Check out this not-so-brief history of tequila (written by ian chadwick and stolen
from the web (http://www.ianchadwick.com/tequila/production.html)
by me.
The making of tequila: from blue agave to golden liquid
Tequila is not made from the typical grains or fruits most alcoholic
beverages are made from. It is distilled from the roasted center
(piña) of the blue agave (maguey) plant - the
agave tequilana weber azul - one of 136 species of
agave that grow in Mexico (with 26 sub-species, 29 varieties and 7
types). It has a lifespan of 8-14 years, depending on soil,
climate and cultivation methods.
The
blue agave was classified by German botanist F. Weber in 1905. It's
commonly - and mistakenly - called a cactus, but it is really a
succulent that belongs to the lily (amaryllis) family. It is
sometimes known as cabuya, maguey mezcal, mexic, pita and teometl.
The agave used in mezcal, although similar, is harvested younger
than the tequila agave.
Most of Jalisco state
where tequila is made is a high plateau that averages 7,500 feet
above sea level, with sandy, mineral-rich red soil in the highlands,
and black earth in the valleys. It is a mountainous, hilly region -
but agave grows best above 1,500 meters. According to some, the
best agave plants grow on the slopes of the extinct volcano beside
the town. Others say the best tequila is made from agave taken from
the highlands to the east because highland agave tend to grow
larger.
One variety, the Arandas agave, is very large and considered
a premium plant that commands more money. Another term for large
agave is mano larga or long hand. It may also be that highlands
distillers tend to use more traditional production methods to
manufacturer smaller quantities of tequila, while those around the
town are more modern and produce more export
product - usually mixto (made with sugars added to the fermenting
agave to increase the alcohol content).
Once all tequila had to
be made by law in Jalisco state. Although
that has been changed for more than 20 years, only two
distilleries are currently in business outside Jalisco. The owners
of La Gonzaleña - makers of Chinaco - fought a long battle to
get the laws changed to permit tequila
to be made outside Jalisco. They won their fight only in 1977, and
now operate the sole distillery in the northeast state of
Tamaulipas. The other distillery
outside Jalisco is Tequilera Corralejo, which opened in 1996 in the
city of Penjamo, in Jalisco's neighboring state of Guanajuato. This
distillery is named after one opened in the
state in 1755.
Blue agave for tequila use may also be
grown in the states of Nayarit, Guanajuato and Michoacan. The agave
plants are grown in cultivated orchards called potreros (pastures,
also called agave fields, or campos de agave - also called huertas,
or groves, in the Los Altos region). Traditional plantings may still
have corn and beans growing between the rows. Agaves are grown from
shoots (mecuates or hijuleos) taken from the adult plants at the
start if the rainy season in their fourth to sixth year (when the
shoots themselves are at least a year old, and about the size of a
leek or small onion). The shoots are left in the fields to dry out
for about a month before they are planted in a nursery for another
year, after which they are transferred to the fields. Sometimes the
shoots are planted right away, just before the rainy season, so they
can get established in the soil more quickly. The agave may also be
grown from seed, although this is generally not done any more. There
can be anywhere from 1,000 to 2,000 plants in an acre.
The agave plant takes at least eight years to
reach the stage where it is suitable for fermentation and may be
left for up to 12 before harvesting; the more mature, the better its
natural sugars (agave sazon means
ripened). During this time it is pruned (barbeo), cutting the points
of the leaves with machetes to encourage the piña to grow. Some
farmers also use a technique called 'shotgun plowing' (barbeo de
escopeta) to induce premature ripening of plants, but most fields
are hand grown and cultivated, using traditional methods passed down
from generation to generation.
Modern producers often spray agave
fields with fertilizers and pesticides. Most use farm hands to
meticulously control the weeds by hand. Fields are not irrigated;
the plants depend entirely on the rainy season for moisture.
Experiments with irrigation showed the larger plants
that resulted did not produce any more agave sugars.
The part
of the plant that is used for tequila is the heart (root), or piña
(also called the head, or cabeza), which looks like a large
pineapple or pinecone. It starts underground, but soon pushes its
way into the light.
A mature piña usually weighs 80 to more than 300
pounds (although most are under 200 pounds). Even 500-lb. piñas
have been cultivated in the highlands, although they are rare.
