WHISKY PRODUCTION

Has 4 basic stages: malting, mash preparation, fermentation and distillation. Followed by even the most important stage of maturation.

Whisky and water

   For whisky production carefully chosen and prepared material is needed. The basic material is water without a proper water source it is impossible to create a whisky of a high quality. Water needs to be crystal clear, as well as of sufficient amount. Water plays three important roles. Water is needed no matter what kind of whisky is produced. It can be seen based on the location of old distilleries – they were always built close to the water source (a good examples is a distillery at Spey river in Scotland). Water is also needed to prepare a fermented pulp, it i sused to cool down condensators and also to dilute whisky, either at casking or bottling. Therefore nowadays, when new distilleries take buying the land around the water source to prevent from pollution. The course

water takes also affects the taste of whisky.  

         One of the most important motives for starting a production of nestville whisky was a crystal clear water of high quality. It´s analysis showed a mineral content that is very appropriate for whisky production. The water comes from Belianske Tatras to Lubovnianska kotlina and it is enriched with a unique mineral content. This uniquely composed water (rich in Ca, Mg, Fe) adds to our blended whisky a distinctive taste and originality. The taste can be changed by aging in oak barrels (casks), by malt smoking, but only a water is specific by adding a whisky unique taste and stability. Nestville blended whisky is made of a few white oak barrels (casks) with whisky distillate. The result is an unforgettable pleasure of whisky taste.

 

Grain and its production process

Grain selection

   

      Except for quality water the raw material is also the base. Carefully selected grains, with the highest starch content, which is the high acquisition to the process of fermentation. The most appropriate grains include barley, which grows in the harsh countryside. Its advantage is that it grows on soil poor of nitrogen, and thus is most suitable for production of malt. The less nitrogen the barley contains the more sugar content it has in the future, of course, necessary for the production of alcohol. To grain whisky distillate are used other grains such as corn, wheat and triticale. 

 

 

 

Malt house

    Malting is a technological device for converting barley into malt, which is an essential ingredient in the manufacture of beer and whisky. Barley is first cleaned and is left for a few days (usually 2-3 days) to soak in water. When the water content in the grain increase, it is spread to the concrete surface (threshing floor). It is left there in the damp and darkness to germinate (5-8 days). During this time there is a production of enzymes that break down starch to simple fermentable sugars. During the entire period, the barley is  being aerated and turned to avoid intertrigo. 

   

    Such prepared so called green malt is dried for 24-48 hours in hot air on kiln, where it very slowly and gently removes excess water. In the production of malt for the manufacturing of whisky, there is smoke from hardwood or turf used to deliver a distinctive smoky smell to whisky during  the process called ‘’hvozdenie’’.

 

 

Malting scheme:

vyroba whisky

Fermentation process

    Fermentation process takes palce in the fermentation room, it is a technological device for converting the saccharification mash to fermented mash. In the fermentation tanks fermentation takes place during which the fermentable sugar is converted into ethanol (alcohol) and carbon dioxide (CO2) by yeast activity without air. The essential process takes place by the temperature of 32-33°C and lasts for 72 hours. The result of the fermentation is the fermented mash containing 9-10% ethanol and no sugar.

 

Distillation - production of grain spirit

   

  Distillation is a process where is a separation of ethanol (distillate) from a fermented mash. A selection of ingredients in the distillation process is based on different volatility, which usually corresponds to the boiling point. In the first step we get a distillate from a fermented mash and then it is concentrated to the required quality. It is used a  process of multiple distillation (rectification), carried out in other sections of column.

    We have one of the most modern complex distillation systems with different pressure with low power consumption. The product of distillation is a high quality grain spirit with concentration min. 94% of the volume, which is the basis for future whisky. 

 

Aging

      Our Whisky is the first Slovak whisky. It is stored in oak barrels from quality American white oak, which is unique for its quality and is generally used for maturing whisky in the world..

      Whisky maturation takes a minimum of three years. It is tasted at time intervals. After three years of production lots are taken. Whisky can not be bottled earlier. It is important to mention that whisky is matured only in barrels, never in a bottle. Anually about 2 to 5% of whisky evaporates into the air. The amount of this loss, which is poetically called "angels share". The ammount of that loss depends on the humidity in the warehouse where barrels are stored and on the wood of which the barrels are made​​. In our cellars there are currently several thousand  of barrels, filled with whisky with 65% to 70% of a carefully prepared whisky from malt and grains.

        The biggest exchange is taking place in whisky barrels during aging. The result whisky  taste also affects the time; how long the previous product matured in barrels. For example, if the whisky in   barrels matured after a bourbon  for 10 years,  the whisky will have more oaky flavor and darker color, where bourbon matured for four years. Unlike with sherry or port, the taste of bourbon will not get into whisky. Whisky’s taste is also influenced by the structure  of the barrel itself and the degree of the inner surface burn. Each barrel has its identification number under a seal.

 

Whisky character:

 

 

  • taste – in whisky Nestville predominant taste of vanilla and oak yields - soft tan, fine for grain and malt 
  • colour – fine yellow-brownish color
  • smell – soft vanilla aroma of oak wood, grain - malt, without disturbing odors
  • Nestville Distillery
  • Hniezdne 471
  • 065 01 Hniezdne
  • Marketingové oddelenie
  • 052/42 636 15
  • This email address is being protected from spambots. You need JavaScript enabled to view it.

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