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More on the Mighty Oak Barrel
Every oak barrel is made out of bent planks of oak (called staves). Only the highest quality of oak is used, and the staves used are always chosen by hand. The reason these are normally hand selected, is that the quality of the completed oak barrel lies heavily in these staves.
After being inspected and selected, the cooper receives the staves needed to assemble the oak barrel. Now is when the creation of the barrel really begins. In a process often referred to as
The final shape begins to take place when three metal hoops are forced into place. At the workshop, the cooper then passes each barrel through fire and water. The cooper seals the joints by passing a wet cloth over the staves (both inside and outside), then heating the barrel over a wood fire for about 30 minutes. The heat and humidity makes the oak flexible. The wood fiber is bent by the cooper, who slowly tightens the staves into an arch with the use of a winch. This is how the body of the barrel gets its shape. The cooper trusses the oak barrel in place until the metal hoops are definitely in place.
The toasting level is achieved based upon the heating time (around 30 minutes). The flavors of the wine partially depend on this. When heated longer than 30 minutes the toast level is heavier. When heated less than 30 minutes, it is lighter. There are multiple toasting levels, which can be adjusted according to what you need. These levels are heavy, medium, medium+, and light. The toasting process happens when a caramelization in the wood occurs (during the heating of the staves). Some examples of the aromas this brings, are: a touch of nut, vanilla, fresh bread, or buttered bread. When one tastes a wine, they will often find these amazing aromas.
After the toasting level is reached, the coopers are ready to finish assembling the oak barrel. The grooves inside the oak barrel (called crozes) receive an application of wheat flour paste (while the barrel is upright). After this the crozes have heads fitted in. Put into place with a large mallet, the final hooping is then complete.
The oak barrel completed, the cooper selects more staves and starts the process all over again.
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