Cooperage
Present in over 30 countries, Tonnellerie Saury meets strict control criteria to guarantee consistent quality and expertise. Each barrel undergoes rigorous quality control at every stage of production.
THE STAGES OF BARREL MAKING
01 - Reception, inspection, and sorting of the staves
01 - Reception, inspection, and sorting of the staves
02 - Backing
02 - Backing
03 - Tapering
03 - Tapering
04 - Hollowing
04 - Hollowing
05 - Inclination
05 - Inclination
06 - Raising the barrel
06 - Raising the barrel
01
Reception, inspection, and sorting of the staves
Once seasoned, the staves are sorted according to their grain before entering the cooperage.
02
Backing
This consists of planing the exterior face of the stave to create a slight curve.
03
Tapering
This is when the stave is given is conical shape.
04
Hollowing
The interieur of the stave is hollowed out slightly to facilitate bending.
05
Inclination
The ends of the staves are shaved to form a sloping edge.
06
Raising the barrel
The staves are raised in a circle with the help of hoops, using pressure to flex the wood.
This tension, calculated according to the limit of elasticity of the wood, also comes into play at the next stage of bending.
Quality processes
07. Two methods of pre-heating
Traditional
With traditional pre-heating, the Saury oak barrel staves are bent after having been raised in a circle, over a wood fire, with superficial humidification.
This highly delicate stage calls on all the fine skills of the master cooper.
A study into the impact of this method of bending undertaken by the Exact Laboratory in 2014 revealed a 49% reduction in ellagintannins after traditional bending. Traditional barrels therefore give wines structure, density and depth, with greater aromatic complexity and elegance.
Immersion
First developed by the Saury cooperage in 2000, the immersion technique consists of first soaking the raised barrel in extremely hot water.
Once taken out, the staves are bent and undergo classic toasting, M, M+, or Lumière depending on the qualities desired. During immersion, the water penetrates deep into the wood, rinsing it of its harsh tannins.
- Fruit, tannic structure, freshness.
- Vanilla, smoothness, generosity
- Ripe fruit, toasted notes, richness
- To facilitate bending
- The extraction of hydro soluble polyphenols responsible for astringence and bitterness.
- Gentle toasting to the heart of the wood thanks to the heat transfer properties of water.
Traditional
08. Toasting
Traditional
This procedure brings out the aromatic molecules present in the oak which will develop as the staves mature.
The barrels are placed over braziers, whose fires are fed by oak offcuts from production, and turned several times to obtain an even toast, without the flame ever coming into direct contact with the wood.
It is a crucial stage during which the oak will reveal all its organoleptic qualities.
The differents levels of toast
- Light
- Lumière
- Lumière +
- Medium
- Medium+
- Heavy
- Burgundy
09 - Chiming
09 - Chiming
10 - Bunghole
10 - Bunghole
11 - Making the heads
11 - Making the heads
12 - Attaching the heads
12 - Attaching the heads
13 - Testing
13 - Testing
14 - Finishing (sanding and changing of hoops)
14 - Finishing (sanding and changing of hoops)
09
Chiming
This is when each end of the barrel is cut to make the chime, (chamfered end of the barrel) the howel (a concave cut below the chime), and the croze (a narrow groove that holds the heads of the barrel.
10
Bunghole
After having been pierced it is cauterized with a hot iron rod, which smooths the interior of the hole and ensures it is watertight when the bung is in place.
11
Making the heads
The ends of the barrel, or heads, are composed of staves assembled by tongue and groove. The edges are then bevelled to ensure a good seal with the croze.
12
Attaching the heads
The cooper then loosens the head hoops and attaches each head to the barrel with the help of lag bolts after applying a waterproof seal made of flour and water around the howel.
13
Testing
Before passing to the final stage, the cooper tests the barrel for impermeability by filling it with water and injecting air under pressure to simulate fermentation. The barrel is tested once more before being approved for finishing.
14
Finishing (sanding and changing of hoops)
Classic finish : galvanized hoops, laser engraving.
Special Finish : black hoops, chestnut hoops, head bars, laser engraving, client logo.