
Making bourbon at home is a complex process that involves several steps, including mashing, fermenting, distilling, ageing, blending, and bottling. While it is legal to make a bourbon mash in the United States, distilling bourbon at home, even for personal consumption, is illegal without the proper permits. In Australia, however, home distilling is permitted, and enthusiasts can create their own bourbon using a variety of recipes and techniques. This introduction will explore the process of making bourbon at home in Australia, covering the necessary ingredients, equipment, and steps to produce a high-quality spirit.
| Characteristics | Values |
|---|---|
| Grain Bill | 7.5 kg cracked corn, 2 kg malted barley, 1.9 kg malted wheat, 2 x 3 g dried enzyme packets |
| Mashing | Add 40 L water and 3 L backset to boiler, boil at 100°C, add 20 L boiling water to mash tun, ramp temperature to 75°C for mash out, sparge with 9.7 L water, boil for 30 minutes |
| Fermentation | Use yeast such as SafSpirit American Whiskey yeast or a derivative of M-1 Whisky yeast, ferment at 20-35°C, leave to stand for 1-2 days, distil wash |
| Ageing | Dilute to 62.5% ABV with high-quality water, age for at least 9 months, preferably 12 months, use charred oak dominoes |
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What You'll Learn

Fermentation
To make bourbon at home in Australia, the fermentation process is a crucial step. Here is a detailed guide on how to perform this step:
Firstly, understand the role of fermentation in bourbon-making. Fermentation is the process by which sugars are converted into alcohol through the action of yeast. In the context of bourbon, the sugars come from the starch in grains, primarily corn. The fermentation process will determine the alcohol content and influence the flavour of the final product.
Now, prepare the ingredients and equipment for fermentation. The grain mixture, or "mash bill," must contain at least 51% corn, with the rest being a combination of grains like malted barley, rye, or wheat. Ensure you have the necessary equipment, including a fermenter (a vessel to hold the mixture during fermentation), a thermometer, and a sanitising solution to prevent contamination.
Next, create the sugar solution. This involves "mashing," which is the process of converting starch in the grains into sugar. Combine your grain mixture with water and heat it to a specific temperature range, typically between 140-160°F (60-71°C), to activate the enzymes that convert starch to sugar. You can adjust the temperature within this range to favour the production of shorter-chain sugars that are more easily fermented by yeast. Constantly stir the mixture to prevent scorching and maintain even heating.
Then, add yeast to begin fermentation. Cool the sugar solution to an optimal temperature range of 20-35°C (68-95°F) for fermentation. Add yeast to the mixture, ensuring it is a strain suitable for bourbon fermentation, such as those used by traditional bourbon makers. The yeast will consume the sugars and produce alcohol, releasing carbon dioxide in the form of bubbles.
Finally, monitor the fermentation process. Keep the mixture within the optimal temperature range and regularly check the airlock and specific gravity to track the progress of fermentation. Fermentation is complete when the airlock stops bubbling and the specific gravity remains stable for two consecutive days. At this point, allow the mixture to stand for another 1-2 days for any remaining solids and yeast to settle, and then proceed to the next step of distilling your bourbon.
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Distillation
Distilling is a crucial step in the bourbon-making process. It involves separating the alcohol from the fermented mash, and it must be done with care and precision. In Australia, distilling spirits at home is illegal, so it is important to understand the local laws and regulations before attempting to make bourbon at home.
The first step in distilling bourbon is to prepare the fermented mash for distillation. This involves ensuring that fermentation is complete, which can be determined by taking a specific gravity reading; a reading of 1.010 or less indicates that fermentation is likely complete. Once fermentation is complete, the wash should be left to stand for 1-2 days, allowing any remaining solids and yeast to settle.
The next step is to siphon the wash into a still, carefully leaving behind the sediment. This process is important to ensure that the final product is not contaminated or affected by the sediment. The type of still used can vary, but a pot still or non-reflux column still is generally recommended for bourbon.
During distillation, the wash is heated, and the alcohol vapours are collected and condensed back into a liquid form. This liquid, known as the distillate, will have a higher alcohol concentration than the original wash. The distillate is then collected and prepared for the next steps, which include proofing and ageing.
The proofing process involves adjusting the alcohol content of the distillate to the desired level. For bourbon, the alcohol content should be between 100 and 125 proof. This can be achieved by adding water to dilute the distillate to the desired alcohol percentage.
