Rye Whiskey Mash

Mash In and Liquefy (Approx. 90 minutes)

• In a large pot (at least 8-10 gallons), heat 5 gallons of chlorine-free water to 165°F (74°C).
• Turn off the heat. Slowly stir in the flaked rye and flaked corn, mixing vigorously to prevent clumps from forming.
• Check the temperature; it should stabilize around 155°F (68°C).
• Stir in the alpha-amylase enzyme. This enzyme begins breaking down the long starch chains.
• Hold this temperature for 75-90 minutes, stirring every 15 minutes to prevent scorching. The mash will thin out considerably as the starches liquefy.

Convert Starches (Saccharification) (Approx. 60 minutes)

• Allow the mash to cool naturally to 148°F (64°C). You can speed this up by adding the remaining 1 gallon of cool water if needed.
• Once at temperature, vigorously stir in the crushed malted barley and the glucoamylase enzyme.
• Hold the mash between 145-148°F (63-64°C) for 60 minutes, stirring occasionally. The natural enzymes in the barley and the added glucoamylase will convert the liquefied starches into fermentable sugars.

Cool the Mash (Approx. 30 minutes)

• After the 60-minute conversion rest, you must rapidly cool the mash down to 75-80°F (24-27°C).
• The most effective method is using a sanitized immersion chiller. Alternatively, you can place the covered pot in an ice bath in a sink or large tub.
• Cooling quickly minimizes the window of opportunity for airborne bacteria to contaminate your sugary mash.

Pitch Yeast and Begin Fermentation

• Carefully transfer the cooled mash into your sanitized fermenter. Splashing during the transfer is beneficial as it introduces oxygen, which the yeast needs for its initial growth phase.
• If you have a hydrometer, take a specific gravity reading now. It should be between 1.060 and 1.070.
• Sprinkle the distiller's yeast and optional yeast nutrient evenly over the surface of the mash.
• Seal the fermenter and attach an airlock filled with sanitizer or vodka. Place the fermenter in a dark place with a stable ambient temperature around 70-75°F (21-24°C).

Monitor Fermentation (5-10 days)

• You should see active bubbling in the airlock within 12-24 hours. This is CO2, a byproduct of fermentation.
• Allow the mash to ferment undisturbed for 5 to 10 days.
• Fermentation is complete when the airlock bubbling ceases and the specific gravity reading is stable for two consecutive days (typically around 1.005 - 1.010).
• The mash, now called a 'wash', is ready for distillation.