You're the proud owner of a cute little cask.

It looks like you have one of our 1 litre American Oak casks. Let us introduce you to how the cask is made, a little background reading about spirit ageing, then some important tips on how to prepare the cask for its first use.

A nip of history

Whisky likely has its roots in ancient Babylonian civilisation, where some evidence of distillation activity as far back as 2000 BC has been found. Its introduction into Scotland and Ireland in the 15th Century eventually cemented whisky’s status as a well regarded drink. In these regions, barley was a readily available resource, and as a result barley based spirits (i.e. malt whisky) flourished.

Knowledge of whisky distilling soon spread to the new world. White settlers in America, many whom emigrated from Ireland and Scotland, soon started to distill whisky using old methods. But the warmer American climate tended to favour other cereals like corn and rye, so the distillers followed suit. Bourbon whiskies (mostly corn based) and rye whiskies emerged as distinctive styles. Australian distillers today have the luxury of a range of locally grown cereals, and so there’s no single distinct ingredient that represents ‘Australian whisky’.

Of course, the distilled grain or malted barley is only half of the whisky making process. The humble wooden cask, used for hundreds of years to store and transport goods, is the silent second craftsman. It’s hard to definitively rule out the possibility that someone simply had an epiphany one day and intentionally put un-aged whisky into casks and waited a few years before consuming it. But in all likelihood, the result was discovered by accident. It turns out that storing a spirit in a cask for some time can improve its palatability, round out the ‘rough edges’ and impart a golden hue.

Nowadays, people have come to appreciate an aged whisky, and so despite the irrelevance of wooden casks in modern society, various pieces of legislation in most countries mean that a spirit must be aged in a wooden cask for some time before it can be legally called whisky. In Australia, the minimum time is two years.

Most Scotch whiskies on the market today are aged for eight or more years in an oak cask, with most being aged in ex-Bourbon and ex-Sherry casks. The use of these two types of casks isn‘t exactly random. American Bourbon whisky is aged in virgin oak casks (brand new casks which haven’t previously been used to store any other liquids) as this is a legal requirement. Afterwards, the spent casks are useless to Bourbon distillers, and are therefore sold to other distilleries as ex-Bourbon casks. Similarly, Spanish Sherry makers eventually retire their casks and sell these on as ex-Sherry casks. These casks are now in very short supply because the number of Sherry drinkers in the world continues to dwindle while whisky aged in ex-Sherry casks is increasingly popular.

In Australia, distilleries have also embraced the ex-Bourbon and ex-Sherry cask movement that has given Scotch whisky its reputation. Some distilleries also collaborate closely with local wine makers to use their spent casks, releasing whiskies aged in ex-Shiraz, ex-Pinot Noir and other such casks.

New-make spirit

Your cask may have also been delivered with a bottle or two of new-make spirit. What on earth is this?

The un-aged spirit that is placed in a cask to mature into whisky is also known as ‘new-make’. If a bottle of new-make spirit was purchased along with the cask, you will have either some single malt spirit, peated single malt spirit or corn spirit. If you haven’t yet ordered a bottle of new-make spirit, you can always head here to grab one.

The single malt spirit is made for us from scratch using Australian malted barley by Belgrove Distillery in Tasmania. It's made from malted barley wash and double distilled in a pot still directly heated by an oil furnace.

The peated single malt spirit is also a Belgrove Distillery creation and clocks in anywhere between 60% to 68% ABV depending on the batch. This spirit is made from grains smoked with peat from a local Tasmanian peat bog. It's very unique and our personal favourite, but it's always in short supply.

The corn spirit is made by Whipper Snapper Distillery in Western Australia. It comprises locally grown corn, malted barley and wheat from the WA wheat belt. It makes a fantastic base for creating Bourbon style whiskies.

