The Making of a Barrel

                             Barrel making is an arduous, tedious & expensive undertaking

Wine-Knows was in Burgundy a few days ago.  In addition to visiting some of the area's premier wine producers, we toured one of the most fascinating elements involved in  wine-making:  a barrel factory.  The process of making a barrel involves dozens of steps.  I’ve bucketed these many activities into these five major groups:

                          Proper aging of wood is critical to making a world-class barrel

1     1.  CURING

The process begins with choosing high quality oak.  The wood is then seasoned for months to several years to reduce its moisture content, and ultimately to create a tighter grain.

                        Computers are essential for precise cutting of each piece of wood

2      2. CUTTING & SHAPING

The seasoned wood is cut with precision into long thin pieces (staves).  As there are no adhesives used, it is critical that all parts of the barrel fit together perfectly to ensure a faultlessly tight seal.

 

                          Dried staves & a metal hoop begin the process of assembling

3      3. ASSEMBLING

The staves are assembled in a circle with metal hoops holding them in place. The staves are then soaked in water to make them more pliable, allowing them to be bent into the classical barrel shape.

                             The amount of fire dramatically influences a wine's flavor

4     4.  TOASTING

        The barrel is now placed over an open fire.  This step is crucial as it influences the             flavor of the wine.  The toaster follows the request of the winemaker:  “light,”                  “medium,” or “heavy toast.”

Appearance is vital to the top price barrels command.

       5.  FINISHING TOUCHES

The charred barrel is finished by placing additional hoops around the bottom, and both bottom & top receive a rounded precision-cut wood.  Finally, the barrel is sanded and inspected for quality.

Everything in the barrel’s process is expensive---from aging the wood to the skill required by numerous artisans involved in birthing a barrel.  It’s no wonder why today’s barrels sell for > $1,000 per masterpiece.

If you ever have the opportunity to visit a barrel maker, do not pass up the experience.