Question: 1. Create a Flowchart for the whiskey process Whiskeys have different names depending on the composition of the grain mash. Bourbon whiskey, the kind made

1. Create a Flowchart for the whiskey process

Whiskeys have different names depending on the composition of the grain mash. Bourbon whiskey, the kind made by Ranger Creek, has to be made from mash that consists of at least 51 per cent corn. Other kinds include corn whiskey (at least 80 per cent corn), malt whiskey (at least 51 per cent malted barley) and rye whiskey (at least 51 per cent rye). The milling batch size for a case of whiskey was 1,600 pounds, and mashing proceeded similarly to beer brewing, but since the mash was heated at higher temperatures, it took four hours to be ready, after which it took two and a half hours to cool off to fermentation temperature. After the mash was cooled down, it was transferred to the fermentation tank, inoculated with yeast and fermented for three days, after which the mixture of grain and liquid was boiled and distilled in a tall copper still whose column was filled with perforated plates. Legally, once the yeast was added and alcohol was formed, whiskey and beer products each had to be stored in dedicated containers that could not be shared with the other products process. This explains why at Ranger Creek bourbon had its own dedicated fermentation tank. Every distillation batch took around 15 hours. A vapour with high alcohol content was produced from the top of the still and cooled by room-temperature water to turn it back into a liquid state. The first portion of the distillate was called heads and was discarded. The middle portion was called hearts and was the bulk of the volume, and the last portion was called tails and was eventually recycled into new batches. The entire first distillation was called low wines. In the first distillation, 225-gallons were obtained from the original 930-gallon fermented mash, together with 65-gallons of heads and 75-gallons of tails. At Ranger Creek, the whiskey was distilled twice and the second time the distillation process took seven hours. Double distilling seemed to be the norm for bourbon production, although there were some whiskeys with single or triple distillation. About 200-gallons of 140-proof alcohol were obtained after the second distillation. After the alcohol was distilled for the second time and the cuts were made, the hearts were diluted with water to 120 proof and filled in charred oak barrels for the maturation process. The barrels were placed on one of two shipping containers, where each container held 200 5-gallon barrels or 24 53-gallon barrels. In the maturation process, the temperature fluctuations during the day and night made the liquid seep into the oak wood and extract various aromatic compounds that yielded distinctive flavours. Though maturation took four to six years in Kentucky, smaller barrels and the heat of Texas made bourbon ready for bottling in about one year. When the bourbon was ready to bottle, it had lost about 30 per cent of its original volume due to evaporation. The lost portion was sometimes called the angels share. The bottling was done by a simple gravity tank, and took three hours to set up and six hours to fill 100 cases, with each case being 12 375-millilitre bottles. Obtaining manpower for labeling was difficult, because it presented a localized demand of several workers, and Ranger Creeks strategy so far had been calling for volunteers who could donate four hours of their time to help label bottles and in return obtain a plant tour and Ranger Creek merchandise.

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