American white oak barrels are the backbone of whiskey aging around the world—but not all spirits interact with oak in the same way. Whether you're aging a traditional bourbon or a single malt, choosing the right toast and char levels can make all the difference in shaping the final flavor.
Let’s break down the key differences between single malt and bourbon, and how you can optimize your American oak barrel to get the best out of each style.
🥃 What’s the Difference Between Bourbon and Single Malt?
While both are types of whiskey, they have distinct production rules and flavor foundations.
| Category | Bourbon | Single Malt |
|---|---|---|
| Base Grain | 51%+ corn (typically with rye or wheat) | 100% malted barley |
| Distillation | Column still (commonly) | Pot still |
| Flavor | Sweet, bold, spicy, caramel, vanilla | Malty, fruity, grassy, nutty |
| Barrel | Must be new, charred American oak | Often used barrels, but new oak is optional |
Bourbon starts off sweet and full-bodied, while single malt is lighter, with more grain complexity. Because of that, their interaction with toasted and charred wood differs—requiring different aging strategies.
🪵 Why Use American Oak for Both?
American white oak (Quercus alba) is prized for:
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High levels of vanillin and lactones (sweet, creamy flavors)
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Natural durability and leak resistance
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A broad range of flavors unlocked through toast and char
Even though bourbon requires new oak by law, many craft distillers and hobbyists age single malts in new or custom-toasted American oak to add bold flavor and depth.
🔥 Best Toast and Char Profiles for Bourbon
Bourbon benefits from the boldest expression of oak flavor. Since it’s distilled from mostly corn and usually carries inherent sweetness, the goal is to complement and intensify those notes without overpowering the spirit.
Recommended Profiles:
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Toast: Medium or Medium Plus
Brings out caramel, toffee, and baking spices -
Char: #3 or #4
Creates the classic bourbon depth—marshmallow, dark sugar, oak char
Ideal Combo: Medium Toast + Char #3
A balanced profile that develops rich vanilla, caramel, and oak without becoming overly tannic.
🔥 Best Toast and Char Profiles for Single Malt
Single malt is more delicate, and heavy charring can easily overpower its malt character. The goal here is to enhance, not dominate, the whiskey with gentle oak extraction and nuanced sweetness.
Recommended Profiles:
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Toast: Light or Medium
Accentuates malt, honey, nuts, and dried fruit -
Char: #1 or #2
Provides soft filtering and a light oak backbone
Ideal Combo: Light Toast + Char #1
This pairing brings out soft vanilla and toasted cereal without masking the character of the malted barley.
🧪 Aging Considerations by Spirit Type
| Feature | Bourbon | Single Malt |
|---|---|---|
| Aging Time (Small Barrels) | 6–18 months | 4–12 months |
| Extraction Rate | High, due to sweetness and oils | Slower, due to lighter distillate |
| Flavor Target | Bold, layered, oak-forward | Gentle oak, balance with grain |
🥂 Final Thoughts
Aging whiskey isn’t one-size-fits-all. Bourbon and single malt each demand a different approach when it comes to toast and char—and American white oak gives you the versatility to dial in exactly what you want.
Bourbon loves boldness.
Single malt prefers subtlety.
Whether you’re experimenting with a hybrid barrel or aging your first batch, choosing the right toast and char levels based on the whiskey type will elevate your results every time.
🔗 Ready to Get Started?
Explore our lineup of handcrafted American oak barrels—available in customizable toast and char combinations—perfect for both single malt and bourbon lovers alike.
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