Left
to grow in the wild, these piñas would extend a tall shoot, 15 feet
high or more, with pale yellow flowers at the top. The wild flowers
are pollinated by local long-nosed bats (Leptonycteris nivalis), and
then after producing 3,000-5,000 seeds, the plant would naturally
die. The dwindling population of these bats is an environmental
concern and may spell serious trouble in the future for wild agaves
used for fibre, pulque and mezcal.
The young, tender flower stalk is
called a quiote or quixotl, and is picked and eaten as a vegetable.
The stalk is not allowed to grow on cultivated agaves, because it
uses up the nutrients in the plant to produce its seeds, and is cut
so the piña grows fatter. The piña is ripe when it starts to shrink
and develops a maroon tinge, and red spots appear on the leaves.
When ready for harvesting, the carbohydrate-rich piña is cut from
its stalk. Then the 200 or more 6-7 foot spiky and thorn-covered
leaves (pencas) that stand out from the agave are cut away from the
heart by a jimador or harvester (from the Nahuatl word jima, or
harvest), using a sharp, long-handled tool called a coa. The skill
of harvesting is passed down from father to son and some fields have
three generations of jimadors working in them. Methodical, but
efficient, a good jimador can harvest more than a ton of piñas in
a day. He loads the heavy piña on a truck, Full
truck loads are carried to the factory (fabrica) where
the piñas are usually quartered or halved before baking. The
remainder of the agave has no other uses.
Harvesting is done
year-round because the plants mature at
different stages in the fields. Some large distillers pick young
agaves, but others, like Herradura, use only plants 10 years or
older. Some distillers will 'pre-cook' the piñas to rid them of
external waxes and solids that may be retained in the penca. These
can make a bitter or unpleasant juice. The steam-injected autoclaves
used in modern distilleries also wash away any external materials
from the piñas. Farmers who sell piñas by weight may leave on more
of the penca, while those paid daily wages by the producer are more
likely to cut them off closer to the piña. It takes about 7
kilograms of piña to produce 1 litre of 100% agave tequila - which
means the average piña can make 60-100 liters. Small distillers may
simply purchase agave syrup to ferment, without any of the
intervening processes.
Traditional distillers (tequilleros) let the piñas soften in steam
rooms or slow-bake ovens for 50-72 hours. The traditional stone or
brick oven is called a horno - hence the name of Sauza's
Hornitos. This bakes the agave to process
its natural juices (baking, or roasting is tatemar) at around
140-185 degrees F. This slow-bake process softens the fibres and
helps keep the agave from
caramelizing, which adds darker and bitter flavors to the juice and
reduces the agave sugars. Baking in ovens also helps retain more of
the natural agave flavors. Here's where
mezcal and tequila part ways: mezcal piñas are baked slowly in
underground pits, rather than steamed. Many large distillers prefer
to cook their piñas faster in efficient steam autoclaves and
pressure cookers in as little as a single day (8-14 hours). The
baking process turns the complex carbohdryates into fermentable
sugars and softens the piña so they can easily release their juice.
Fresh from the oven, the piñas taste a bit like a sweet potato or
yam, with a mild tequila aftertaste. In traditional distilleries,
the piñas are allowed to cool for another 24-36 hours after
steaming, then they are mashed to separate the pulp (bagazo or
bagasse) from the juice (although some traditional distillers keep
them together during the fermenting).
Originally, the manufacturers beat the piñas with
mallets to break them up once they were soft and cool. Then they
moved to the tahona, a giant grinding wheel that can weigh up to two
tons, operated by mules, oxen or horses (nowadays more likely by a
tractor). Modern distilleries use a mechanical crusher, or shredder,
like a giant wood-chipping machine to process out the waste bagazo
(usually given away as animal food or fertilizer). Using one of
these methods, the piñas are minced and strained to remove the
juices (called aquamiel, or honey water), then
mixed with water in large vats. The resulting wort (tepache) is
sprinkled with yeast. Traditionally this is a yeast that grows
naturally on the leaves of the plant, but today it may be a
cultivated form of that wild yeast or even a commercial brewer's
yeast (natural fermentation from airborne yeasts is sometimes
allowed in some traditional mezcals and pulque).
Tequila Herradura
boasts it is the only company that uses 'natural fermentation.'
However, according to a story in the Wall Street Journal (May, 1999)
when yeasts are used to speed fermentation, some distillers must
add antibiotics to kill unwanted microbes that
result. The must (mosto) is left to ferment in wooden or stainless
steel tanks. This can naturally take seven to 12 days, but modern
plants add chemicals to accelerate yeast growth
so fermentation only takes two to three days. Longer fermentation
results in a more robust body. Fermented must may also be used as a
starter mixture for the next batch.
