Customized oxygenation.

Crafting Innovative Whiskeys Through Customized Barrel Oxygenation

Not all whiskey matures the same. We use customized barrel oxygenation to shape each spirit. The barrel matters, but so does the air that moves through it. That idea guides DEEP CASK. We treat oxygen as a measurable, adjustable variable that can influence flavor. Each cask becomes a controlled environment rather than a random vessel.

AirBung^TM

The patent-pending AirBung™ sits at the heart of this work. It replaces the wooden bung with an oxygen-selective insert. Distillers set a precise oxygen ingress rate instead of relying on natural barrel permeability. This lets them dial in oxygen exposure and separate it from evaporation loss. No pumps, hoses, or power are needed. The barrel stays sealed. The headspace breathes at a chosen pace. AirBung offers a new maturation lever that works alongside the barrel. Wood still provides extractives. Oxygen now follows a plan.

Our findings are encouraging, though development continues. Bench trials show that controlled oxygen speeds key oxidative reactions and reduces angel’s-share losses. Early tests reach flavor milestones sooner. Still, larger warehouse trials are needed to confirm these results. We track congeners, oxygen permeation, and sensory scores. Each data point builds the case. The numbers suggest a clear outcome: customized oxygenation can become a valuable tool for craft distillers. It won’t replace tradition—but it adds a new dial to the control panel.

DEEP CASK invites collaboration with distilleries that value tested innovation. Choose barrels from five to fifty-two gallons. Order AirBungs with specific oxygen rates. Run these beside your standard casks and compare spirits over time. No special equipment or major investment is needed—just swap the bung and record the results.

Whiskey innovation moves slowly—barrel by barrel, season by season. Managed oxygen can unlock new dimensions in your maturation program. Contact us to plan a trial, set timelines, and implement it in your distillery. Then let the results speak for themselves.

Oxygenation Bung for Barrel Aging

Overview

The AirBung™ is a precision-engineered oxygenation bung designed to bring oxygen control into the craft of barrel aging. Built from white oak and featuring an ultra-thin polymer film (UTPF), AirBung lets distillers manage oxygen ingress without evaporation losses. It turns a passive element of aging into a tunable variable.

Key Features

• Oxygen-Selective
  Uses an ultra-thin polymer film with customizable thickness and surface area to precisely control oxygen flow.
• White Oak Construction
  Built to from traditional materials while offering modern functionality.
• No Power or Equipment Required
  Installs like a standard bung; no pumps, hoses, or electronic controls needed.
• Full Maturation Cycle Compatibility
  Functions consistently throughout the entire aging process.

Technical Advantages

Decouples Evaporation from Oxidation
Preserve spirit volume while achieving oxidative benefits.

Custom Flavor Development
Fine-tune oxygen ingress to influence aroma, texture, and finish—tailoring each cask to your target profile.

Improved Barrel Consistency
Reduce variability in oxygen exposure across barrels for more uniform results.

Yield Protection
Minimize angel’s share losses without compromising maturation quality.

Faster Time-to-Market
Accelerate flavor development while maintaining depth and balance.

How It Works

At the core of the AirBung is a polymer-based system that selectively allows air (oxygen) to pass. Adjusting the membrane’s thickness and area lets distillers set an oxygen ingress rate tailored to each cask. This provides unprecedented control over maturation, enabling innovation without disrupting standard workflows.

Who It’s For

The AirBung is ideal for:

• Craft distilleries seeking flavor consistency
• Researchers running controlled barrel trials
• Producers looking to optimize yield and maturation time
• Innovators aiming to modernize traditional practices

Ready to Integrate

AirBung is available in multiple configurations for 5- to 52-gallon barrels. No special equipment is required—just swap the bung and start recording results.

Let the Results Speak for Themselves

Contact us to request a spec sheet, set up a pilot program, or discuss your maturation goals.

To learn more, get in touch with us here.

We welcome collaborations with distilleries, researchers, and product developers interested in exploring the role of oxygen in cask maturation of spirits and wines. To start a conversation, reach out at [email protected] or drop us a message through the Contact form.