
I’ve never aged a sour beer in a small (< 50 gallon) barrel because I’m wary of them. Small barrels are usually about same price as full-sized barrels, and thanks to their high surface-to-volume ratio they quickly impart a potent oak flavor, allow a higher rate of oxidation, and more rapid evaporation. However, when
Balcones Distillery offered to send me two of the five gallon American oak barrels they age their spirits in I knew I’d find something to age in them.
Aging clean beers in small barrels has a number of advantages for homebrewers. Filling one requires a single batch, so the chances of introducing unwanted microbes (as we did with our
first group bourbon-barrel-aged beer) is much lower. I switched to eight gallon buckets for primary fermentation last year; these larger fermentors allow me to brew six gallon batches, large enough to fill the barrels to the brim with fermented beer. Head space accelerates oxidation by allowing the staves at the top of the barrel to dry, so partial filling is not a viable option.

For some advice I emailed Doug Dozark, of
Peg’s Cantina, brewer of some very well regarded
beers aged in 5 and 15 gallon whiskey barrels. He suggested checking the oak level imparted by first use five gallon barrels after just three weeks, compared to two to three months for 15 gallon barrels. By comparison beers aged in full-sized barrels often age for six to twelve months before packaging.
The first barrel I’ll be filling (later this week) previously held Rumble, which Balcones distills from Mission figs, wildflower honey, and unrefined cane sugar. Those flavors made me think of a dark Belgian ale. I wanted something strong enough to stand up to the rapid extraction of oak and booze, Belgian Dark Strong (aka Quadrupel) fit the bill. It didn't hurt that I really enjoyed the
batch of Pomegranate Quad I brewed in February with my neighbor, which I only kept a six-pack of for myself.
While this batch is technically a test-batch for Modern Times (
we're on the hunt for a head brewer), it is more of a proof of concept than a recipe we can actually scale up. I used
Valley 2-Row Pale Ale Malt as the base (also included in my
Dubbel last year), which being malted on a small scale in Massachusetts probably won’t find its way into our Southern California mash tun. To the boil I added a pound each of D-90 and D-180 from
Candi Syrup Inc, which I don’t believe is available yet on a craft brewing scale. I fermented the dense wort with East Coast Yeast Belgian Abbaye (ECY09), which isn’t available in commercial pitches. Not to mention aging in that small barrel (we'd need 186 of them to age a single brew on a 30 bbl system)!

I do not plan to clean or otherwise sanitize the barrel before filling, the previous 124 proof resident took care of that. Oak is nearly impossible to sanitize with chemicals anyway because its porous texture allows microbes to penetrate deep into its grain. Heat is the best option, but even with near-boiling water it is difficult to sanitize a barrel completely because wood is such a good insulator. In addition, hot water would rinse away much of the residual spirit character.
Balcones Whisky barrels, the other one they set, can be purchased through
some homebrewing stores. There are a number of other nano-distillers located around the country that sell their used barrels. In the DC area,
Catoctin Creek’s 30 gallon rye barrels are a common sight at brewpubs. Tuthilltown in New York sells a variety of barrel sizes
on their website that previously aged their whiskey.
Doug warned me against refilling barrels, but I’m hoping that I can rack the first beer out of the barrel, give it a quick rinse with really hot water to remove any trub, and then refill it immediately with a second batch. My planned second fill (a cinnamon/vanilla spiced imperial porter) will take a bit longer to extract adequate oak flavor, and should receive a softer spirit character. After each barrel ages two clean beers, I’m planning on splitting a 10 gallon batch of sour brown between them. I’m interested to taste the results, but I’ll be prepared to move the sour beer into carboys for additional aging if the oakiness becomes too potent before the beer is ready to bottle.
Rumble Barrel Belgian Strong Dark
Recipe Specifics
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Batch Size (Gal): 6.25
Total Grain (Lbs): 20.13
Anticipated OG: 1.079
Anticipated SRM: 28.9
Anticipated IBU: 26.5
Brewhouse Efficiency: 66%
Wort Boil Time: 120 Minutes
Grain/Sugar
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59.6% - 12.00 lbs. Valley Pale Malt
24.8% - 5.00 lbs. German Vienna Malt
3.7% - 0.75 lbs. CaraMunich Malt
1.2% - 0.25 lbs. Crystal 120L
0.6% - 0.13 lbs. Carafa Special II
5.0% - 1.00 lbs. D-90 Candi Syrup
5.0% - 1.00 lbs. D-180 Candi Syrup
Hops
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1.50 oz. Hallertauer Tradition (Pellet, 6.00% AA) @ 90 min.
Extras
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0.50 Whirlfloc @ 15 min.
0.50 tsp Yeast Nutrient @ 15 min.
Yeast
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East Coast ECY09 Belgian Abbaye
Water Profile
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Profile: Washington, DC
Mash Schedule
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Sacch Rest - 60 min @ 151 F
Notes
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9/6/12 Made a 1.25 L starter for my stir-plate. Didn't see much activity for 24 hours, but it looked and smelled fine after that.
9/8/12 Brewed by myself
No water adjustments.
Undershot pre-boil gravity slightly, and overshot my pre-boil volume. 9 gallons @ 1.052, 1.058 with the addition of the candi syrup (1 lb each D90 and D180). Extended the boil 30 minutes longer to further concentrate the wort.
Chilled to 68 F, pitched entire starter, hit with 30 seconds of pure oxygen, left at 64 F to ferment.
Strong fermentation by 12 hours Quickly threatened to blow-off in the 8 gallon bucket.
After 36 hours, from pitching, increased ambient to 66 F since fermentation already appeared to be slowing. 24 hours later, with the fermentation appearing nearly complete, I moved the fermentor to 74 F ambient to finish.
9/29/12 Down to 1.018, a bit sweeter than expected, but it should be perfect with the oak. Racked into the Balcones Rumble barrel, filled to the brim. Replaced the hard bung. The wood provided nucleation sites that caused the beer to foam when I checked on it a couple hours later. Left at 70 F ambient to age for a couple weeks.
10/21/12 Bottled with 2.75 oz of table sugar, aiming for 1.9 volumes of CO2. Solid, but not overpowering barrel character. Tastes pretty good.
3/15/13
Turned out really well, nice blend of barrel and base beer characters.