Aroma and Depth: Roasting Levels for Winemakers and Distillers
"Discover how we shape the flavor profile of our barrels with the power of fire! From the delicate nuances of Light roasting to the bold intensity of Char 4, each barrel imparts a unique character to wines—from hints of berry jam to roasted nuts, and from caramel to citrus tones. Choose the perfect roast for your wines and spirits, and elevate every sip to new heights!"
About the Roasting Process
Our barrels are crafted at varying levels of toasting, each offering distinct aromatic profiles to our users. Partners can select from Light, Medium, Medium+, Heavy, or Hybrid roasts to suit their needs. For spirits, the options range from the mild Char 1 to Char 2, Char 3, and the most robust Char 4, characterized by its crocodile-skin finish.
Every barrel is bent over an open flame, and after bending, it is returned to the fire. The duration and temperature of this process determine the barrel's roasting level. The most common and popular roasting levels for wines are Medium and Medium Plus.
Medium Roasting (M)
The Medium roasting level strikes a balanced note, allowing the oak's natural, rich aromas to flourish while providing a soft depth and texture to the matured spirits. At this roast level, the oak is treated with moderate heat for an extended period, resulting in an intensified warmth without overwhelming the flavors imparted by the barrel.
How is Medium Roasting Achieved?
To achieve the Medium roast, the oak barrel is heated internally for approximately 35-40 minutes over a medium flame. This process prompts a deeper transformation within the wood's structure, enhancing the more intricate aromas without completely saturating the oak.
Temperature and Duration: 200-220°C for 40 minutes | Depth of discoloration: 2-4 mm
Flavor and Aroma Profile of Medium Roasting
Wines or spirits aged in Medium-roasted barrels develop a rich, complex flavor profile, characterized by sweet, nutty nuances and warm, spiced tones. This roast level is ideal for those looking to highlight the following flavor notes:
• Roasted Nuts: Contributes a rich, soft nuttiness, infusing the spirit with a deeper, warmer character.
• Silky Caramel: Sweet, slightly melted caramel tones smooth the structure of the spirit.
• Baked Apples and Spices: Enhances the oak's fruity and spicy nature, pleasantly complementing the character of the wine or spirit.
Medium roasting is a superb choice for achieving a well-rounded, silky flavor profile, where the oak’s elegant richness meets soft, delicate texture, creating a harmonious experience in every sip.
Medium Plus Roasting (M+)
Medium Plus Roasting
The Medium Plus roasting level represents a refined approach to barrel aging, bringing forth deeper and richer aromas from the matured spirits. This roast level requires a more intensive treatment compared to Medium, allowing the wood to impart more complex and pronounced flavor characteristics to wines and spirits while preserving the oak’s natural elegance.
How is Medium Plus Roasting Achieved?
To reach the Medium Plus roast, the oak barrel is heated internally for about 45-50 minutes over a medium-high flame. This longer and more intense roasting process allows for a deeper transformation of the wood's structure, resulting in richer aromas without the dominant flavors overshadowing the spirit.
Flavor and Aroma Profile of Medium Plus Roasting
Wines or spirits aged in Medium Plus-roasted barrels can achieve a complex and sophisticated flavor profile, where the rich aromas from the oak harmonize with fine spices and unique notes. This roast level is ideal for those seeking a deeper and more layered flavor experience:
• Spicy Tones: Subtle hints of cinnamon, clove, and nutmeg enrich the character of the spirit, adding an elegant spiciness.
• Caramelized Sugars: Deep, sweet caramel flavors emerge, harmonizing beautifully with other aromas.
• Roasted Nuts and Almonds: The lightly toasted notes from the roasting process add a crisp texture and complexity.
• Baked Fruits: Subtle flavors of roasted peach, apple, or plum contribute freshness and fruitiness to the spirit.
• Toasted Bread Crust and Ripe Fruits: Adds a full, toasty flavor profile, harmoniously complemented by the notes of matured fruit.
Medium Plus-roasted barrels are perfect for wines and spirits seeking a balance between the oak’s natural aromas and the complex flavors imparted by the roasting process. This roasting level allows the spirit to attain a rich, layered, and sophisticated flavor profile that captivates connoisseurs and elevates the quality of the product.
