5 Gallon Bourbon Mash Recipe for Perfect Homemade Whiskey

Making your own bourbon mash at home is a rewarding and enjoyable process that connects you with the rich tradition of American whiskey-making. Whether you’re a seasoned distiller or a curious hobbyist, crafting a 5 gallon bourbon mash batch allows you to experiment with flavors and control the quality of your final product.

Bourbon mash is the foundational mix of grains that, when fermented and distilled, becomes that beloved amber spirit with notes of caramel, vanilla, and oak. This recipe is designed to be straightforward yet authentic, ideal for small-batch production that fits in a home setup.

In this detailed guide, you’ll find everything you need to create a classic bourbon mash recipe perfect for a 5 gallon batch. From carefully measured ingredients to step-by-step instructions and expert tips, this post covers it all.

Plus, if you love experimenting with recipes, you might also enjoy some of our other culinary inspirations linked throughout. Let’s dive in and get your bourbon mash bubbling!

Why You’ll Love This Recipe

This 5 gallon bourbon mash recipe balances traditional flavors with practical simplicity. It uses the classic bourbon grain bill—corn, rye, and malted barley—in proportions that are true to the spirit’s heritage.

The recipe is perfect for those who want to produce a flavorful, smooth mash for fermentation without complicated techniques or obscure ingredients.

You’ll appreciate how the mash yields a rich, sweet base with just the right amount of spice and malt complexity. It’s easy to scale this recipe up or down, making it flexible for your distilling needs.

Plus, this recipe encourages you to learn and appreciate the nuances of each grain and their contribution to bourbon’s distinctive taste.

Ingredients

• 8 lbs of cracked yellow corn – the backbone of bourbon, providing sweetness and body
• 4 lbs of rye grain – adds a spicy, peppery kick
• 2 lbs of malted barley – supplies enzymes to convert starches into fermentable sugars
• 5 gallons of water – preferably filtered or spring water for best fermentation
• 1 packet of active dry yeast – bourbon yeast or a strong distiller’s yeast like EC-1118
• 1 tsp of yeast nutrient – optional but recommended to support healthy fermentation

Equipment

• 5 gallon fermentation bucket with airtight lid and airlock
• Large stainless steel or food-grade pot for cooking the mash
• Grain mill or grinder (if grains are not already cracked or milled)
• Thermometer – to monitor mash temperatures accurately
• Hydrometer – to measure specific gravity before and after fermentation
• Stirring spoon – preferably food-grade stainless steel or food-safe plastic
• Sanitizer solution – for cleaning all equipment to avoid contamination
• Heat source – stove or burner to cook the grains

Instructions

1. Prepare your equipment: Thoroughly clean and sanitize all equipment including your fermentation bucket, stirring spoon, and pot to prevent contamination.
2. Crack or mill grains: If your grains aren’t cracked, use a grain mill to crack the corn, rye, and malted barley. This helps the enzymes access starches during mashing.
3. Heat the water: Pour 5 gallons of water into your pot and heat it to approximately 165°F (74°C). This temperature helps gelatinize the starches in the corn.
4. Add cracked corn: Slowly stir in the cracked corn into the hot water. Maintain the temperature between 150°F and 155°F (65°C – 68°C) and hold for 60 minutes. This is the “cooking” stage to break down starches.
5. Add rye and malted barley: After the corn has cooked, add the rye and malted barley. Stir well and maintain the temperature at 150°F (65°C) for another 60 minutes. The malted barley enzymes will start converting starches into sugars.
6. Cool the mash: After mashing, cool the mixture down to about 70°F (21°C) as quickly as possible. You can use a sanitized ice bath or wort chiller if available.
7. Transfer to fermentation bucket: Pour the cooled mash into your sanitized 5 gallon fermentation bucket. Top off with additional water if necessary to reach 5 gallons total volume.
8. Check gravity: Use your hydrometer to measure the specific gravity. A typical starting gravity will be between 1.070 and 1.090.
9. Pitch the yeast: Sprinkle your yeast onto the mash. Add yeast nutrient if desired and stir gently to combine.
10. Seal and ferment: Attach the airlock and store the fermentation bucket in a dark, temperature-stable area around 68°F – 75°F (20°C – 24°C). Fermentation should start in 24-48 hours.
11. Monitor fermentation: Over the next 5-7 days, monitor the airlock for bubbling and check the specific gravity daily. When gravity stabilizes around 1.010 or lower, fermentation is complete.
12. Strain and distill: Once fermentation is done, strain the mash through a fine mesh or cheesecloth to separate solids from the liquid wash. The wash is now ready for distillation (note: distillation requires legal permits and safety precautions).

Tips & Variations

“Patience is key!” Allowing the mash to ferment fully ensures maximum alcohol yield and flavor development. Rushing this step can result in off-flavors.

Try experimenting with grain ratios to tailor your bourbon’s flavor profile. Increasing rye will give more spice, while more barley enhances maltiness.

Using heirloom or organic grains can also add unique nuances.

Temperature control during mashing and fermentation impacts enzyme activity and yeast health. Investing in a good thermometer and keeping fermentation temperatures stable will improve your results significantly.

Consider adding small amounts of sugar or malt extract if your gravity is too low, but remember bourbon’s character comes primarily from the grains.

Nutrition Facts

Note: Nutrition facts apply to the mash before distillation. Distillation concentrates alcohol and removes most nutrients.

Serving Suggestions

Once your bourbon mash is distilled and aged, it’s ready to be enjoyed! Bourbon pairs wonderfully with classic cocktails like the Old Fashioned or Manhattan.

Serve it neat or on the rocks for a pure tasting experience to appreciate the complex flavors from your homemade mash.

For a fun twist, try bourbon in cooking — it enhances barbeque sauces, glazes for roasted meats, and even desserts like bourbon pecan pie. If you’re interested in more homemade recipe ideas to complement your bourbon evenings, check out our Veg Grilled Sandwich Recipes That Are Quick and Delicious or Backpacking Dehydrated Vegan Meal Recipes for Easy Camping.

Conclusion

Creating your own 5 gallon bourbon mash is a fulfilling endeavor that blends tradition, science, and a bit of artistry. This recipe offers a reliable foundation for producing a flavorful mash that can be fermented and distilled into genuine bourbon-style whiskey.

By following the outlined steps and tips, you’ll gain insight into the distillation craft while crafting a mash that honors the spirit’s heritage.

Remember, patience and cleanliness are your best allies in this process. Whether you plan to distill immediately or age your spirit for months, this mash recipe sets you on the right path.

For further kitchen inspiration and complementary recipes, explore our extensive collection such as the Chinese Vegetarian Nasi Lemak Recipe Made Easy and Delicious or the Apple Barn Pigeon Forge TN Vegetable Soup Recipe Guide.

Cheers to your bourbon-making adventure!

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