneven distribution will result in leakage.
Barrel Making
ToastingThe staves are steamed and bent before being secured with steel rings and undergoing toasting. Toasting turns oak sugars into caramel compounds that are easily extracted by the liquid.
Barrel Making
CharringToasting, unlike charring, isn't a requirement for Bourbon production. Barrels are charred at varying intensities ranging from 1 – 4. This helps filter out whiskey's sharp notes. Once charred, the barrel is cooled and hooped.
Barrel Making
TestingOnce hooped, it's onto testing. First they determine the optimal location to drill the bunghole. Then water and air pressure are added to check for leakage.
Barrel Making
The Finished BarrelIf the barrel doesn't pass all tests, it's sent to the most experienced workers in the cooperage to find and fix the problem. When the barrel passes all the tests, it can be shipped anywhere in the world to play its part in the whiskey production process
Waiting Game
There are a multitude of factors that can affect whiskey during the aging process, so periodic tastings are key to successfully dumping a premium batch.
Factors of Aging
Several variables factor into the development
of whiskey, including the warehouse location, climate,
and oak barrels used for the aging barrels.
COOPERAGES
Barrels give whiskey all of its color, and much of its flavor and aroma. The char filters and flavors. The oak develops the whiskey's character.
Warehouse Location
Hillside rickhouses are drier and experience more dramatic temperature changes than rickhouses in valleys.
Rick Position
Whiskey extraction and evaporation varies all around the rickhouse. In fact, the temperatures between floors may differ by up to 15 degrees .
Weather
Kentucky's climate, with freezing winters and blazing summers, accelerate the liquid's extraction, concentration, and evaporation.
TIME
The longer the aging period, the more extraction, but extracting too many tannins, for example, would negatively impact the Bourbon, so determining the precise dump date is crucial.
The Tasting Journal
As whiskey ages, the barrel's wood expands and contracts due to the changing weather and seasons. This allows the liquid to soak in and out of the wood and extract flavors from the oak. Wood compounds add spice, vanilla, and buttery notes while bonding with alcohol acids to create fruity, savory, and sweet esters. While we regularly age our whiskey for a minimum of four years, a longer aging period will certainly improve taste.
Follow along as we conduct regular tastings and document every step of the aging process. As the whiskey develops color, flavor, scent, and character, we'll log it down here for you to see as we determine when these whiskeys are ready for bottling.
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