Temperature and Duration: 200-220°C for 50 minutes | Depth of discoloration: 3-6 mm
Heavy Roasting (HT)
Heavy Roasting
Heavy roasting unveils the most intense flavor profiles from oak barrels, imparting deep and pronounced aromas to wines. This roasting level contributes a smoky character, rich spiciness, and intense caramelized notes to the flavor profile of spirits. Choosing a Heavy-roasted barrel is for those who appreciate bold flavors and wish to enrich their wines with new, complex layers.
How is Heavy Roasting Achieved?
During Heavy roasting, the barrel is exposed to intense heat for longer durations, often exceeding 60 seconds. This deep roasting process transforms the internal layers of the oak, resulting in more pronounced flavors and aromas. Due to the heat, the compounds within the oak take on entirely new flavor dimensions, imparting distinct and unique aromas to the wine.
Flavor and Aroma Profile of Heavy Roasting
Heavy roasting delivers intense, rich aromas that provide a unique and profound tasting experience. The flavor profile of barrels roasted at this level combines roasted, sweet-spicy tones with caramelized notes while maintaining balance with the wine’s natural character. The following flavor notes characterize Heavy-roasted barrels:
• Dark Chocolate and Ripe Coffee Beans: Enriches the wine with a dark, full-bodied character featuring bitter chocolate and deep coffee flavors.
• Candied Fruits and Spices: During aging, intense, honeyed fruit and spicy aromas develop, enhancing the complexity and depth of the spirit.
• Caramelized Sugar and Toasted Nuts: Characterized by rich, full flavors that provide a slightly sweet, mildly bitter character, highlighting the delicate balance of aging.
Wines aged in Heavy-roasted barrels boast exceptional depth and complexity, where each sip offers a smooth yet characterful journey into the world of oak and roasting. This roasting level ensures minimal oak flavor transfer, maintaining the elegance of the wine while providing a velvety finish. Ideal for those who love a rich, full-bodied flavor experience and seek unique, pronounced aromas in their wines.
Temperature and Duration: 280-300°C for 60 minutes | Depth of discoloration: 5-9 mm
Cooper's Insights
"For me, this type of barrel offers a truly exciting and culinary delight. It holds a special place in my heart because it captures the essence of fire. If we want the wine to inherit this dynamic energy, this is the right barrel type!
Light Toasting (LT)
Temperature: 180-200 °C for 30 minutes
Discoloration of staves: 0-3 mm
In light toasting, a relatively high amount of tannin remains in the wood, leading to stronger, more acidic flavors and more pronounced aromas. The flavors and aromas most perceivable in the wine will be from the wood. Notes of blackthorn, quince, green herbs, and sometimes slightly waxy or astringent flavors can develop in the resulting wine.
• Delicate almond and sweet grain tones: The wine’s natural flavor profile stands out, complemented by subtle almond and grain notes that reflect the pure character of the oak.
• Gentle floral aromas and fresh wood: Thanks to the restrained nature of the light toasting, the oak’s natural floral tones may also emerge, giving the beverage a fresher, more airy effect.
• Green tea and lightly spicy notes: A layer of flavor reminiscent of green tea, derived from the freshness of the wood, gently permeates the wine, while a hint of spice provides an exciting yet refined character.
Cooper's Insights: Lightly toasted barrels do not guarantee a "light" and easily drinkable wine. The compounds, acids, and tannins in the wood do not burn away, allowing the must or wine to react directly with the wood, extracting the compounds and acids from it, which then integrate into the wine. Thus, it is not recommended for wines with strong acidity, as it can lead to excessive sourness. Care and caution are necessary when using this type of barrel.
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Hybrid Toasting
Hybrid toasting is an exciting, mixed technique that combines multiple levels of toasting to achieve complexity and unique layering in the flavor profile of the wine aged in the barrel. In this method, different toasting levels are applied to various parts of the barrel – for example, stronger Heavy toasting at the bottom and lighter Light or Medium toasting at the top – allowing the wine to experience the full flavor spectrum of the oak. This versatile approach creates a refined balance between the oak's natural fresh notes and the deep, caramelized tones.
How is Hybrid Toasting Made?
