How Fire-Charred Whiskey Barrels are Made | Eater

"Founded by husband-and-wife team Joe and Kelly Blazosky after noticing lingering demand for quality spirit barrels in and around Remsen, New York, this small cooperage focuses on artisanal, fire-driven barrelmaking rather than automated, machine-heavy production. They source American oak from Missouri and age it two to five years — Missouri wood’s heavy rain and snow help wash out tannins and yield a mostly impervious stave that contributes pronounced flavors — and shape staves by hand into a mise en rose before assembling and fitting metal rings. Unlike most U.S. shops they heat and char with open flame and use a Scotland-designed toasting-and-charring machine nicknamed “The Dragon,” a process that starts caramelization and imparts complex notes of smoke, coconut, vanilla and caramel. Finished barrels are cooled, have a side bung hole drilled and cauterized, bottoms sealed, sanded, fitted with house-made hoops, pressure-checked for leaks, rinsed and packed for shipment. Co-owner Joe emphasizes the cooperage’s belief that coopers contribute the majority of a spirit’s flavor (he estimates around 80%) and his personal commitment to hands-on woodworking and quality over automation." - Terri Ciccone