Toasted vs. Charred: Can It Be Both?

Toasting and charring is no gimmick, it’s wood science. Here’s why some distillers do both, and when a second barrel means it’s no longer bourbon.

Yes, and here’s how. Toasting and charring is no gimmick. It’s wood science.

Toasting is a slow, gentle heating of the inside of the barrel. It warms the wood without setting it on fire, drawing out natural flavors like vanilla, caramel, and baking spice.

Charring is a quick, intense flame that actually burns the inside layer of the barrel. It creates a layer of charcoal that helps filter the spirit and adds deeper notes like smoke, oak, and dark caramel.

So why do both? Toasting brings out the sweet, subtle flavors hiding in the oak. Charring creates the bold backbone bourbon is known for. Used together, they add complexity and depth.

Some distillers toast the barrel first to open up the wood, then char it to meet the legal requirement for bourbon. If you see “toasted barrel finish” on a label, it usually means the whiskey spent time in a second barrel that was toasted, not charred. And once you add that second barrel, it’s no longer bourbon. It’s a finished whiskey. Still delicious, just a different category.

Stay tuned for more wood science. Did you know that 70% of the flavor comes from the wood?

Angelique Rison Founder Sipping in the South

Taste Toasted and Charred Bourbon

The difference between toasted and charred barrels is easiest to notice side by side. Learn more about bourbon barrels, check bourbon's barrel rules with the Kentucky Distillers' Association, and compare toasted and charred finishes on Bourbon Bootcamp. Ask your guide which bottles on the day are toasted and charred; you'll find more on our Bourbon Education page.