How Jack Daniel's Whiskey and New Balance Sneakers Are Really Made | Made In America |Travel Channel

George Motz visits the historic Jack Daniel's distillery in Lynchburg, Tennessee, to break down the production steps of classic Tennessee whiskey. For culinary professionals, this process provides an instructive study in grain chemistry, sour-mash fermentationFermentationA biological process in which microorganisms transform sugars and other compounds, creating acidity, gas, alcohol or complex flavours., and natural filtration techniques. The whiskey begins with a precise mash bill of corn, rye, and malted barley, mixed with iron-free cave spring water. Maintaining this specific grain ratio is crucial to establishing the sweet, robust baseline profile of the spirit. ## The Chemistry of Sour Mash and Fermentation. The fermentation stage relies on a sour-mash technique, where a portion of the spent mash from a previous distillation is introduced into the new batch. This process controls bacterial growth and maintains a consistent pH level, ensuring the yeastYeastA microorganism used to ferment sugars and produce carbon dioxide, particularly in bread-making. performs optimally. For chefs who work with sourdough starters or fermented foods, this is a prime example of lactic acid management in action. The mash ferments for several days before heading to copper column stills, where heat vaporises the alcohol, separating it from the water and grain solids to produce a clear, high-proofProofTo allow yeast-leavened dough to ferment and rise before baking. spirit. ## The Lincoln County Process. What separates Tennessee whiskey from bourbon is the charcoal-mellowing step, traditionally called the Lincoln County Process. Before entering the charred oak barrels for agingAgingHolding an ingredient under controlled conditions to develop flavour, tenderness or other desirable characteristics., the unaged spirit is slowly dripped through ten feet of sugar maple charcoal. The distillery burns raw sugar maple wood on-site to produce this charcoal. This filtration process physically absorbs bitter compounds and heavy congener oils, resulting in a cleaner, smoother liquid. Understanding this mellowing process explains why Tennessee whiskey acts as such an excellent glazeGlazeA shiny coating applied to food to add flavour, colour, moisture or visual finish. base or deglazing liquid. Because the harsh edges have been filtered out, the spirit introduces clean caramel and woody notes to sauces without overwhelming the palate with raw alcohol burn. Additionally, the final maturation in toasted and charred virgin American oak barrels extracts wood sugars, providing the deep amber colour and distinct toasted-oak finish that chefs rely on to balance heavy fats and smoke in the kitchen.