Walking into the cooperage at Ch. Smith Haut Lafitte is like stepping back in time, filled with the smell of seasoned wood, an open fire and the same tools that barrel-makers have used for centuries. Few estates have the luxury of an in-house cooper. While producers inevitably work closely with the tonnelleries (barrel-making firms, such as François Frères, Stockinger and more), having an artisan on-site, working alongside the winemaking team to craft casks exclusively for your specific terroir is different. “It’s very important for the precision of the wine,” explains Cellar Master Yann Laudeho.  Florence and Daniel Cathiard, owners of the Pessac-Léognan estate, built a cooperage on-site almost 30 years ago, in 1995, and their current cooper, Yann Dez, has been working here since 2021. The Bordeaux native’s father was a metal worker, and Dez fell into the world of barrel-making entirely by accident – having a friend who was a tonnelier, and a job opening at an opportune moment. Before he knew it, Dez had learnt the trade from some of the best coopers in the country (including one who now makes the barrels at Ch. Margaux), and spending 15 years working under Didier Fesil. Fesil was the Cathiard family’s first cooper back in 1995, who went on to create his own small tonnellerie (Tonnellerie Bordelaise), and has been named the nation’s best “Master Cooper” – twice. Indeed, Fesil is still very involved with the estate, helping choose the wood for barrels and advising on all things oak; and it was Fesil who put Dez forward for the role at Smith Haut Lafitte.  “There are no books,” Dez says, when I ask about the art of barrel-making. “It’s passed on from tonnelier to tonnelier." The first evidence of coopering as a trade dates back to 900BC – with the craft passed down the generations ever since. “I continue the tradition,” Dez says, clearly with a sense of pride in this ancient, artisanal skill. But with the dust, noise and physical labour involved, tonnellerie schools, Dez tells me, are struggling to recruit young people. It’s common for coopers to have issues with their shoulders and ears (from the non-stop hammering) – and Dez himself has broken an elbow.  In theory, the process can be mechanised – but Dez is clear on how important it is to work by hand, and not just to preserve this ancient art. “I hear the nose, I feel the resistance,” he says. Each barrel, he explains, is different – with a slightly different number of staves and slightly different shape, all adapted according to the wood he’s working with. Selecting the right wood is key – “reading” it, he explains, looking at the grain to see where potential weaknesses are, understanding where will take the most pressure and placing each stave accordingly, ensuring not a drop can seep from the finished barrel. “It’s a job that is both physical, and at the same time requires thinking,” says Dez – and this combination is much of its allure for him.  Hearing the way Dez talks about barrels is fascinating; for him, they each have a unique personality. When I ask Dez how he knows he’s made a really good barrel, he shrugs: “On le sent.” (“You feel it.”) As you toast a barrel, he tells me, the scent of the smoke changes, releasing different aromas – something I smell as he works in front of me. Knowing when it’s spent the perfect amount of time over the fire is the secret – and it’s about more than just the smell, it’s a gut instinct that he can’t quite explain.  Smith Haut Lafitte sources oak from a range of forests, and are always trialling wood from different forests, toasts and doing blind tastings, although – after over 25 years – they know what works for their wine, and terroir. Cellar Master Laudeho explains that, for him, Tronçais and Jupilles are the best – “diamonds” that flawlessly complement their site. And that balance is key; the wood works for the wine, not the other way around.  It seems like a lonely job, I comment, hammering away in his tower – but it’s not something that bothers him. “I’m a bit of a perfectionist,” he tells me. Having only himself to depend on, and knowing that he can ensure each barrel meets his exacting standards, suits him. Indeed, he doesn’t even settle for standard tools – making most himself, custom-designed to suit the way he works. He talks me through a specific hammer that he made, and how it allows him to work better and more precisely, the wooden handle almost silken from the hours of use, shaped to his hand.   The lone electronic technology to have earned a place here are noise-cancelling headphones and a Marshall speaker. He’s a musician in his spare time, and an additional perk of working alone is that he gets to spend all day listening to music. “All the barrels I’ve made,” he says, “are made with music.” He avoids anything too modern or electronic, favouring old jazz, with some reggae, ska jazz and funk in the mix, depending on the day. While he doesn’t feel the music he listens to influences his coopering, he suspects his mood does – and music is a big part of that.  Woodwork is much more than a job for Dez. I spy a beautiful chest alongside his speaker, and it’s one that he made. He has a workshop at home too, spending his free time making everything from guitar stands and toys to chandeliers – anything, he says, that isn’t straight, and therefore can’t really be done by a machine.  It’s amazing watching him work – in the same way as coopers have for centuries – with a natural intuition, ease and precision. There’s definitely something musical to it, a craft that has its own rhythm. He makes around 300 barrels a year, and they may not be soloists – but each one contributes their own note to that year’s symphony.  Explore all current listings of Ch. Smith Haut Lafitte or read more about Bordeaux 

