How Oak Barrels are Made

A Tour Inside Vicard Cooperage

Oak barrels play an important role in the production of wine and eau de vie. Go inside Vicard Cooperage in Cognac, France for a look at how barrels are made.

The process of making a barrel starts with the oak tree. Seventy five percent of Vicard’s barrels are made with French oak; 20 percent are made with American oak and 5 percent are Hungarian or Romanian oak. Only thirty percent of the trunk is used for barrels.

The logs are sprayed with water to maintain the level of humidity and to keep bugs away.

To make the staves, the log is split into quarters. Following the natural lines of the wood, the oak is carefully cut into planks. The wood is laid in a pattern for aging and placed outdoors for two to three years. The exposure to sun, wind and rain seasons the wood and eliminates the undesirable tannins.

To assemble the barrel, the staves are placed inside a metal hoop. Using steam and force the wood is pulled into the recognizable shape of a barrel. More hoops are then placed on the wood to maintain the shape.

Toasting the barrel is very important as the amount of toast affects the flavor of the wine inside. Vicard uses computerized technology to monitor each barrel and to ensure the ideal toast profile.

As the finishing touches are put on the barrel, the metal hoops are adjusted or removed. The round ends are inserted and carefully fit into place. The wood is sanded and new metal hoops are placed on the barrel.

The final step is to add the logo. Using a computerized system and lasers the image is burned into the wood.

Vicard produces 55,000 barrels each year.

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