Ageing the bourbon is the final critical step in the process. It involves storing the bourbon in an oak container, such as a barrel or using oak sticks, to impart colour, flavour, and aroma to the spirit. The oak should be charred, either purchased in this state or charred by the distiller themselves. The ageing process can take anywhere from nine months to two years or more, with longer ageing periods contributing to a smoother, more complex flavour profile.
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Ageing
Aging is a critical process in developing the flavour and quality of bourbon. Here is a detailed guide on how to age your bourbon at home in Australia:
Water Quality
When preparing your bourbon for ageing, it is essential to use high-quality water. Bottled spring water or rainwater is recommended, while filtered tap water should be avoided. Dilute your bourbon to 62.5% alcohol by volume (ABV) with your chosen water source. This ABV limit is crucial as bourbon introduced to the barrel at a higher strength may negatively impact the ageing process.
Oak for Ageing
For ageing, it is recommended to use charred oak dominoes, with two dominoes per 4.5 litres of 62.5% ABV product. Toasting or charring the oak yourself can enhance the flavour profile, as bourbon barrels are typically toasted before being charred. Alternatively, you can purchase oak that has already been prepared for ageing.
Age your bourbon for a minimum of nine months, with a preference for 12 months to achieve a well-balanced flavour profile. While shorter ageing times are possible, it may result in an overpowering oak flavour. If you opt for a shorter ageing period, adjust the recipe accordingly by reducing the amount of oak used.
You can age your bourbon in a 6-8 litre medium-toast oak barrel, either new or previously used for whisky. Alternatively, you can use a glass container with one oak stick per half-gallon, ensuring the oak is well-seasoned to remove tannins.
If you plan to label your bourbon as "Straight Bourbon," it must be aged for a minimum of two years. Any bourbon aged for less than four years must include the duration of ageing on the label, stating the age of the youngest whisky in the bottle.
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Blending
Firstly, it's essential to have a clear understanding of the flavour profile you want to create. Consider the specific flavours and aromas you're aiming for, such as a balance between sweetness, oakiness, spice, and fruitiness. This vision will guide your blending process, helping you select the right whiskeys and adjust their proportions accordingly.
When blending, start with a small number of barrels, typically two or three, and gradually increase the number as you become more experienced. Each barrel will contribute unique characteristics due to variations in aging, wood type, and other factors, so blending is an art that requires careful consideration and experimentation. Always use a measuring device, such as a graduated cylinder or a measuring cup, to ensure precise measurements during the blending process.
Begin by tasting each whiskey individually, taking note of their distinct flavours, aromas, and overall intensity. Look for whiskeys that complement each other, perhaps one with a strong, bold character and another with a softer, more subtle profile. Gradually add small amounts of one whiskey to the other, diligently recording the ratios as you go. This meticulous approach allows you to fine-tune your blend, ensuring a harmonious marriage of flavours.
During the blending process, pay close attention to the proof of your whiskey, as this will impact the final product. The proof affects the flavour, mouthfeel, and overall balance of the bourbon. You can adjust the proof by adding small amounts of distilled water to lower it or incorporating a higher-proof whiskey to increase it. However, be cautious and precise with these adjustments, as they can significantly influence your bourbon's character.
Finally, always let your blend rest after blending. This resting period, ideally for a few weeks, allows the whiskeys to integrate and harmonise, smoothing out any discordant notes. Conduct regular tastings during this maturation to ensure your desired flavour profile is achieved and make minor adjustments if needed. Blending is a patient art, and you may need to experiment with different combinations to craft an exceptional bourbon.
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Bottling
Once you have distilled your bourbon wash, it's time to proof it. The proofing process involves bringing the alcohol content to between 100 and 125 proof. It is illegal to introduce bourbon into a barrel at a proof higher than 125. Many say that 100 proof is ideal.
To proof your whiskey, put it in a glass container and use one oak stick per half gallon to age it. The oak should be well seasoned to remove a large percentage of tannins. You can char the oak yourself or purchase oak that has already been prepared for the aging process.
After proofing, you will need to age your bourbon. For a superior product, age your bourbon in a charred oak barrel for at least 9 months, preferably 12 months. If you are going to age for a shorter term, you may want to reduce the amount of oak to prevent an overpowering oak infusion.
Once the aging process is complete, you are ready to bottle your bourbon. Bottle your bourbon once it has reached your desired proof.
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