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.
Bourbon
For our first mashbill recipe, we were able to utilize both the corn and almost all of the wheat on the Peterson's farm.
Rye 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.
The Making of a Barrel
All 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.
Our Cooperages
McGinnis Wood ProductsLeroy McGinnis founded McGinnis Wood Products in Cuba, Missouri in 1968. He originally sold white oak barrel staves. (The McGinnis Family)
Our Cooperages
McGinnis Wood ProductsIn 1987, McGinnis expanded his business and built a cooperage. “The second load of barrels we sold was to Heaven Hill,” says McGinnis. “It's always been based on a handshake between us.”
Our Cooperages
McGinnis Wood ProductsAt age 94, Leroy McGinnis still goes to work daily. His son, Don McGinnis, now leads the company. “We travel together, go to timber sales together, and along the way we've become best friends,” Don says.
Our Cooperages
Independent Stave Company“I've always associated the cooperage with things I enjoyed,” CEO Brad Boswell says. “So working here isn't a burden. I see it as a privilege to be part of what our family does.”
(From left: The Boswell siblings Brad, Amie and Joe)
Our Cooperages
Independent Stave CompanyBrad Boswell is the fourth-generation CEO of Independent Stave Co. He took over the business from his father, John (center-right). John led ISC on an expansion run in the 1980s and turned the company into the world's largest maker of whiskey barrels.
Our Cooperages
Independent Stave CompanyCEO Brad Boswell credits the three generations that preceded him for clearing his path. “My job is to clear an even bigger path for the next generation,” he says.
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
Selecting the Seed
Each year, we select different and distinct strains of corn to create our
original mashbills. Learn about the types of seed we grow, harvest,
and distill for our Grain to Glass project:
| STRAIN | Becks 6158 |
| SEED CHARACTERISTICS | Specific qualities grow especially well for this region in Kentucky |
| WHY IT WAS SELECTED | This seed has never been sold for distillery use, resulting in a first-of-its-kind ingredient for American Whiskey |
| STRAIN | Becks 6225 Waxy |
| SEED CHARACTERISTICS | Waxy corn gene results in 99% amylopectin vs. regular dent corn (which is 75% amylopectin& 25% amylose) |
| WHY IT WAS SELECTED | Unique starch content produces a higher yield: amylopectin is water-soluble, allowing all the available starch to be cooked into the mash |
| STRAIN | Becks 6269 |
| SEED CHARACTERISTICS | A strain with isolated seed variables expected to grow well in Bardstown and surrounding areas |
| WHY IT WAS SELECTED | More starch than regular dent corn, but a 'soft' starch with less intentional flavor. Therefore, the final product will showcase the flavors of the other grains used to produce the distillate. |
Grain to Glass Master Tasting Journal
September 17, 2019
The new make distillates were all very distinctive... it's fascinating to see how each one is maturing in its own unique way. Now in year three of the Grain to Glass program, we’re continuing to innovate with unique corn hybrids & other locally-grown grains to develop an exciting range of whiskeys that showcase our craftsmanship & passion for this project. - Conor O'Driscoll , Master Distiller
High Rye Bourbon
The rye really comes through on both the nose and the palate. Pleasant grassy and dried hay notes… with a rye spice finish starting to develop. Has mellowed a lot in its first two years of aging, but quite a way to go before it’s ready to bottle.
High Wheat Wheated Bourbon
Already starting to mellow nicely, but still very young. Lots of barrel character on the nose. Very distinctive yeast/bread notes (no surprise there with the high wheat content.) The smooth, gentle character of a wheated Bourbon is very evident, especially when tasted next to its high rye cousins.
High Rye Rye Whiskey
A big, bold whiskey already! A lot of rye character blowing up here, full of all kinds of peppers and spices. Of the three, this one will probably have to age the longest to allow everything to mellow out, but it already has the makings of a very fine whiskey.
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