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Old Barrels at the Port Vale Sugar Factory used for starting the boilers.

Barbados Rum Trip 2

The Rumelier had just got back from the Miami Rum Renaissance in May 2010 when he was asked if he wanted to go to a Mount Gay Rum conference in Barbados, staying four nights at the Barbados Hilton. After very little thought he volunteered for another rum adventure to the beautiful southern Caribbean country of Barbados. Unfortunately The Rumelier only had one day, a Saturday, to do some rumming after all his official functions had been completed. As it was "slow season" all of the rum distilleries are closed on Saturdays to visitors, so he was limited in what he could discover on this, his second trip to the "home of rum".

He had however managed  to make contact with the organizers of the upcoming "Caribbean Rum and Beer Festival", which is scheduled to take place in November, 2010. Two of the organizers of the Festival very kindly volunteered to be The Rumelier's guides around the island for the day.  A generous offer, very gladly accepted by the Rumelier. ( http://www.rumandbeerfestival.com/ ) 

Even though all of the rum attractions are supposed to be closed on Saturdays the small group of rum adventurers did manage to access three of the islands top attractions, even if on just a limited basis. Aswell there are always well over one thousand rum shops to visit, which would keep anybody busy for a day. Apparently there are as many rum shops as there are churches! This rum adventure along with The Rumelier's official visit to Mount Gay made for another great visit to Barbados, even if a fairly short.

The Mount Gay Aging and Blending Warehouses

The Rum Refinery of Mount Gay.
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The Rum Refinery is situated alongside the Blending and Aging Warehouses.
Entrance sigh to the Rum Refinery of Mount Gay.
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The main reason for flying to Barbados was that The Rumelier had been invited to attend a Remy-Cointreau seminar in Barbados for two full days, where he was to not only learn a great deal about Mount Gay Rums but also about Remy Martin Cognacs, which he learnt were distilled and aged very similarly to rums in the Caribbean.

However, his first official function was a tour of the Mount Gay Aging and Blending Warehouses in the parish of St.Lucy, situated in the northern part of Barbados, a long drive from Bridgetown. The Rum Refinery of Mount Gay is a seperate sister company that is situated alongside the blending and aging warehouses on top of a hill, overlooking the surrounding fields full of sugar cane, at various stages of growth. Once the rum is distilled at the refinery using the copper pot stills and column stills it is then pumped via pipes to the blending and aging facility. Once the rum arrives at the blending warehouse, the double distillate rum from the copper pot stills and single distillate from the column stills is stored in huge tanks (pictured below) until it is ready to be blended and stored in oak barrels for slow aging for up to 30 years.

Large Rum Storage Tanks.
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The distilled rum is pumped to the blending warehouse from the nearby distillery.

The small group of Mount Gay distributors arrived at the facility eager to learn as much as possible about one of the world's most famous rums. Once they were inside the compound they were greeted by their guide for the tour, Master Blender, Alan Smith (pictured below). This was a special treat for the group, to be given a tour by a master blender is a rare occurrence that few receive, especially as tours are not usually given of the facility.
After the welcoming greetings were over the group were briefly shown a view of the rum refinery next door and given a brief explanation of the distillation processes used. The group could see the molasses tanks and the still house from the blending warehouse. Next the group was taken inside to see where the rum is blended in even larger tanks (100,000 gallons) before it is pumped into the used Kentucky Bourbon barrels. The same location is also used for emptying the barrels after the rum has been aged for several years.
The same area was also used as a staging area for all the "new" Kentucky Bluegrass barrels that arrive in 40 foot shipping containers. The new barrels were much cleaner than the older barrels that are sometimes stored for up to 30 years in one of the three huge aging warehouses.

Alan Smith, Master Blender at Mount Gay Rum.
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The new barrels are previously used bourbon barrels which are filled and emptied from the side of the barrels, where the bourbon is usually poured into a tank in the ground when they are emptied. At Mount Gay, and like many other rum distilleries, the new barrels have a hole drilled into the top of the barrel so that the barrel is filled and emptied standing upright. This means the barrels are also stored upright to avoid leaking, as opposed to bourbon barrels that are usually stored on their sides. At Mount Gay 6 barrels are stored and transported on special hardwood pallets that originate from Guyana in South America. The pallets are only stacked 5 high due to the weight of the rum and barrels. To stack the rum any higher the pallets would have to be wider to avoid any swaying of the stacks of rum.
Currently Mount Gay have three aging warehouses, with each one storing approximately 9000 barrels. There are plans to build another one in the near future, as all the warehouses are filled to capacity with aging rum at the present time.
The whole pumping, filling and blending process is completely computerized from a control room situated on the second floor of the warehouse building. This was the next stop for the small group during their tour of the facility. Once inside the much needed air conditioned room Alan Smith demonstrated how the computer system worked and showed how the rum was pumped from one location to another.

