How Mezcal Is Made
Mezcal is more than just a drink - it is a centuries-old tradition, deeply rooted in Mexican culture and craftsmanship. Unlike industrialised spirits, mezcal is still made using time-honoured, hands-on methods that have been passed down through generations. From the agave fields to the bottle, every step of the process contributes to the unique flavours and character of this beloved spirit.
We walk you through the entire mezcal-making process, from harvesting the agave to the final distillation and bottling.
Step 1: Harvesting The Agave (La Jima)
Selecting The Right Agave
Mezcal can be made from over 30 different agave species, each bringing its own unique flavours (check out our guide on Agave Varieties And Their Flavour Profiles). The most common is Espadin, but wild agaves like Tobala, Tepeztate, and Cuishe are also highly prized.
How It’s Done
Once an agave plant reaches maturity (which can take anywhere from 6 to 30 years), skilled harvesters called jimadores use a sharp, flat-bladed tool called a coa to cut away the leaves, revealing the heart of the plant - the pina (or "pineapple"). This pina is where the sugars needed for fermentation are concentrated.
Did you know? Wild agave mezcals are rarer because these plants take decades to mature and can’t be farmed easily.
Step 2: Roasting The Agave (Coccion)
The Traditional Pit Oven
One of mezcal’s most distinctive characteristics is its smoky flavour, which comes from roasting the agave in underground pits. These pits are lined with stones and filled with wood and hot volcanic rocks, creating an earth oven.
How It’s Done
- The pinas are cut into smaller pieces and placed into the pit
- The pit is covered with palm leaves, soil, or mats to trap heat
- The agave roasts for 3 to 7 days, allowing the heat and smoke to break down the plant’s starches into fermentable sugars
Why It Matters
This slow, smoky roasting process is what gives mezcal its signature earthy, smoky, and complex flavours.
Step 3: Crushing The Roasted Agave (Molienda)
Traditional vs. Modern Methods
After roasting, the softened agave must be crushed to extract its juices. There are two main methods:
- Tahona (Stone Mill): A giant stone wheel, usually pulled by a donkey or horse, crushes the roasted agave fibres
- Hand Crushing: In smaller batches, mezcaleros use wooden mallets to manually mash the agave in hollowed-out logs
- Mechanical Mills: Some modern producers use motorised mills, but many traditional mezcaleros avoid this to preserve authenticity
The Difference? Stone-milled or hand-crushed mezcal often has a richer, more fibrous texture, whereas mechanical methods can result in a lighter, cleaner profile.
Step 4: Fermentation (Fermentacion)
Natural, Open-Air Fermentation
Unlike industrial spirits, mezcal fermentation is done in open wooden vats, stone pools, or clay pots, allowing natural yeasts from the environment to do the work. This process can take 5 to 30 days, depending on the temperature, agave variety, and location.
The Role Of Wild Yeasts
Because mezcal relies on wild fermentation, each batch develops unique flavours based on its surroundings. Some mezcals have fruity notes, while others may develop funky, earthy, or even slightly sour characteristics.
Fun Fact: Some mezcaleros even add agave fibres into the fermentation tanks to enhance texture and depth.
Step 5: Distillation (Destilacion)
Once fermentation is complete, the liquid (called tepache) is distilled to concentrate the alcohol and refine the flavours. Mezcal is usually distilled twice, but some high-end mezcals undergo a third distillation for extra purity.
Distillation Methods
- Copper Alembic Stills: These are the most common and provide a cleaner, refined flavour
- Clay Pot Stills: Found mainly in Oaxaca and Guerrero, clay stills produce earthier, rustic mezcals with mineral notes.
Why It Matters? The type of still used dramatically influences the final texture and aroma of the mezcal.
Curious about the science of distillation? Read our in-depth article on Tequila vs Mezcal: Differences, Similarities And Which To Choose.
Step 6: Ageing And Bottling (Maduracion y Embotellado)
Types Of Mezcal Ageing
Unlike tequila, most mezcals are unaged (joven), but some are aged for different periods, creating unique expressions:
- Joven (Young): Unaged or rested for up to 2 months. Purest expression of agave flavour
- Reposado (Rested): Aged 2 - 12 months in oak barrels. Smooth, with hints of vanilla and caramel
- Anejo (Aged): Aged 1+ years, with deep, complex flavours similar to whiskey
- En Barro (In Clay): Aged in clay vessels, enhancing mineral and earthy notes
Want something smoky and bold? Stick with a joven. Prefer a smoother sip? Try a reposado or anejo.
Final Thoughts
Mezcal production is a labour of love, requiring patience, craftsmanship, and a deep respect for tradition. Every step, from the choice of agave to the distillation method, influences the final character of the spirit.
Why Mezcal Stands Apart
- Handcrafted in small batches
- Made from diverse agave species
- Uses traditional, slow production methods
- Influenced by regional terroir
As passionate spirit merchants, we encourage you to explore different mezcals and appreciate the artistry behind every bottle.