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From Oak to Stave to Barrels

Updated: Nov 22

A look at the journey our whiskey barrels take before they get to us!






The Life of Whiskey Barrels

We utilize whiskey/bourbon barrels in our creations. From Blanton’s stopper holders to personalized barrel heads, we take pride in giving barrels a second life after serving their original purpose. 


So what do barrels go through before they get to us? Let’s dig deep into the elaborate process that goes into making a whiskey/bourbon barrel!


What Are Barrels Made Of?

Whiskey barrels are typically crafted from oak wood. This is because oak is well-known for being durable, strong, and porous. The wood's porosity helps prevent leaks, which is crucial for storing large quantities of liquid. Additionally, during the aging process, the whiskey flows in and out of the wood's porous structure, which enhances its flavor profile.


Before oak is made into a whiskey barrel, it undergoes a process called seasoning. This involves leaving the wood outside to dry for a period that can range from 6 to 24 months! 

Regardless of the weather, the wood remains exposed, which helps break down compounds and release tannins from within the oak.


Tannins are a chemical compound that helps give whiskey color, flavor, and maturity. They may also have several health benefits, such as anti-inflammatory and antioxidant properties. 


Shaping The Barrels

Once the oak has dried, it’s shaped into staves. Staves are the individual parts that make up the barrel. Once dried and shaped, the staves are assembled into a barrel.

 

After shaping, the barrel enters the charring stage, where it is exposed to flame for a specific duration—anywhere from a few seconds to a few minutes. This charring alters the chemical structure of the wood, contributing to the whiskey’s distinctive taste and aroma. The caramel color of the bourbon is also influenced by this process.


In the U.S., there are four recognized levels of char. Each level is determined by how long the wood is torched. The first level involves charring the wood for just 15 seconds. The second level lasts 30 seconds, the third for 45 seconds, and the fourth for 55 seconds. 


The fourth level is known as "alligator char" due to its rough, textured appearance. The deeper the char, the more caramelization occurs, which imparts a sweeter, smoky flavor to the whiskey. This deep char can also help to absorb any impurities in the spirits, which can lead to a more refined, smoother flavor.

How Many Times Can a Barrel Be Used?

After all of the work that goes into simply creating the barrel, you may be surprised to learn that for true bourbon, you may only use the barrel ONCE.


This isn’t just best practice; in the United States, it’s the law. The barrels do not go to waste, though! When the bourbon has been leeched from the barrel, the barrel is then typically used to age scotch, Irish whiskey, Canadian whiskey, and various other spirits. 


After a few uses, most of the flavor that the barrel originally contained is going to dissipate. When this happens, distillers have little use left for these barrels. Lucky for us, their trash soon becomes our treasure.

From Barrels to Barware 

We have a passion for taking what would otherwise be discarded and forming it into something truly beautiful. Our barrel flights are the perfect example! Created with authentic whiskey and wine barrel staves, each one is a testament to the versatility of these barrels. 


It’s not just the staves either. No part of the barrel goes to waste! We repurpose the metal rings around the barrel for various detailing on some of our wooden pieces. The tops of the barrels can be used for our clocks, engravings, and even office furniture!


To Wrap It Up

As of today, barrel-art has recycled and reused over one million pounds of wooden barrels that may have otherwise been discarded. We take pride in our process. 


Not only are the products made with top-notch care and quality, but they are also a direct example of how sustainability and craftsmanship can go together seamlessly. 

 

Come see for yourself! Check out our catalog of authentic barrel creations.


Cheers!



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