Oak barrels have a 2,000-year history and play a crucial role in bourbon production by enhancing flavor. Independent Stave is the world's largest barrel maker, emphasizing the historical value and global operations of barrels. Barrels are crafted with precision, using a charring process to enhance whiskey's flavor profile. Bourbon regulations require new charred oak barrels, driving demand due to rising bourbon interest. Barrels contribute up to 80% of bourbon's flavor, imparting notes like caramel and vanilla. The "alligator char" process textures the barrel interior, adding complex flavors to the whiskey. Temperature fluctuations in storage facilities allow the bourbon to interact with the wood for aging.

Used bourbon barrels, rich with flavors, are highly sought after globally, often repurposed for aging diverse spirits like scotch, tequila, and rum. The bourbon barrel industry is export-heavy, with Kentucky shipping $300 million to countries like Scotland for aging other spirits.