Handmade oak barrels
Traditional handmade oak barrels are a rarity in today’s world. ZIP Barrel is one of a few companies that preserves this tradition.
Established in 1993, the main profile of ZIP Technologies is the planning and production of complete equipment for the gastronomy industry; the company produces equipment from stainless steel, complete micro breweries and other equipment for the cognac industry.
During its expansion in 2002, the company began to work on the production and commission of equipment for the production of wine. To accommodate the new winery branch of the company, ZIP Barrel was launched as a wholly owned subsidiary of ZIP Technologies. Since then, the company has revived the rich tradition of winemaking in Tokaj, Hungary and creates all accessories and equipment needed for production of wine- including barrels for wine, cognac and other alcoholic beverages (calvados, whiskey, brandy, etc).
In barrel production, ZIP Barrel is merging centuries-old traditions of handmade work with technologically advanced, modern manufacturing methods.
ZEMPLÉN Oak and Wine barrels
Wine barrel quality depends heavily on the quality of the raw materials- the wood is by far the most important element of the wine barrel.
Barrels manufactured by ZIP are made exclusively of Hungarian Zemplen oak: Qnercus patraea. Oak trees of this species grow in the northern forests of the Zemplen mountains and are only cut after reaching an age of 110- 120 years. The species is characterized by slow growth and a large number of rings located close to one another. The Tokaj region has a favorable climate, fertile soil, and clean air; all very important for Zemplen oak.
Additionally, the Zemplen mountains are a part of the historic cultural landscape of the region of Tokaj (http://whc.unesco.org/en/list/1063). This ideal location allows for the production of wine and cognac barrels which produce wine unique in both taste and quality. The soil is a product of many natural transformations that have occurred as a result of volcanic activity during the Miocene era 15 to 20 million years ago. This is where the highest, best-preserved volcanic peak, the Tokaj Nagy Kopas, can be found. It still stands tall to defend the Zemplen hills, aided by the Tisza and Bodrog rivers. The other side of this winery region is bordered by the mountains of Shator, which are the result of the collapse of the center of a volcano thought to have been the size of modern day Mount Etna.
Among the features of this ecological region are the Quercus petrea species of oak, considered first class raw material for the preparation of barrels. In the case of oxidative aging, wood barrels play a large role in the process of fermentation and add favorable effects to flavor and color. Zemplen oak has long been recognized in international winemaking circles as it is the typical tree of Hungarian forests. In fact, in quality Zemplen oak doesn’t differ from the French Limousine Oak. Due to its slow growth, the timber has an excellent structure, high wear resistance, and is very strong due to tannin (tannic acid).
In Tokaj, the town Erdőbénye is considered the most advanced in Hungary for the production of wine barrels. It is also where the barrel production of ZIP Barrel is located.
THE EFFECT OF QUALITY ON THE FINAL PRODUCT
Harmony in the flavors of wine can only be achieved if the materials used are high in quality. A fine wine needs time to ferment and acquire its taste. These years of fermentation are needed for the wine to age in the barrel and acquire the unique flavor characteristics from the barrel itself.
It is also important to note that an oak barrel is vital for wine not only from the standpoint of flavor and taste, but also to ensure the ideal conditions for fermentation to take place. Some wine makers today use oak chips instead of oak barrels, and although this method adds the necessary taste qualities of oak barrel aged wine, it doesnt provide for a well structured wine because the fermentation conditions are not the same as when the wine is envoloped in an oak barrel.
Production
The high quality of Zemplen oak has a sizeable effect on the quality of the barrels themselves. The coopers' shop of ZIP Barrel produces over 2.000 barrels yearly, including both traditional and barrique barrels. Among them the most famous is the Gonci barrel, which is vital for the fermentation of of Tokaj aszu wines. Oak for the production of barrels is picked with great care- it must be first grade and free of knots, with a solid wood structure.
Other than barrels created for the storage and fermentation of quality wines, oak barrels are also used for the reserve of vintage cognacs. As with all ZIP products, the right relationship between quality and price is present. And although the structure and quantity of barrel manufacturing changes constantly, depending on demand, ZIP maintains a team of over 20 engineers, technologists and designers to meet buyers' demands. As a result, every client receives fast, effective and professional consulation and support.
The majority of barrels created by ZIP Barrel go to the Hungarian and Eastern European markets. Additionally, wineries from Italy, Moldovia, Bulgaria, Greece, Russia («Moscow International Winemaking Factory»), Ukraine («Guliev Wines» «Zelenyj Gaj» «Alef- Binal», «French Boulevard», «Odessa Cognac Factory») also use barrels made by ZIP Barrel.