Wooden barrels line most of the finest wine cellars around the world – and many are made by hand. Continuing our series taking you behind the scenes in Bordeaux, we ducked into the cooperage at Smith Haut Lafitte to find out more about this special craft

We visited Pessac-Leognan’s Smith Haut Lafitte to talk to the wine estate’s master cooper, Yann Dez – and find out all about the art of barrel-making

Meeting Smith Haut Lafitte’s Master Cooper

Working to the beat: Smith Haut Lafitte’s Master Cooper

Oak barrels have been used in winemaking for thousands of years. While initially their purpose was simply as a holding vessel, today it is much more than this. As we have learnt about wine production at a molecular level, we have discovered the unique interaction between oak and wine – adding flavour, textural complexity and increased ageing potential. These intrinsic qualities have seen oak at the forefront of fine wine’s greatest success stories – but also some of its greatest failures. The use of oak to improve a wine requires great skill and finding that balance has shaped the modern history of fine wine.  What is rather beautiful about winemaking, particularly in fine wine circles, is that despite the input from developments in science and technology, production remains an artisan craft, relying both on tradition and technology. The barrel-maker is a perfect example of this partnership and no one understands this better than François Frères. This lauded Burgundy cooper’s ties to the world’s greatest wines make it one of a very small number that have lived through the development and fashions within fine wine.  Today, business has never been better for François Frères; they produce 30,000 barrels a year and export to every major wine region in the world. The secret to the François Frères barrels historically, Gigandet believes, is their consistency, while the all-important signature toasting is paramount. To keep up with the ever-growing world of fine wine, François Frères produces tailor-made barrels that fit the varying climates and varying styles of each winemaker, meeting the standards set by today’s precision-led winemaking. Despite the growth of the business in recent years, François Frères still remains intrinsically linked to its homeland in Burgundy and the specific microclimate of Saint-Romain that is so important for the seasoning of their oak – another key factor behind the company’s success. “The microclimate of Saint-Romain, in a windy and pollution-free environment is ideal for the seasoning and drying of the oak. This oxidation of phenolic compounds under the influence of fungi, releases enzymes that hydrolyse the phenolic compounds, reducing the wood’s astringency, producing oak of the finest quality for wine production,” Gigandet tells me. The art of the cooper is much more than just sawing and toasting – it’s about sourcing, traceability, control of drying time and heating, hygiene, temperature control, sorting and more. With increased knowledge, the quality of the barrels, like that of the wines, has greatly improved. Even just a few years ago, Gigandet admits that in colder Burgundy vintages, sometimes their barrels jarred with the wine – they “brought too much tension and could sometimes seem too austere”. But now they have a better understanding of the qualities their barrels can bring to Burgundy: “François Frères barrels remain attractive to winemakers because they are great at retaining freshness and minerality.” Perhaps most importantly, François Frères wants its barrels to amplify a wine’s intrinsic qualities. “It wants to accentuate the beautiful tannic structure of a wine, contribute to its flavour but without excess of sweetness from the toasting, as well as amplifying the wine's tension and minerality, helping retain its freshness and its fruit,” Gigandet says. As technology has developed, so has François Frères. It is what Gigandet aptly calls “the evolution of taste” – “the cask has evolved considerably over the last few decades along with the quality of the wines. Today, the barrel is much more specific, manufacturing almost tailor-made barrels for each customer’s needs.” The business was founded by Joseph François in the early 1900s, never imagining that being a cooper would become a full-time job. Back then, Gigandet reminds us, “It took several trades to live.” But the next generation, Robert and Henri François, saw the demand for oak casks rise, at that time mainly used to transport wines. They took the operation full-time, creating the François Frères brand in 1942. In those days, as Gigandet points out, “The tradition of maturing wines in barrels was reserved only for the very top red and white wines of Burgundy and the great Bordeaux châeaux.” Even within these regions, barrels were a luxury, re-used year after year given their expense, therefore