Of Oak and Men: The Art of Vat Making

Established in the Cognac region since the 1930s, Tonnellerie Bernard combines authenticity and craftsmanship to meet the needs of its customers, whether winemakers or distillers. In the heart of Grande Champagne, the artisans at Tonnellerie Bernard have mastered the skills and techniques required for the meticulous craft of barrel and vat making.

XXL Casks

There are barrels and there are casks. There is wine and there are spirits. And in between, there are coopers. At the Barret workshops, the teams at Tonnellerie Bernard have just completed the production of 42 casks ordered by a distillery in Grande Champagne. The first batch was delivered at the very beginning of the year, and the second this March. Two capacities, for the same cellar: 250 and 160 hectoliters. It took more than four months of meticulous work to fulfill this exceptional order—a challenge met with skill and dedication by the teams led by Cyrille Royer, Spirits Sales Manager at Tonnellerie Bernard and Production Manager at Atelier du Foudrier. “Orders like this are rare,” says Cyrille. “It’s a real human and technical challenge. Everything is custom-made, specially designed for the cellar that will house these casks. From the design office to delivery, through every step of the production process, the entire team worked together to serve our client.”

First, the Oak…

It all begins with the selection of wood—specifically, oak planks. “We use extra-long staves, several meters in length, to form the body of the casks. The wood must be of exceptional quality—perfect. The grain must run straight along the entire length of the stave, which is an absolute requirement,” explains Cyrille Royer. “Unlike traditional cooperage, where the wood is split, here it is sawn while still maintaining a straight grain throughout its length.” Naturally, the workspace is designed to accommodate the production of large casks. Each step requires multiple craftsmen working together. The assembly of the cask’s structure and the subsequent stages even require scaffolding. The brasero used for toasting is suspended from a chain, ensuring the staves are evenly heated. “Large casks have a longer lifespan than standard oak barrels, and their use is entirely different. Each cask is custom-equipped, and the finishing touches are particularly important and carefully executed.”

… Then, the Craftsmen

There would be no large casks without the hands that shape them. While the quality of the oak plays a crucial role in the excellence of the vats and casks crafted by Tonnellerie Bernard, the true added value lies in the expertise of its teams. “L’Atelier du Foudrier is Charlois’ dedicated cooperage workshop—a hub of craftsmanship serving both eaux-de-vie distillers and winemakers. Being a foudrier is an exceptional trade, especially considering the scale of some of these large casks,” emphasizes Cyrille Royer. From the timber yard to final delivery, each step—of which there are many—requires a high level of expertise and precision. The craft of making a vat demands an average of 160 hours of labor. In 2024, a total of 53 casks were produced in the vat making workshops for Tonnellerie Bernard.