Sometimes the must is fermented with the residual pulp from the
piñas left in it to impart the most flavor to the liquid - another
traditional practice - but more often the pulp is disposed of. It
may be sold to construction firms for adding to bricks or as
packing material.
Some manufacturers use cane or brown sugar cones (piloncillo) to
speed fermentation to be able to use immature and fewer plants. This
type of tequila can be sold in bulk for shipping out of the country,
and can be bottled anywhere, including other countries where the
regulations regarding agave content are not necessarily maintained.
These tequilas are called mixto, and will not be labeled 100% agave,
which purists demand. After fermentation is finished, the must may
be left another 12 hours to richen and settle before distillation.
The result of fermentation is a liquid with about 5-7% alcohol. It
is then distilled twice in traditional copper pot stills called
alambiques, or in more modern stainless-steel column stills. The
best copper stills are said to come
from Tomelloso, in Spain. Distillation takes four-eight hours. The
first distillation takes 11/2-2 hours. It is called the ordinario
and is about 20% alcohol. The second distillation takes 3-4 hours.
It has about 55% alcohol. It has three components: the cabeza, or
head, has more alcohol and unwanted aldehydes, so it is discarded.
The middle section is the El corazon, the heart, which is the best
part and saved for production. The end is the colos, or tails, which
is sometimes recycled into the next distillation to make it more
robust, or may also be discarded. The residue, or dregs (vinazas) is
discarded. Most mezcal is only distilled once,
although some premium brands now offer double distillation.
All tequila is clear right after distillation. The color comes
later, from aging in wooden barrels (barricas) or from additives
like caramel (in mixto only) or wood essence. Before bottling, most
tequila is filtered through activated carbon or cellulose filters.
One premium blend offers triple-distillation, although some
connoisseurs say it comes with a subsequent loss of flavor. Most
distillers add de-mineralized water to bring the proof down to 80
(40% alcohol), although some will stop the process at the required
proof. Reposado and añejo tequilas will be
stored in wooden casks. These barrels are generally purchased used
from American distillers (bourbon barrels are the most prized but
some distillers use sherry barrels, whiskey barrels, cognac barrels
and even new oak barrels to impart sharper flavors) and older ones
may be 50 years or older and still in use. They will be stored in
warehouses or bodegas. Blanco will remain in stainless steel tanks
until bottling. It may also be bottled immediately after
distillation.
The passion for premium aged tequilas that
look like brandies has led some distillers to age them longer in oak
barrels to absorb the maximum coloring. Others simply add coloring
to create the impression of age - which may also affect the flavor.
Some distillers, like Centinela, disdain the use of any such
additives. Note too that changing barrels (replacing old ones with
new) can also darken a tequila and change its flavor until the
barrels are 'broken in.' The color of a tequila does not necessarily
reflect either age or quality. The final product is usually blended
with other barrels of a similar age to create a consistency of taste
and aroma. Representatives of the Tequila Regulatory Council oversee
the production to ensure the distillers meet the standards and
quality controls in place under Mexican legislation. The resulting
mix is then bottled or tanked for bulk shipments. A few 'single
barrel' tequilas are available in the premium market. All 100% agave
tequilas must be bottled in Mexico and marked "Hecho en Mexico" -
made in Mexico. Only mixto tequila is allowed to be sold in bulk and
bottled outside the country.
"Distilled from melancholy and from lucidity; from an intense love
for good; from a need to bite into the earth and hear the poetry of
the people's song."
Author unknown, quoted in the Guia de Tequila, published by Artes de
Mexico,1998.
Tequila production is facing a crisis in production - the combined
result of a plague of diseases and pests with spiraling agave costs
and an agave shortage. The looming shortage of agave has seen
several distillers drop their low-end brands in favor of
higher-priced premium products. The shortage could also seriously
impact mezcal producers because tequila manufacturers are already
buying agave from Oaxaca state to shore up their dwindling supplies.
Mezcal producers face a 40% increase in costs due to the demand by
tequila manufacturers for the agaves from Oaxaca. This appears to
violate the Mexican NORMAS and DOT standards for tequila - but the
industry seems remarkably quiet in its response.
Okay, you now
know way more about tequila than any of your friends.