The Art and Science Behind Irons One Distillery

By Abigail Harrison, DHI Communications Coordinator

Irons One Distillery, located in Huntsville’s Lowe Mill ARTS & Entertainment, is a small-batch distillery known for its handcrafted bourbon. For 40 years, owner and master distiller Jeff Irons has been perfecting his craft, creating a product that stands out in both Alabama and the wider whiskey market.

Jeff began his journey in distilling as a hobby. Realizing the potential of his craft, he decided to pursue his license and officially opened Irons One in 2015. His bourbon is crafted from a majority corn base, with secondary grains like rye and malted barley contributing to the rich and complex flavor.

The process of making bourbon at Irons One is a meticulous balance of art and science: “I call the whole process a combination of cooking and chemistry,” Jeff explains. “It all begins with corn, the majority grain.”

The corn is cooked, followed by the addition of rye and then malted barley at precise temperatures. The malted barley releases an enzyme that converts the starch into sugar, which is key to producing alcohol during fermentation.

After fermentation, the liquid—referred to as distiller’s beer—is distilled to separate the alcohol. Jeff uses a still to carefully heat the beer, simmering off the alcohol, which is then aged in new charred oak barrels for three years.

“The wood gives the bourbon its signature flavors—caramel, vanilla, even a little smoke,” Jeff explains.

Jeff offers a range of products that he calls “expressions” of his bourbon, each with a unique flavor profile. He produces two main bourbons, aged in barrels with different levels of char.

“One is a char three, and the other is a char four,” Jeff says, explaining how even small differences in the burning process can significantly impact the flavor.

His char three bourbon develops caramel and vanilla notes, while the char four bourbon, aged for just 20 seconds longer, offers hints of chocolate and almond. In addition to bourbon, Jeff also makes a bourbon mash whiskey.

“Bourbons are aged in new charred oak barrels. But I use my barrels two times. The second time I fill the barrel, it’s no longer bourbon, it becomes bourbon mash whiskey,” Jeff explains.

He adds French oak during aging to impart notes of maple and cinnamon, complementing the flavors from the American oak.

For those eager to sample Irons One’s products, the distillery offers tastings and tours.

“We have samples available for just two dollars each, or you can do a tour and tasting for twelve dollars,” Jeff says.

The tour takes visitors through the distillery and barrel house, offering an in-depth look at the entire process. Bottles are available for purchase at the distillery for fifty dollars, and whiskey cocktails, including Jeff’s popular barrel-aged Old Fashioned, are available for ten dollars.

Irons One products can also be found at local package stores like Liquor Express and Mary’s Groceries, as well as restaurants including Purveyor and The Poppy and Parliament. However, for the most personal experience, Jeff recommends stopping by the distillery at Lowe Mill, where he often personally conducts tastings and is always happy to discuss his craft.

Irons One is located at Lowe Mill Studio 2061. Anyone interested in planning a trip to Irons One can find out more information by visiting www.ironsone.com or by emailing ironsonewhiskey@gmail.com.