Revolutionizing Barrel Toasting
For the first time, distillers and blenders now have the power to precisely control their toasting process. At ZAK Cooperage, we’ve moved beyond the traditional light, medium, and heavy options. Our new state-of-the-art toasting unit provides unprecedented control over time and temperature exposure, ensuring repeatable and consistent results with every barrel.
Traditional methods of toasting over wood fires are notoriously difficult to control, leading to inconsistent finishes. Other modern units often only utilize timers, limiting their effectiveness. Our advanced technology addresses these challenges, giving you the ability to fine-tune the toasting process to achieve your desired flavor profile.
We are actively enrolling distillers in our collaborative toasting program to help them achieve the best toasted barrel finishes. This innovative approach not only enhances the quality of the final product but also allows for greater experimentation and customization.
Experience the future of barrel toasting with ZAK Cooperage and take your spirits to the next level.
Integrated Infrared Technology
At ZAK Cooperage, our state-of-the-art Dynamic Toasting Unit redefines the art of barrel toasting with unmatched precision and innovation. Powered by a cutting-edge PLC (Programmable Logic Controller) system and multiple high-precision sensors, our advanced technology provides meticulous control over temperature, time of exposure, and multiple toasting phases. This allows us to target specific oak compounds to unlock a diverse range of flavors and aromas, tailored to elevate the unique character of your spirits.
Key Features of Our Dynamic Toasting Unit
- Precision Control: Our PLC system manages every parameter, ensuring precise temperature regulation, time of exposure, and even heat distribution across each stave.
- Multiple Phases of Toasting: Designed to incorporate multiple toasting phases, targeting specific oak compounds such as vanillin, lignin, and hemicellulose to create desired flavor profiles.
- Real-Time Feedback: Sensors continuously monitor and adjust the process in real-time, maintaining optimal conditions for consistency across every barrel.
- Customizable Profiles: Toasting options are fully customizable, allowing us to cater to unique spirit profiles such as vanilla-forward bourbons, caramel-rich rums, or spicy rye whiskeys.
- Targeted Compound Activation: Highlights specific oak-derived flavors, such as vanilla, caramel, honey, spice, and toasted almond.
- Efficient Heat Management: Even heat application ensures uniform penetration into the oak layers, reducing inconsistencies and enhancing flavor extraction.
Dynamic Toast Profiles
- Honeyed Oak: Low Temperature, Short Exposure – Light, sweet flavors of honey and fresh oak.
- Toasted Almond: Low Temperature, Medium Exposure – Toasted almonds and hazelnuts with a creamy undertone.
- Vanilla Essence: Low Temperature, Long Exposure – Smooth vanilla flavor with subtle caramel notes.
- Fruity Delight: Low-Medium Temperature, Long Exposure – Fruity esters with notes of dried fruits and subtle sweetness.
- Caramel Harmony: Medium Temperature, Medium Exposure – Rich caramel flavor with hints of toffee and butterscotch.
- Buttered Biscuit: Medium Temperature, Long Exposure – Flavors of buttery, baked goods with light spices.
- Spice Medley: High Temperature, Short Exposure – Spicy, peppery notes with a touch of smokiness.
- Dark Chocolate: Medium-High Temperature, Medium Exposure – Dark chocolate notes with hints of coffee and cocoa.
- Smokey Ember: High Temperature, Long Exposure – Deep, intense smokiness with charred wood notes.