In hybrid toasting, different parts of the barrel are charred with varying intensities of flame, blending multiple toasting levels within a single barrel. This carefully designed, precise technique aims to extract different aromas from the oak at varying temperatures. The bottom of the wood receives deeper, more characterful notes, while the upper parts feature the oak's natural, lighter flavors.
Temperature: 280-300 °C for 10 minutes and 180-200 °C for 30 minutes
What Flavors and Aromas Does Hybrid Toasting Provide?
Wines aged in hybrid-toasted barrels offer a complex, multi-layered flavor experience that ranges from the oak's natural freshness to deep, caramelized, rich aromas. The following flavor notes often appear in wines aged in hybrid-toasted barrels:
• Toasted spices and fine caramelized sugar: Roasted and caramelized tones add depth to the wine, while restrained spiciness provides an exciting, warm base note.
• Fresh oaky and fruity layers: The fresh character of the oak brings elegant green tones that add lightness to the drink, combined with fresh fruitiness.
• Rich dark chocolate and sweet, toasted almonds: The deeper toasting levels provide darker tones that lend a fuller, silkier texture to the wine.
Hybrid toasting is an extremely refined technique that is ideal for wines where rich flavor layers and complex character play an important role. This mixed toasting ensures that new, surprising flavor layers unfold with every sip, balancing the natural aromas of the oak with the deeper notes evoked by the toasting.
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Char Toasting
In all cases, the internal self-ignition of the barrel body and its burning time define the toasting level.
Char 1
Char 1 toasting level is one of the mildest, finest toasting levels applied to the inner wall of oak barrels. During toasting, the barrel is lightly charred on the inside, causing certain compounds in the wood to change, enabling the barrel to impart special aromas to the spirits aged within.
How is Char 1 Toasting Made?
Char 1 toasting is typically performed for a short duration, usually around 10-20 seconds, using a milder heat. As a result, only the surface of the wood is lightly charred, just enough for the natural compounds in the oak (such as lignin and cellulose) to undergo initial transformation. This process helps the barrel impart finer aromas and flavors to the spirit without introducing an overly dominant burnt character.
What Flavors and Aromas Does Char 1 Toasting Provide?
During Char 1 toasting, the oak's natural vanilla and caramel notes emerge subtly, without creating an overly intense burnt flavor. This toasting level is particularly suitable for spirits where preserving the character of the wine or drink is important, and excessive oak flavor is not desired. The mild toasting results in discreet yet rich flavors such as:
• Subtle vanilla: Delicate, sweet vanilla notes emerge due to the breakdown of the wood's lignin.
• Caramel: Light caramel flavors contribute to the sweeter character of the spirit without adding excessive sweetness.
• Fruity notes: The fine toasting allows the barrel to highlight the natural fruity aromas of the oak.
These properties make Char 1 toasted barrels an excellent choice for achieving a fine, well-structured, yet rich flavor experience in spirits without the dominance of burnt wood flavor.
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Char 2
Char 2 toasting level is a medium, well-balanced toasting level that imparts a more intense character to the spirits but is not as strong as the higher levels. This toasting level is applied when there is a desire to enrich the flavor profile of the spirit with deeper, more complex notes without an excessively smoky or burnt character.
How is Char 2 Toasting Made?
Char 2 toasting is performed for a longer duration than the milder toasting levels, typically around 20-30 seconds. During this stage, the inner layers of the wood undergo deeper transformation, leading to the breakdown of lignin and other components found in the oak. The result is a toasting level that imparts deeper, richer aromas while still maintaining a balance with the oak's natural flavor notes.
What Flavors and Aromas Does Char 2 Toasting Provide?
During Char 2 toasting, the oak's rich, caramelized, and woody aromas become more pronounced, while the burnt notes do not become overly dominant. The following flavor and aroma notes are characteristic of Char 2 toasting:
• Rich vanilla: Thanks to the increased breakdown of lignin, more pronounced vanilla aromas develop, making the spirit creamier and sweeter.
• Caramel and roasted sugar: The breakdown of cellulose and hemicellulose in the wood results in specifically caramel-like, slightly roasted sugary flavor notes, adding deeper sweetness to the drink.
• Light smoke and toasted nuts: The slightly longer toasting process brings out mild smoky notes while also imparting toasted nutty, hazelnut-like shades.
