Whiskey Production Process - Redwood Empire Whiskey

: Step 1
Mash Bill
We source our grains—corn, rye, wheat, and malted barley—primarily from family-owned farms in California’s Sacramento Valley. These grains form the foundation of 12 distinct mash bill recipes. All grain is milled on-site into a flour-like consistency before entering the mash tun.
Corn, the signature grain in bourbon, becomes neutral over time, allowing the barrel to define the flavor. Rye imparts spice—pepper, clove, nutmeg, and cinnamon—while malted barley contributes rich chocolate notes.

: Step 2
Mashtun
Our custom-designed mashtun uses direct steam injection to efficiently convert starches into fermentable sugars. Each batch combines 10,000 pounds of milled grain with 5,000 gallons of hot water at approximately 190°F. Over 7–8 hours, gelatinization occurs, releasing sugars critical to fermentation.
Depending on the mash bill, we ferment both on the grain (with solids) and off the grain (solids removed) to maximize aromatic and flavor complexity.

: Step 3
Fermentation
Once cooled, yeast is pitched into the mash and transferred to one of our four jacketed fermentation tanks. Over the course of 3 to 5 days, the yeast converts sugars into alcohol, producing what we call “distiller’s beer” at 8–10% ABV.
From here, the liquid moves to our beer well (BW) tank, which feeds directly into the still.

: Step 4
Distillation
Our copper and brass Vendome column still stands three stories tall and processes 18 gallons per minute. The distiller’s beer enters near the top and descends while steam rises from below, vaporizing the alcohol and leaving solids behind. This process concentrates the alcohol to around 120 proof (60% ABV).
The vapor then passes into a doubler for a second distillation, raising the alcohol to 140 proof (70% ABV). Throughout the process, our team monitors quality using a spirit safe and parrot.
The resulting distillate is collected in blending tanks (BT1 & 2, HT1 & 2), proofed down to 110 before barreling.

: Step 5
Maturation
Whiskey is matured in 53-gallon charred and toasted new American oak barrels. Toasting enhances sweetness (vanilla, caramel), while charring aids in color and filtration.
We season our staves for a minimum of 36 months—well beyond the industry standard—resulting in a smoother, more nuanced whiskey with reduced tannin harshness.
Redwood Empire now oversees the largest barrel inventory on the West Coast, with over 22,000 aging barrels. Unlike Kentucky’s extreme seasonal shifts, our cooler climate ensures a slower, more balanced maturation—much like the terroir that makes Sonoma and Napa world-renowned for wine.