How are sherry whisky casks made?

We were lucky enough to be invited into the historic cooperage Paez Lobato in Jerez to discover how a sherry cask is made, from wood to whisky. These vessels, which are seen as the gold standard in the maturation of premium single malt scotch whisky, are a critical part of the whisky making process and a popular option for whisky cask investors.
This video lets us view every step in the making of a cask from the arrival of pallets of freshly cut oak from France to the delivery of the finished cask. Initially the wood needs to spend up to two years drying in the Andalusian sunshine. The wood is then converted into staves, flat planks of wood that are bent into the form of casks. After being attached to copper collars, the staves are then ‘toasted’ with flames to char the inside of the cask, an essential part of the process to ensure the proper maturation of the spirit. The cask is dampened with water and then begins to take shape. A machine is used to attach the rest of the collars and the cask tops are added. The process is still largely done by hand and has remained unchanged for centuries.
Paez Lobato is a third-generation family business in the heart of Jerez, that produces an extraordinary amount of casks for the world’s largest whisky makers. The video is narrated by Señor Paco Lozano, who has worked at Paez Lobato for over forty years and was enjoying his last week at the company before a well-deserved retirement.

[@andybrown6793]

An excellent video, very informative and Pablo comes across as a really interesting guy. His English is great too!

[@KarlWhitfield]

Absolutely fascinating, thank you.

[@sikhpilot.]

What is the result of an untoasted cask on ageing sherry and later on whisky. Does it make a big difference to the flavour? Positive or negative.

[@kobiemelverton2231]

you wouldn't get very much, if at all colour and flavour to your whisky. the toasting caramelises the compounds on the wood which impart the signature dark colour and aged taste to your whisky.