Meet your cask

To make this mini cask, American White Oak planks are cut into small staves and arranged into a barrel shape by a craftsman known as a cooper. Prior to the two ends being sealed, a blowtorch is inserted into the cask for just a few moments to give the inner surface a light toasting. This process opens up grains in the wood, helping the whisky move more freely through the wood during the ageing process. Finally, a tap, bung and stand are fabricated to complete the cask.

Due to the hand-made nature of the cask, you may notice small wood or charred fragments rolling around inside. This is perfectly normal and won’t adversely affect the ageing process nor the resultant spirit.

Initial preparation

The first and most important step in the ageing process is to ensure that the cask is appropriately cured. Without proper curing, the staves will not be bound together tightly enough, and the spirit will end up leaking right out of the cask.

To cure the cask, first rinse the inside of the cask by filling and emptying 2 or 3 times to remove any wood debris. Then, fill the cask with water for 3 to 5 days. This will allow the oak to expand and retain liquid. The cask may leak during this time, but that's normal.

After this initial curing, place the cask on the stand in a dry area. Liquid will continue to slowly drain through the wood for the next 3 to 7 days. Keep the cask filled during this time. When the cask stops draining, empty the contents and rinse again. The cask is now ready to take in spirits.

Ageing spirit

There are actually a virtually unlimited number of combinations of ways to age your spirit. We’ll discuss a few of the more popular ones below.

Bourbon style whisky - Pour the corn spirit right into the cask. Because the cask is virgin American Oak, it’ll impart all the typical Bourbon flavours. Place the cask in a cool place to minimise evaporation loss. Check in on the spirit every week or so. We wouldn’t suggest ageing for more than six months, but results will vary. After ageing the first batch of spirit, the cask is now an ‘ex-Bourbon’ cask.

‘Ex-Bourbon’ cask whisky - This can be made with a malt spirit by ageing it in the cask after it’s been used to make Bourbon style whisky at least once. You could use another batch of corn spirit again (instead of malt spirit) but that would just be like making another Bourbon whisky, although it may have a more rounded taste.

‘Ex-Sherry’ cask whisky - Season the cask by ageing a bottle of sherry in it for a month or so. Pour out the sherry (drink if you wish) and leave to stand for a day to dry slightly. Pour in malt spirit to age for up to another six months. You should begin to notice a hint of sherry influence almost immediately, and the sweet notes should continue to develop and mature with time.

‘Ex-anything’ cask whisky - Basically it’s possible to season the cask with any sort of liquor before ageing the spirit. Fortified wines like sherry and port are easy due to their higher ABV which minimises the risk of spoilage, but red wine is also fine - just make sure to fill the wine right up to the bung to push out all the air. The joy of whisky making is experimentation, so go ahead and satisfy your curiosity to its fullest.

Things to keep in mind

Cask curing - It’s paramount that the cask is properly cured before being used. Attempting to pour the spirit right into the cask before curing will result in heartache, lost spirit and a messy (but nice smelling) room. If a cask continues to leak after curing, try submerging it completely in a tub of water for a couple of days before checking again.

Evaporation loss - Due to the small cask size and its thin stave thickness, you can expect to see the spirit evaporate fairly quickly. In some cases, it isn’t unusual to be left with only half the spirit after six months of ageing. In other words, you will certainly be left with less spirit than originally put in. It’s a double edged sword for distilleries around the world, but particularly true in Australia’s hot and variable climate. To minimise the effects of this ‘angel’s share’, keep the cask in a cool dark place.

Accelerated ageing - The small cask size is great for speeding up the ageing process. Smaller casks have greater surface area, so more wood comes into contact with the spirit, resulting in faster ageing. In some cases, you can expect the spirit to be adequately aged in a matter of weeks. The resultant spirit can’t legally be called whisky if it’s aged for less than two years, but if it tastes great, we’re not complaining!

Storing the cask - When not used to age spirits, we recommend keeping the cask filled with filtered water. If the cask is left empty after it’s been used, it will naturally dry out and will require re-curing to prepare it for its next use.