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internally and are made from high quality oak, they are ideal for maturing
light flavoured Scotch – especially the faster maturing grain spirit. To facilitate
transport of empty casks, North American barrels were broken down into
bundles of staves (shooks) and then reconstituted, sometimes with the addi-
tion of an extra stave to create a ‘dump hogshead’. Availability of suitable oak
is now creating problems on both sides of the Atlantic, and since sherry wine
is not so popul ar as it once was, new solutions have proved necessary. Once a
cask is deemed to be ‘exhausted’, after a number of refills and prolonged
periods of maturation (up to 25 years), it can be mechanically scraped to
remove old ‘char’ and then re-charred and treated with imported bulk sherry
if necessary (Philp, 1989). With average maturations of between five and
twelve years for standard and deluxe blends respec tively, cask re-use can
now be extended almost indefinitely. However, shortages of suitable re-use
casks and wood for the coopering of new casks remain a concern within the
industry.
Blending of Scotch whiskey is a relatively new techno logy, given a history
spanning hundreds of years. Originally new-make wh iskey was consumed
straight from the still as a clear spirit somewhat similar to schnapps, and
was very erratic in quality. Early distilling must have been a hit-and-miss
affair, since there were no adequate measuring devices to aid process and
quality control, and so the variation in new-make spirit character must have
been equally hit or miss . The introduction of hydrometry, and in particular the
Sikes hygrometer in 1802, to measure alcohol strength did make distilling
more consistent. However, the whiskey merchant must have had great diffi-
culty in maintaining quality, and the only effective means he had was to mix
batches to create a consistent spirit char acter. The first blending operation was
not, however, a blend of grain and malt, but rather a mix of batches of a single
malt, and had to have approval by Customs & Excise. Andrew Usher was, in
1853, the Edinburgh agent for Glenlivet malt whiskey, and he is accredited
with producing this first vatted malt. Blending of grain whiskey with malt was
not given approval until 1860. It was from that date that the great brands of
blended whiskey flourished. The proportion of grain to malt, the specif ic dis-
tilleries used as the source of the spirit, the age of each malt and grain whiskey,
and the type of wood used for matur ation gave the blender an almost infinite
number of combinations to create a unique blend. The recipes for the most
successful blends are closely guarded secrets, so it comes as a surprise to
outsiders to find that individual brand companies swap or ‘reciprocate’ malt
and grain whiskies with one another. However, internal trading is regarded as
one of the strengths of the industry, giving the blender a much wider scope in
selecting appropriate malt and grain characters for a wider range of products.
Packaging of Scotch whiskey has always been an important aspect of mar-
keting and of presenting the consumer with an image of the highest quality.
For more than a century the industry has promoted ‘bottled in Scotland’ as a
means of maintaining the exclusivity of the product, so preventing counter-
feiting and bulk blending of Scotch with locally distilled spirit. In contradic-
tion to this, Scotch was originally sold to British publicans in bulk, and the
spirit had then to be decanted into large glass decanters that usually sat in a
Chapter 1 History of the development of whiskey distillation 13