• Spicy notes: During Char 2 toasting, delicate spicy characters, such as cinnamon or clove, also emerge, further enriching the flavor experience.
This toasting level is particularly suitable for aging whisky, bourbon, and rum, as these spirits benefit from the oak's deeper, richer flavor profile. Spirits aged in Char 2 barrels thus receive a more complex, rich flavor experience where sweetness, smokiness, and oaky aromas harmoniously blend without being overly dominant.
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Char 3
Char 3 toasting level is often referred to as a medium-deep toasting level, where a more pronounced, characterful flavor profile develops, showcasing the oak's deeper, smoky, and caramelized notes. This toasting level is frequently used when there is a desire to bring out more intense wood and spicy flavor notes in the spirits, and it is particularly popular in aging bourbon and whisky.
How is Char 3 Toasting Done?
During Char 3 toasting, the inner surface of the oak barrel is burned for a longer duration, approximately 30 to 40 seconds. This constitutes a significant heat treatment that penetrates deeper layers, leading to the breakdown of more compounds and the release of additional aromatic components. As a result of the toasting, a thicker charred layer forms on the inner surface of the barrel, imparting stronger smokiness and caramelized and spicy notes to the spirits.
What Flavors and Aromas Does Char 3 Toasting Provide?
The Char 3 roasting level imparts richer, deeper, and more intense aromas to the beverages aged within, giving a distinctive character to the spirit's flavor profile. Characteristic flavors and aromas include:
• Intense Vanilla and Caramel: Due to the increased toasting, more lignin and sugars break down, resulting in deeper, creamy vanilla and sweet caramel flavors that enhance the drink's sweetness.
• Toasted Oak and Smoke: Char 3 develops strong smoky and slightly burnt oak aromas that add distinctive, robust flavor notes to the spirit, ideal for stronger-tasting beverages.
• Spicy Undertones: Prominent notes of cinnamon, clove, and pepper emerge, deepening the complexity of the spirit and adding a pleasant, warming spicy layer.
• Coffee and Chocolate Tones: The extended toasting process gives rise to even more complex aromas, often associated with roasted coffee or dark chocolate notes. These flavors add a unique richness and depth to the drinks.
Spirits aged in Char 3 toasted barrels are often fuller-bodied, more complex, and boast a diversity of flavor notes. This level is particularly suitable for aging bourbon and whisky, as these spirits harmonize well with the oak's rich smoky, caramel, and spicy character. The result is a powerful, characterful spirit that showcases all the rich aromas of the oak.
Char 4
Char 4 toasting is the most intense toasting level for oak barrels, often referred to as “alligator toasting” because the internal surface of the wood becomes characteristically deeply cracked under such strong charring, resembling alligator skin. This toasting level provides powerful burnt and smoky notes to the spirits, giving them a unique, rich, and robust character.
How is Char 4 Toasting Done?
Char 4 toasting can last from 55 seconds to a minute or more, creating a thick charred layer from the oak. This deep toasting layer not only imparts more intense aromas and flavors but also acts as a kind of filter, as the charred layer helps absorb certain unwanted compounds, thereby clarifying the aged beverages.
What Flavors and Aromas Does Char 4 Toasting Provide?
Char 4 toasting creates intense, deep flavors that make the beverages richer, darker, and more robust. The following flavor and aroma notes dominate this level:
• Intense Smoke and Burnt Wood: The charred layer formed during Char 4 produces strong smoky and burnt wood notes that give depth and robust character to the spirits.
• Burnt Caramel and Deeper Sweetness: Toasted sugary notes like burnt caramel or molasses are more pronounced, imparting a powerful, deep sweetness to the drink.
• Toasted Nuts and Chocolate Notes: The intense toasting of the oak highlights flavors such as roasted hazelnuts, cashews, and subtle dark chocolate notes, making the spirit particularly rich.
• Strong Spiciness: The charred wood layer brings out stronger, peppery, and slightly smoky spice notes, such as cinnamon, nutmeg, and smoked paprika, adding an exciting, spicy character to the spirit.
• Dried Fruits: Char 4 toasting typically brings forth deeper fruity notes like dried plums, black cherries, and raisins, enhancing the fullness and complexity of the drink.
