Making Premium Wood Barrels

GOOD TRADITION

The art of barrel making, known as cooperage, is an ancient skill. At the Barrel Mill, though we benefit from modern research, analysis, machinery and wood selection techniques, the actual wood barrel making process has changed very little over the years and is extremely time intensive. To achieve the highest standards of quality, most of the work must still be done by hand by a highly skilled cooper.

GOOD WOOD

Every season, when trees are felled, our coopers are on hand to select the best oak wood for use in the manufacturing of our wooden barrels. This selection is the initial phase that essentially determines the quality of the finished product.

The oak is examined both before and after being cut, and wood is selected based on many criteria, including tree shape and growing conditions. These factors determine the textural variety of wood fibers, the fineness of its grain and its tannin content. Tight grain and fine tannin content are found in the best wood.

GOOD STAVES

After aging, the staves are formed by machines into the proper shape and form for oak barrel assembly. After they are cut to the proper length, they are tapered at each end and beveled. Then they are planed on the outside, slightly hollowed on the inside and jointed by high precision machining.

After being inspected and selected, the staves are given to a cooper for assembly. At this essential stage of the manufacturing process, the handwork begins. Our craftsmen with irreplaceable experience and, above all, appreciation for work well done now adds their personal touch. The sharp-eyed cooper selects his staves, setting aside those that do not suit him. Then he assembles the staves inside a metal hoop that serves as the assembly jig. This operation, so spectacular in its speed and precision, is what the cooper calls the "mise en rose" or "raising the barrel."

GOOD TOAST

Solidly held in place by three metal hoops that have been forced into place, the "rose" is then subjected to a trial by water and fire in our workshop, where it takes its final shape. Repeating movements that are part of the most ancient tradition of his art, our coopers seal jointsby passing a wet cloth inside and outside the staves, then heating the barrel over a wood fire for approximately 30 minutes. Rendered flexible by heat and humidity, the wood fiber can now be bent by the cooper, who uses a winch to gradually arch the staves and tighten them to obtain the shape of the barrel body. The body is held trussed in place like this until the metal hoops are definitely placed.

The length of heating results in a "toast level" on which the flavors of the wine aged in the wooden barrels will partially depend. During the heating of the staves, some substances of the wood are caramelized and develop a multitude of aromas, such as vanilla, fresh bread, buttered bread, or a touch of nut, that will be found in the final taste of the wine. Toast level will be adjusted according to the customers' requests: light, medium, medium+ or heavy toast.

GOOD ASSEMBLY

Our coopers then finish the assembly of the oak barrel. The body is set up and the heads fitted into the crozes that have been coated with a paste of wheat flour. Then comes the final hooping, put in place with a large mallet.