keeping the demand for new barrels low. By the 1960s the brothers were met by the development of stainless steel and plastic containers. The barrel quickly lost it supremacy as the preferred vessel for transportation and demand plummeted. It was only the top producers that helped keep the cooperage going. By the 1970s François Frères was producing barrels for one of the world’s most famous estates, Domaine de la Romanée-Conti – a partnership that would be instrumental in the continuation of the business through a difficult period. The next generation – Robert's son, Jean – was confronted by the economic downturn of the early 1970s and turned to export to save the family business. Fortuitously at this time, oenologists in the United States started to highlight how ageing wines in new oak barrels brought complementary flavours and complexity to the wines. In the 1980s, the French market caught onto the idea and both export and domestic markets grew. The oak barrel was entering an era where it would become the star of the show – and a must for all top producers. François Frères’s reputation for working with the best saw it perfectly placed to capitalise on this new-found love for the barrel. But according to Gigandet, it wasn’t just the fashion of using new oak in the 1980s and ’90s that saw such a huge increase in demand. This trend emerged just as wine exports exploded. What he calls “the democratisation of wine” saw the world of wine suddenly open up to the middle classes – and this increase in sales saw an ever-increasing need to maintain quality and improve consistency. Such demand prompted and funded a better scientific and technological understanding of wine production. More importantly for François Frères, it fuelled the need for a better understanding of what barrel-ageing does to wine – and why. It was already clear that contact with new oak changed wine profoundly. Most obviously the aromas and flavours of the wine develop, becoming more complex. These aromas and flavours are formed during the toasting of the barrels. “It is this toasting of the barrel that remains the signature of the cooper,” explains Gigandet. But the oak didn’t just impact the flavour, they came to understand that, being porous, oak allowed the wine to undergo “controlled oxygenation”. The exchange of air through the oak staves, in particular for red wines, helps stabilise the colour and polymerise the tannins. This polymerisation not only softens the wine, but brings a textural complexity, a millefeuille layering of mouth-feel brought about by the linking of long tannin chains, encouraged by the micro-oxygenation process that the wine goes through when aged in oak barrel. “François Frères barrels are ageing tools, which contribute to the textural improvement of wines, when used wisely,” Gigandet explains. As the wine world’s love of oak grew, François Frères’ main export customers went from little-known names to pioneers in their respective regions – with Robert Mondavi in the US, Angelo Gaja in Italy, Nicolas Catena in Argentina and Australia’s Rosemount winery. Each of these producers further cemented the cooper’s reputation, representing the very pinnacle of oak barrel production. Of course, like all fashions, the oak craze of the ’90s saw some extreme uses – 200% new oak ageing or an over-reliance on oak to provide flavour to wines that lacked the natural concentration to carry it. This saw many producers and consumers react strongly against its presence in wine at all. Even Gigandet admits that there are wines with “excess woodiness” to their detriment. Today, the barrel also has to compete with new trends in wine maturation – concrete eggs and clay amphorae, for instance. But while these new vessels have captured the imagination of the world’s top winemakers, it is not necessarily at the expense of the barrel. “The barrel has an important oenological role in the development of wines from certain grape varieties,” states Gigandet – notably Cabernet Sauvignon, Merlot, Syrah and Pinot Noir. But he also outlines how different ageing vessels combined can also benefit a wine’s potential for complexity. This is certainly the case amongst some leading producers in Bordeaux and Burgundy that are using both oak barrels and alternative ageing vessels. Coopers like François Frères have weathered the changing relationship wine has had with the barrel; with shifting views of critics and drinkers over the last century. Fortunately for fine wine lovers, there’s little sign of oak fading into the background. Oak remains a vital ingredient in many of the world’s greatest wines, adding to its flavour, textural complexity and – of course – ageing potential. Today oak has never been so deftly handled, bringing so much to a wine, while retaining the grapes’ natural expression. The art of the cooper lives on. Read more Editorial 