"New" Oak Barrels from Kentucky at Mount Gay.
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The Barrels are stacked on special hardwood pallets from Guyana.
Barrels Waiting to be Filled with Rum at Mount Gay
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Bourbon Barrels are filled from the side and are usually re-drilled on top at rum distilleries.
A Tanker being filled with rum headed for Brandons
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The Mount Gay Visitor Center

Sign at the Mount Gay Visitor Center.
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The oldest pot still in the world.
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Mount Gay Ambassador Chester Brown, left.
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A flight of Mount Gay Rums.
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Mount Gay, the Rum that Invented Rum.

The West Indies Rum Distillery

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Beachfront view of the West Indies Rum Distillery.
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Still House at the WIRD.
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Molasses Underground Tank.
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Aging Warehouse at WIRD.
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Barrels at the West Indies Rum Distillery.
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The Portvale Sugar Factory and Museum

Entrance to Portvale Sugar Factory.
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Sir Frank Hutson Sugar Museum at Portvale.
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The site of the Caribbean Beer and Rum Festival.
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Storage Tanks at Portvale.
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Old Machinery at Portvale Sugar Factory.
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Brief History of Sugar Production in Barbados

Tobacco and cotton used to be the main crops of choice in Barbados before sugar cane was introduced to the island planters in the mid 1600's. At the time of sugar cane's introduction to the island the tobacco industry was on the decline and the planters were looking for a new source of income for their plantations. It was a Dutchman, Peter Blower, who bought sugar cane plants from Brazil. The cane flourished in the ideal conditions of the Southern Caribbean and it went on to be a most lucrative cash crop for the already wealthy plantation owners.

As the sugar export industry grew on the island so did the amount of vast sugar plantations. Much of the land at the time was forested, but most of the trees were felled to make way for more sugar plantations, changing the landscape of Barbados for ever.

Seeding Sugar Cane in Barbados late 1890's.
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Fresh Barbados Sugar Cane.
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One requirement for large-scale sugar production at the time was a large labour force. This labour force were imported African slaves. By the early 1800's the population of slaves had reached almost 400,000. They were needed to grow, harvest and process the sugar cane and turn it into raw sugar, that was shipped off to the colonial master, England. Much of this process was performed by hand, before the later introduction of power. Windmills were introduced to reduce the work load of the slaves and remnants of many of these windmills can still be seen dotted allover Barbados.

There were several hundred sugar plantations in Barbados at the peak of sugar production, but today there are only a handful left still producing sugar. Those plantations that no longer produce sugar are often found for sale. One exception is St.Nicholas Abbey, that has started sugar cane farming again, as well as distilling their own rum.

Switching from tobacco and cotton production proved a blessing for the economic growth of Barbados. Sugar cane thrived in the good soil and climatic conditions of Barbados and produced up to 20kg for every square metre planted.

The interesting photograph from The Rumelier's collection shown above shows sugar cane being seeded on a sugar plantation in the early 1980's. Today sugar cane is grown from cane cuttings which can be harvested several times after it has been planted. However, each successive crop will yield less sugar and need to be replanted after several seasons of growth.

The cane fields are often set on fire to allow the leaves to be burnt away, which in turn exposes the roots for harvesting. Burning the fields also helps eliminate any unwanted animals, especially snakes from attacking any of the cane cutters. When the cane is harvested by hand with a large knife or machete, the cane is piled into large stacks and loaded onto trucks for delivery to the sugar factory. Mostly in these modern times the fields are harvested using large machines and only the difficult inaccessible areas of fields are still cut by hand, which is also less damaging to the crop than the big harvesting machines. Using large machines is much more cost and time efficient for the large sugar plantations.

The Foursquare Rum Distillery

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Fermentation Tanks in the Foursquare Distillery.
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One of the Bonded Aging Warehouses at Foursquare.
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The Rumelier at the Foursquare Distillery.
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Barrel Filling Production Line.
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Copper Pot Still at RL Seale, recently modified.
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Barrels of Tommy Bahama Rum at Foursquare.
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Sugar Harvester and Cane Trucks at Foursquare.
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The Foursquare Bottling Plant.
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Tommy Bahama Rum is Bottled here.