How a Wine Barrel is Constructed

One of the most interesting excursions Wine-Knows Travel organizes on several of our wine trips is an outing to a barrel-maker.  I’ve visited numerous ones around the globe and each time I continue to be mesmerized by the process.  Below is a recap of how a barrel is produced.

The procedure begins outside where cut planks cut from oak wood ("staves") are dried and aged for periods of 18-36 months.  This seasoning rids the wood from water and tightens the grains.

                                     Drying of the wood is a critically important first step.

Next, the aged staves are cut with precision using a computer.  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 to form the neonatal barrel.

Additional metal hoops are used to apply pressure in the shaping process:

The "head" of the barrel is next carefully prepared.

            The barrel's head is also cut using laser-beam accuracy to prevent any leakage.

The barrel is now placed over a fire.

                                         Heat is used to further bend the staves into shape.

Heat is also used for “toasting.”  Winemakers can order “light,” “medium,” or “heavy” toast.

                                      Different toasts add different flavors & aromas to wine.

The charred barrel is now ready for the final phase of finishing by the addition of new metal rings.

                      The final shaping is extremely labor intensive & requires great strength.

But, the barrel's interior also undergoes intense final scrutiny.

                                            A toasted barrel is prepared for its other head.

Exterior decorative touches such as a chestnut rim may be added.

                 Traditional chestnut rims are expensive but are thought to protect against pests.

Bottom heads are finally added to complete the package.

                                This Bordeaux barrel is almost ready for sale.

Everything in the barrel's construction is expensive---from the aging of the wood to the skill required by numerous artisans who are involved in its birthing.  Now you know why France's oak barrels sell for nearly $1,000 each.  If you're among the lucky travelers who are coming on the harvest tour to Bordeaux next September, at Chateau Haut Brion you will be able to view the barrel-making process as this chateau has its own workshop. 

Santé

One of the Best Wine Seminars

                                         Barrel toasting can add many complexities to wine

Have you ever wondered why flavors such as mocha or caramel are present in wine?  I’ve been a member of the Society of Wine Educators since 1982.  The society has an annual conference drawing attendees and speakers from countries around the globe.  Over the course of 3-4 days, attendees have the opportunity to taste hundreds of wines in formal seminars that are conducted several times throughout each day.  One of the most enlightening break-out sessions in my nearly 30 conferences was a seminar on the effect of the barrel’s toast level on a wine. 

First, let’s discuss toasting.  Oak barrels are “toasted” (or charred) with fire to impart complexity to the wine.  Toast levels can vary from low intensity up to a heavy char.   A winemaker chooses the degree of toasting depending upon exactly what he/she wants to accomplish in their final product.  Some winemakers even choose a variety of different toast levels and then blend the barrels for even more complexity.

Now, back to that fascinating seminar on barrel toast.  The winery that sponsored this session had conducted an experiment over the prior year using one wine.  This white varietal wine that had only been in stainless steel served as the “control wine.”  The control had then placed in 4 different oak barrels—one with light toast, another with medium, a third with medium plus, and the last with heavy toast.  Seminar participants first acquainted themselves with the unmanipulated control wine, then moved through the varying toasts to learn the nuances of each level of toasting on the mother wine.  This exercise was one of the best learning experiences I’ve ever had related to wine.

Below is a general summary of how barrel toasting can influence the final flavor profiles in a wine:

• Light toast:  coconut, hints of vanilla

• Medium toast:  vanilla, subtle spices (e.g. cinnamon, cloves), mocha

• Medium plus toast:  vanilla bean,  butterscotch, coffee, chocolate, more intensity of spices, nuts (e.g. hazelnut)

• Heavy toast:  caramel, smoky, roasted coffee