How is Mezcal Made

Mezcal is crafted through meticulous steps steeped in tradition that transform the humble agave plant into a distinctive and flavorful beverage, full of cultural significance. 

Every region in Mexico has its own special techniques and equipment for making mezcal, using local materials and traditions. These regional differences have a big impact on the taste and smell of the final product, creating a diverse range of flavors and aromas that make mezcal so unique.

Making Mezcal: Step By Step

The production process begins with carefully selecting mature agave plants, which can take several years to reach the right stage for harvesting. Once harvested, the agave hearts, known as piñas, are roasted in underground pits or over wood fires, a technique that infuses the spirit with a smoky flavor characteristic of mezcal. After roasting, the piñas are crushed, traditionally using a stone wheel known as a tahona, and the resulting pulp is fermented, often in open-air containers, where wild yeasts contribute to the complexity of flavors.
Following fermentation, the mash is distilled, typically in small batches, utilizing copper or clay stills that further shape the spirit’s unique profile. It’s fascinating how the production process varies across different regions of Mexico, with each area employing unique techniques and equipment that impart specific flavors and aromas to the final product. This regional diversity reflects the rich heritage of mezcal and highlights the artistry of its makers, who take great pride in their craft.
The result is a spirit that offers a diverse range of tasting notes, from earthy and herbal to fruity and floral, making mezcal a captivating drink enjoyed by aficionados worldwide.

Agave Harvesting and Jima

The journey begins with harvesting mature agave plants, which can take 7 to 30 years to reach maturity. This lengthy growth process is essential, as the quality of the plant greatly influences the final product. Once the agave reaches the desired age, skilled jimadores, traditional harvesters trained in agave cultivation and harvesting, step in to begin the delicate process of extracting the piña.
Using a specialized tool called a “coa,” which resembles a long, curved knife, the jimadores expertly remove the spiky, serrated leaves of the agave plant. This requires physical strength, precision, and a deep understanding of the plant’s anatomy. Each cut must be calculated to avoid damaging the heart, or piña, the part of the plant that retains the sugars necessary for fermentation and distillation.
As the leaves are stripped away, the piña emerges, resembling a large, rounded pineapple.

Depending on the species of agave, the piña can weigh anywhere from 40 to 200 pounds or more.

Once harvested, the piñas are usually transported to the distillery, where they are cooked to convert the complex carbohydrates into fermentable sugars. This initial stage is crucial, as it sets the foundation for the flavors and characteristics that will define the mezcal produced from these agave plants.
The entire process, from cultivation to harvesting, is steeped in tradition and artistry, reflecting the deep cultural significance of agave in Mexican heritage. Each step requires respect for the plant and the land, highlighting a connection that has thrived for generations. With climate and soil conditions playing significant roles, the journey of the agave is not just an agricultural process; it is an intricate dance between nature and human skill, culminating in the vibrant spirits celebrated worldwide.

Cooking Agave

The harvested piñas are then cooked to convert their complex carbohydrates into fermentable sugars. Traditional methods involve roasting the piñas in earthen pits lined with volcanic rocks and filled with wood. This slow-cooking process, which can last several days, not only imparts mezcal’s characteristic smoky flavor but also plays a crucial role in developing its complex aroma and texture.
During cooking, the piñas caramelize, enhancing their natural sweetness and adding depth to the spirit’s overall profile. Volcanic rocks help retain heat and distribute it evenly, ensuring that each piña is thoroughly cooked. The mixture of heat and wood smoke gives mezcal its distinctive earthy notes, setting it apart from other spirits and contributing to the artisanal nature of its production. This traditional roasting technique showcases the rich cultural heritage of mezcal, reflecting the craftsmanship and patience of the distillers who have perfected this art over generations.

Grinding Agave

Once cooked, the softened piñas are crushed to extract their sweet juices, a crucial step in mezcal production. The piñas, which are the hearts of the agave plant, undergo a slow cooking process in traditional earthen ovens, imparting unique flavors to the mezcal. After cooking, the piñas become tender and caramelized, making it easier to extract the sugars necessary for fermentation.
Traditional mezcal production often employs a “tahona,” a large, heavy stone wheel vital in this labor-intensive process. Typically pulled by a horse or mule, the tahona is used to mash the cooked agave fibers, breaking them down to release the sweet juices. This method not only preserves the authenticity of the mezcal but also enhances its flavor profile, as the crushing process allows for the natural essence of the agave to be fully expressed.
Artisans often take pride in using this time-honored technique, as it connects them to generations of mezcal producers who have relied on the tahona’s efficiency. Many mezcal distilleries value the traditional approach, believing it contributes to the unique character of their spirit, setting it apart from mass-produced alternatives. The result is a rich, complex mezcal that carries the distinct taste of the agave plant and the unique terroir of the region in which it is produced.

Mezcal Fermentation

The extracted juices and crushed agave fibers are placed in fermentation vessels, which can be made from wood, stone, or clay, depending on regional practices. Natural yeasts in the environment ferment the sugars into alcohol over several days to weeks, a process that contributes to the unique flavors of each mezcal. During fermentation, the combination of temperature and the specific strains of yeast used can further influence the final taste, adding layers of complexity. This artisanal approach, steeped in tradition, makes each batch of mezcal a distinct representation of its origin and the craftsmanship involved in its creation.

Mezcal Distillation

The fermented liquid, known as “mosto,” is the starting point for the distillation process, which is crucial in producing spirits like whiskey, rum, and agave-based liquors. During distillation, the mosto is heated in a still to separate the alcohol from impurities and create a more concentrated form of ethanol. This process typically involves two distillation cycles, known as “double distillation,” to reach the desired purity and alcohol content.
The first distillation, often referred to as “stripping,” removes a significant portion of the alcohol along with some volatile compounds. The resultant liquid, known as “low wines,” still contains undesirable impurities. The second distillation further refines the liquid, separating desirable components from those that may impart off-flavors.
The still used in this process—be it copper, clay, or wood—plays a significant role in shaping the flavor profile of the final product. Copper stills are particularly valued for their ability to remove sulfur compounds during distillation, resulting in a cleaner taste and more complex aroma. Clay stills, on the other hand, can impart earthy notes to the spirit, while wooden stills may introduce hints of their unique flavors through the interaction between the wood and the alcohol.

The distillation process is not solely about achieving higher alcohol content; it contributes to developing the spirit’s character and complexity.

Factors such as the temperature during distillation, the speed of distillation, and even the shape of the still can influence the final flavor. Distillers often take great care in crafting these processes to ensure that the resulting spirit not only meets alcohol standards but also delivers the desired taste and aroma, creating a unique identity for each type of liquor.

From Agave to the Glass

The diverse landscape of mezcal is shaped by a unique interplay of regional agave varieties, traditional and modern production techniques, environmental factors, and rich cultural traditions. Each expression of mezcal reflects its specific origin, characterized by the distinct flavors and aromas imparted by the agave and the terroir. Through the craftsmanship of mezcaleros, these elements weave a complex narrative into every bottle, inviting enthusiasts to explore and appreciate the artistry behind this beloved spirit.