Our Process

At Irons One, every step of the whiskey-making process is handled with care, precision, and a nod to tradition. One key part of the operation is the use of antique scales, which were rescued from a local shop. Once rusty and neglected, these scales were restored and cleaned. They now serve as a vital tool in measuring the grains for each batch of whiskey. Remarkably accurate, these scales ensure the precise ratios of corn, rye, and barley that are mixed with locally filtered water during the mashing process.
During mashing, the grains are thoroughly combined to achieve a uniform consistency. A stainless steel food mixer, powered by a drill, ensures there are no clumps in the mash. Once the mixture has cooled, it is aerated and brought to the ideal yeast pitching temperature. At this point, specially selected whiskey yeast is added to begin fermentation.
Fermentation is a weeklong process during which the sugars in the mash are converted into alcohol, creating what is known as "distillers beer"—a mixture that contains about 8-10% alcohol.
The next step involves separating the liquid from the grains, a process that ensures maximum liquid recovery. The grains are pressed to squeeze out every possible drop of liquid for distillation, a step that reflects the commitment to efficiency and minimizing waste.

The distillers beer is then transferred to the still, where the magic of distillation takes place. The process involves collecting the distillate in three segments: the heads, the hearts, and the tails.
During the run, the distillate flows through the "parrot" and into the "spirit safe," where the alcohol proof and temperature are closely monitored to maintain quality and consistency.
Specific gravity readings are taken both before and after fermentation to measure the alcohol content and assess the success of the process. These precise measurements are critical in producing a consistently high-quality product.
From restoring antique scales to carefully monitoring every phase of production, the Irons One team’s attention to detail ensures that every bottle reflects the dedication and craftsmanship poured into the distillery’s operations. This blend of tradition, precision, and passion is what sets Irons One whiskey apart.