The fabrication process of Dad's Hat Pennsylvania Rye Small Batch Whiskey begins with a careful selection of grains, with rye being the predominant ingredient, complemented by malted barley and corn. This unique grain bill contributes to the whiskey's signature spiciness and depth of flavor. The grains are ground into a coarse meal and mashed to convert the starches into fermentable sugars. Yeast is then added to this mixture, kicking off fermentation, which typically lasts several days, resulting in a beer-like wash.
Once fermentation is complete, the wash is distilled in small pot stills, allowing for greater control over the distillation process and a more nuanced flavor profile. The distillation is conducted in two stages to create a high-quality spirit that captures the essence of the grains used. The resulting distillate is then transferred into new American oak barrels, which are charred to extract flavors from the wood, such as vanilla and caramel.
The whiskey is aged for a minimum of three years, during which time it develops its character through interaction with the wood, as well as through evaporation, known as the angel's share. After aging, the whiskey is carefully blended, filtered, and bottled, ensuring that every batch has consistent quality while still preserving the unique qualities from each barrel. This meticulous attention to every step ensures that Dad's Hat Pennsylvania Rye resonates with both history and craftsmanship, appealing to rye whiskey aficionados everywhere.