Stave preparation
After the careful selection of oak trees, the oak logs are cut into the appropriate length and then then are split along the fiber in order to preserve the lasting fiber structure of the tree. After the split into staves the bark is removed, along with the upper, under-bark layer. What remains is called the stave, the basic building block of an oak barrel. With a thickness ranging from 35 to 38 mm, staves used by ZIP Barrel are thicker than those used by other producers. As a result, these staves can be used not only for wine barrel production, but also for the production of barrels for the multi year reserve of cognac spirits, whisky, and other various other liquers for which the strength, durability and thickness of material is particularly important.
The thickness of the barrel is also important because when an the barrel is finally in use, its life can be extended by removing the inner layer of the barrel. Approximately 5-7 millimeters are typically shaved off in this process. Thus, ZIP Barrel barrels can increase effience and cost savings for winemakers.
In order to ensure that only quality raw materials are used in production, the staves are picked over a second time. After the second selection the staves are placed on a pallate for storage, which takes place exclusively on open air with a hard covering. Storage in open air is important because in the tart flavors are washed away. The staves are watered many times in the summer to aid this process.
After this the staves go through many checks and are again air dried. Only in this method can the quality of the staves be guaranteed.
Drying
A hard walled storage space is essential in preserving the purity of the stacked piles so that they are not “choked”. Many do not even think about the fact that staves must be stored before their use; they “ripen” in 24 – 34 months. During this time, the staves go through one more additional selection and only after this can the process of barrel production begin. Due to the proximity of the storage site to the barrel production site, ZIP Barrel’s staves can be used in production within two weeks of order placement.
Coopering work
The barrels of ZIP Barrel are produced by coopers in modern surroundings using traditional handwork methods. Handcrafted barrels are characterized by the high quality of the product as well as a resistance to leaking.
The staves, which are to become the walls of the future barrel are linked in the ends. This means that instead of iron hoops binding the oak strips together, first the oak strips „soften” under fire. Although the use of iron hoops became commonplace in middle of the XVIII century, ZIP Barrel preserves the acient tradition of barrel production to this day.
Preheating
Once assembled into a working band in the form of a skirt the staves are bent in preliminary heating, and later will be fired at a low heat created from the waste oak picked over during the selection phase. The gathering of the barrel takes place over weak heat.
Main burning
The main burning is done by a set group of specialists in order to maintain a constant level of quality. The length and intensivity of the proecess of the main burning ultimately affects the aroma and the taste of the wine that is stored in the barrels. The barrels arrive to the end user with varying degrees of burning, depending on the desired aroma indicated by the buyer. Once the barrel’s exterior is worked over, the iron hoops are replaced by galvanized steel rings with a thickness of 2 to 3 mm.
The world famous desert wine- Aszú bor- ferments in barrels created from the Zemplen oak by master coopers who live in the Tokaj region. But wine producers all over the world have also discovered the value of Zemplen oak, and are now using barrels created by ZIP Barrel.
Oak barrels for fermenting wine and cognac
- Liters: 5,10, 20, 30, 40, 50, 60
- Traditional method of production, staves bent under heat from fire
- Barrels can be prepared individually per client order with logo on the barrel
- Liters: 126 (genci), 225.225 (barrique), 250.250 (barrique), 300, 400, 450, 500, 600 liters
- Before being used staves are dried on open air for at least 24 months
- The especially think stave (35- 38 mm) gives the possibility for duplicating use of the barrels
- Barrels are given a thourough workover both inside and outside
- Barrels are bent over fire
- Barrels are to be used for storing wine and spirits under 75%
Prices
| Barreltype | Adomment (EUR) | Barrel (EUR/Pcs.) 1-10Pcs. / >10Pcs. |
| Adomsbarrel 5 l | 10 € | 35€ / 30€ |
| Adomsbarrel 10 l | 10 € | 45€ / 40€ |
| Adomsbarrel 20 l | 10 € | 65€ / 60€ |
| Adomsbarrel 30 l | 10 € | 75€ / 65€ |
| Adomsbarrel 40 l | 10 € | 85€ / 75€ |
| Adomsbarrel 50 l | 10 € | 95€ / 85€ |
| Adomsbarrel 60 l | 10 € | 105€ / 95€ |
| Oakbarrel Gönc 136 Liter | - | 250€ / 230€ |
| Oakbarrel traditional 225 Liter | - | 310€ / 290€ |
| Oakbarrel barrique 225 Liter | - | 340€ / 320€ |
| Oakbarrel traditional 250 Liter | - | 340€ / 320€ |
| Oakbarrel barrique 250 Liter | - | 360€ / 340€ |
| Oakbarrel traditional 300 Liter | - | 380€ / 360€ |
| Oakbarrel traditional 400 Liter | - | 480€ / 460€ |
| Oakbarrel traditional 450 Liter | - | 560€ / 540€ |
| Oakbarrel traditional 500 Liter | - | 670€ / 650€ |
| Oakbarrel traditional 600 Liter | - | 890€ / 870€ |
Contact
Furin István
Address: 3530 Hungary, Fonoda str. 34-36.
Phone: +36 20 343 1864
E-mail:
