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Bourbon - Distillation

Early Times - Beer Still

The distillation works the same way for all American whiskey distilleries using a Column Still (Exception: Labrot & Graham). The pillar like form permits a continuous distillation process which was invented in 1826 by Robert Stein (Haig Co.) in Schottland. The fundamental operation principle is simple: You sets up a upright pipe, which has a height of 5 to 20 meters and diameter from 70 to 150cm. Into this pipe you insert floors with holes so that there is a connection from the bottom to the top. The edges of the holes are somewhat bent upward, so that any liquid cannot flow directly downward. Additionally small tubes are inserted in such a way that the liquid collecting on the floors can flow off to the next lower floor. If the column is filled with beer at the bottom and the column is heated from the lower end, two opposite flows are created. The condensing liquids flow through the tubes downward, while the fume components flow upward through the holes.

Seagram's Waterloo - Cut open Column Still

The temperature of the column is regulated in such a way that the alcohol is completely gaseous at the top (78 - 85°C) and the beer is cooking at the bottom (95 - 100°C).

This process runs for an unlimited time; as long as it is supplied with beer sufficiently. While the alcohol is removed at the top, the water with the fibres and remnants of the grain comes out on the bottom. This product is called 'Stillage' and is converted to animal food and Sour Mash which is added to the fermentation process.

The Column Stills achieves alcohol contents at the top of approximately 120 American Proof (60 Vol.% alcohol). If the columns are higher, the alcohol content can still be further raised.

After the distillation the fumes are run through a doubler, which is a simple copper pot. In it a catalytic conversion takes place, which improves the taste of the raw whisky.

Four Roses - Doubler

Early Times - Condenser

The again liquefied alcohol fumes in the condenser are led through an alcohol safe into vats, from which either the barrels are filled or trucks are loaded for transport.

Four Roses - Spirit Safe

Maker's Mark - Vats for Raw whiskey with Spirit Safes

The White Dog is regularly tasted immediately after the production for which it is diluted to approximately 20% ABV. In this condition the aromatic substances can be judged best.

Four Roses - Tasting of the White Dog

Per Bushel of grain (35.24 litres) about 5 US gallons of 100 Proof Spirit are produced (9.5 litres pure alcohol).

Sour Mash - Back to Start