Gin Production

How is gin made? From choosing the base alcohol to selecting botanicals, and from distillation to bottling, here’s a quick journey through all the stages of gin production—where traditional techniques, modern innovations, and the importance of botanical aromas come together.

 

Base Alcohol

The gin production process begins with the base alcohol, which, according to EU regulations, must consist of ethyl alcohol of agricultural origin, with a minimum alcohol content of 96% ABV (in the US, the minimum is 95% ABV). Unlike other spirits, such as whisky (which must be made from barley) or bourbon (which requires at least 51% corn mash), gin regulations are more flexible. In fact, any fermentable ingredient can serve as the base for gin distillation. This allows for a wide range of base ingredients, each contributing its own characteristics. Here are the most common:

• Wheat & Corn: Ideal for bold, spicy gins, offering a clean canvas with a touch of sweetness.

• Malted Barley: Imparts a malty flavor with subtle hints of juniper, anise, and fennel—reminiscent of young, unaged whisky.

• Rye: With a viscous and oily texture, rye adds softness and herbal notes, with a spicy, peppery finish.

• Oats: Perfect for floral botanical gins, oats add a creamy texture and smooth body.

• Sugarcane: Gives a velvety, viscous mouthfeel and a soft, rich palate.

• Potatoes: Deliver a creamy and smooth texture with delicate floral and fruity notes, finishing long and rounded.

• Rice: Offers a juicy, fruity character, with a light yet slightly gritty texture.

• Grapes: Add a juicy, enveloping mouthfeel with balanced smoothness and notes of dried fruit and floral nuances.

• Apples: Provide a gentle acidity, contributing fresh and vibrant notes.

Botanicals

The heart of gin lies in the botanicals that shape its aromatic profile. Every distiller seeks a signature aroma that makes their gin unique and unmistakable. Juniper, the small bluish-green berry that gives gin its name, is the only essential ingredient. Beyond that, the possibilities are endless: herbs, fruits, spices, roots, and barks—all offer infinite combinations and spark creativity, resulting in gins with distinctive, captivating personalities.

To give gin its botanical flavors, aromatization is necessary and can be achieved in several ways:

Maceration Aromatization: This method involves soaking botanicals directly in neutral alcohol for 24–48 hours. They may be placed in cotton bags or added directly to the alcohol. The mixture can be filtered—or not, depending on the desired intensity before distillation. This technique is ideal for deep, rich aromas, especially for complex botanicals like roots, seeds, and barks that need more time to release their essence.

Infusion Aromatization: Botanicals are placed in a suspended basket inside the still or in a perforated chamber in the neck of the still. As the alcohol heats and generates vapor, it passes through the botanicals, extracting their aromas. The vapor is then condensed and collected. This method suits delicate botanicals like flowers, teas, and fruits that might lose potency through direct contact or prolonged maceration. It results in lighter, elegant, and refined flavors.

Most distilleries use a combination of techniques to achieve a balanced aromatic profile.

 

Distillation

Unlike other spirits, gin is typically re-distilled rather than distilled from scratch, except for gins classified by the EU as simply "gin" (often known as Compound Gin). Different types of stills are used in gin production, each shaping the distillate in unique ways:

Pot Still (Discontinuous Still): A traditional copper still with a boiler-shaped chamber where alcohol is heated until it vaporizes. Vapors travel up a narrow neck and are condensed back into liquid. Botanicals can be added directly or suspended in a bag for gentler flavor extraction. Once all the alcohol is vaporized, the still is cleaned and refilled for the next batch.

Column Still (Continuous Still): Ideal for large-scale production, this still operates continuously. It has a tall column with copper plates that purify the alcohol. It produces high-strength spirits and is often used to create the neutral alcohol that will later be flavored or re-distilled.

Carter Head Still: Designed in the early 1800s by James Carter, this still places the botanical basket outside the still, near the condenser. This unique setup allows for a gentler infusion of flavors, producing a more delicate gin.

Rotary Evaporator (Rotovap): Originally used in pharmaceutical labs, this mini-still works under vacuum pressure, allowing distillation at low temperatures. It's perfect for delicate botanicals that would degrade under heat. Botanicals are often added one by one for precise aroma extraction.

iStill: A modern, fully automated still controlled by software, capable of both pot and column distillation. Made of stainless steel, it can be fitted with copper parts to catalyze sulfur compounds. It also functions as a mash tun and fermentation tank. Loved by micro-distilleries for its precision and versatility.

 

Maturation

Unlike whisky, gin does not require aging, but many distillers let it rest for a period—anywhere from a few days to 5–6 weeks. This stabilization phase helps the flavors meld, especially when multiple botanicals are distilled separately.

For barrel-aged gins, however, a mandatory aging period applies—ranging from 3–6 weeks to 12 months or more. Duration depends on the distiller’s goals and the desired style.

 

Bottling

After resting, the gin is diluted to its final ABV using purified water. According to EU law, gin cannot be sold with an alcohol content below 37.5% ABV. Before bottling, many distilleries perform cold filtration to remove oily substances that could cause cloudiness, ensuring clarity in the final product.

Bottling takes place in a strictly hygienic environment to avoid contamination. Depending on the distillery's size, the process may be automated or done by hand.