This strongest toasting level is particularly favored for whisky and bourbon, as it significantly enriches the character of the beverages, providing a unique and distinctive flavor profile. Spirits aged in Char 4 barrels acquire thick, dark layers of flavor, where burnt, smoky notes, caramel, toasted nuts, and deep fruitiness harmoniously blend.
Cooper's Experiences Regarding Toasting Levels
For me, toasting barrels is always a great experience; it never gets boring, as this is the most beautiful element of barrel making. I love to feel the warmth of the fire on my face and hands, to hear how the fire crackles, and to watch the sparks dance wildly into the sky. It is especially rewarding to see how the wine develops in my barrels, and my greatest joy is when a satisfied customer enthusiastically lists the successes they have achieved with our barrels. This is why it’s worth doing; this is our true super driving force.
Toasting the Inside of the Barrel
The following lines are recommended for those dear enthusiasts who truly wish to delve into the mysteries of the barrel. For experimental winemakers curious about the reasons behind toasting and seeking answers, we will briefly share the accumulated experiences over the years.
The ability of our barrels to age wine depends on three factors:
1. How the staves are thinned.
2. The type of heating basket used.
3. Time and temperature.
How the Inner Surface of the Staves is Thinned:
1. Sawing: This method results in a surface that allows the flames to engage better, causing local charring and bubbling (this is not an issue, as it does not harm the wine in the barrel; according to foreign professional studies, in France, they sometimes ignite the inner wood surface of the barrel for a few seconds). Here, the toasting penetrates deeper, allowing the wine to age faster. The barrel imparts flavors more efficiently. This method is specifically recommended for red wines. To illustrate what this looks like in physical reality: running your hand over the sawed surface will feel rough, and splinters can easily catch in the hand. After toasting, the inner surface of the barrel appears dark brown or black.
2. Planing: This method results in a uniformly smooth inner surface. The staves are evenly planed. Here, the tongues of flame almost slide off, unable to catch on protruding wood fibers, thus allowing the barrel to achieve a lighter toasted color. When running your hand over the planed, sanded surface: it feels smooth and free of splinters. The toasting will not be as deep, and this method is specifically recommended for barrels intended for white wines. After toasting, the inner surface of the barrel appears brown, resembling mature oak or fawn.
The Types of Heating Baskets: We differentiate between three types of heating baskets:
1. Closed, Steel Cylinder: This yields a very even and light-toasted surface (comparable to the natural oak color, fawn, milk chocolate, etc.). Flames cannot escape from this type of heating basket. It is very closed, yet it emits heat strongly, allowing the barrel to shrink easily. Bubbling, surface cracking, and charring are entirely excluded. I emphasize again that wine entering such a barrel is not harmed at all.
2. Perforated Steel Cylinder: This provides an even toasting but darkens the toasted wood surface (dark brown, chocolate brown). We believe this is the most popular type of heating basket. It allows for good control over the temperature and flame tongue of the fire. The barrel's inner surface is not harmed, nor does it bubble, yet it colors and toasts well. Essentially, it is a closed steel cylinder with holes cut into it, allowing good heat release while keeping the flame tongues in check. It combines the best properties of the two extreme heating basket types.
3. Loose Grated Basket: Here, the barrel receives heat and flame almost directly (the inner barrel becomes very dark, black, chocolate brown). The fire scorches, and the heat release from the heating basket is high and immediate. Bubbling and surface damage may occur.
The Relationship Between Time and Temperature:
We have repeatedly mentioned the following data not by accident, as they are the driving force behind toasting. These are the most critical factors in the internal toasting of the barrel. For the sake of completeness, I will mention them again, as they complete the picture.
• Light Toasting (LT): 180-200 °C / 30 minutes, discoloration depth: 0-3 mm
• Medium Toasting (M): 200-220 °C / 30 minutes, discoloration depth: 3-5 mm
• Medium Plus Toasting (M+): 200-220 °C / 30 minutes, discoloration depth: 3-6 mm
• Heavy Toasting (HT): 280-300 °C / 30 minutes, discoloration depth: 5-9 mm
• Hybrid: 280-300 °C / 10 minutes and 180-200 °C / 30 minutes, discoloration depth: 3-8 mm
However, an important fact is that discoloration is not the same as toasting. A barrel’s interior can be very dark, but the depth of discoloration will only be revealed if we cut the stave in half.