Barrel-making
For hundreds of years, people have used oak for wine barrels. Oak has strong, fine-grained wood with subtle aromas. It takes nearly two centuries for an oak tree to reach maturity. The best oak wood comes from trees that grow in the forests of eastern and central France, Eastern Europe, Missouri, Minnesota, and the Appalachians. Selecting perfect trees for barrel staves requires a combination of experience, craftsmanship, and science.
Computers analyze each log and calculate how to cut the most staves from the best parts of the wood. Lasers outline each cut.
Finished staves must undergo a slow aging process. They are carefully stacked on pallets, where they will remain for 24 to 36 months. To obtain the best qualities of the wood, time and the elements must work their magic. Rain washes away astringent tannins, and wind removes excess moisture.
Using fire and steam, the cooper gradually tightens the staves together, and the barrel takes on its final shape. Then, a slow and prolonged heating of the barrel, called bousinage, generates aromas that will be imparted to the wine. Varying the duration and temperature of toasting produces different aromas.
After the barrel heads are installed, each barrel is filled with hot water and pressurized to test for leaks. If a barrel passes the test, the hoops are removed, and the wood is sanded smooth. Galvanized hoops are then put in place, and the barrel undergoes another leak test. Finally, lasers mark each barrel with the cooperage’s logo.