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 cooked for hours in our mash cooker in order to break the sugars down into smaller versions that the yeast prefer. The mash is then cooled to the ideal temperature, and distillers yeast is then pitched into the mash. 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.
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.

In the early days, we would separate the liquid from the grains - trying our best to recover every drop of alcohol. Now, with our new still, we are able to distill "on grain," reflecting our commitment to efficiency and minimizing waste.
Our new still is the perfect combination of a pot still, a reflux column and a glass doubler that is so beautiful that you will have to see it to believe it.
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.
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.