Oak has played a vital role in the changing history of fine wine. In 2021 we spoke to Max Gigandet – Managing Director of leading Burgundy cooper François Frères – to explore the power of a good barrel and why oak isn’t going anywhere

Exploring the vital role oak has played in the changing history of fine wine and the power of a good barrel with François Frères

François Frères on the art of the cooper

Finding the balance: the art of the cooper

Maturation, distillation and the base grain combine to give whisky its character. But – while it only takes a week from milling to filling a cask – the new-make liquid will spend years in cask, a minimum three for it to earn a Scotch whisky label, but often significantly longer. As the spirit lies in wait in a cool, dark cellar, flavour from the cask – and whatever the cask previously held – is imparted. It is believed that as much as 80% of the final style is determined during this time. Most would argue that it is this carefully monitored process that makes whisky such a fascinating and coveted liquid.  But the trend for transferring that whisky from one barrel to another is a relatively modern phenomenon. Cask finishing, wood-finishing, secondary, double or consecutive maturation are all names given to this process, whereby matured whisky is aged for an additional length of time in a second, different cask.   As is often the case with anything whisky-related, the process was pioneered in Scotland, but it has since found its way around the globe. In 1983, under the guardianship of David Stewart MBE, Balvenie launched Balvenie Classic.  Known today as Balvenie DoubleWood, it was one of the first Scotch whiskies to be matured in re-fill American oak casks before being transferred to first-fill European oak Oloroso Sherry butts. Around the same time, Glenmorangie was maturing whisky in Madeira casks. Its experiments led to inconsistent results and the team switched to Sauternes casks – and the Nectar d’Or was born. To this day, the Highland distillery is one of the biggest proponents of finishing – experimenting with casks that have previously held Port, American rye whiskey, PX Sherry and Sassicaia. Fast forward 40 years and some of the biggest names in the blended Scotch world have embraced cask finishing. Blends aged in rum, mezcal and Port casks have all been released in the past year, much to the delight of new and old whisky drinkers.  The rules surrounding this secondary practice are relatively fluid. As such, a cask-finished whisky could have spent anywhere from six months to two years maturing in a barrel that has previously held rum, red wine, Madeira, Port or even stout. The second stint in cask is generally intended to introduce new flavours that complement and enhance rather than dominate and overpower the spirit’s inherent character.   Many of the world’s leading whisky distilleries have embraced the trend, following in the footsteps of the likes of Balvenie and Glenmorangie. With the resulting whiskies regularly winning major awards, high scores and favour amongst consumers, the fashion for cask-finishing shows no sign of abating any time soon.   Explore our range of Scotch whiskies or read more Editorial 

Master distillers have been maturing whisky in oak barrels for centuries. While it is generally accepted that “the cask is king” and “the wood makes the whisky”, cask finishing – or second maturation – is a relatively new fashion. Here we look at what it is and why it matters 

Exploring why the process of cask finishing (secondary maturation or double maturation) can be so controversial in the whisky world.

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