For bourbon and whiskey lovers, the allure of aged spirits lies in the deep, complex flavors that come from time spent in oak barrels. But did you know that tequila makers are also harnessing the power of barrels—both new and used—to create unique and compelling flavor profiles? If you’re a fan of bourbon, exploring tequila aged in these barrels might just open up a whole new world of sipping pleasure. Let’s dive into the fascinating differences between new and used barrels in tequila production and why this matters to your palate.
The Bourbon Connection
First, it’s important to understand the role of barrels in bourbon and tequila. Bourbon, by law, must be aged in new charred oak barrels. Once a barrel has been used for bourbon, it can’t be reused for bourbon again—enter tequila.
Bourbon barrels are a favorite among tequila distillers because they’re readily available and packed with residual flavors. After bourbon aging, these barrels retain notes of vanilla, caramel, and toasted oak, which beautifully complement the natural sweetness of agave. When tequila is aged in these used barrels, it absorbs these characteristics, creating a rich, layered spirit that feels familiar yet distinct.
New Barrels: A Clean Slate
New barrels, on the other hand, offer a clean slate. Fresh, unused American oak barrels impart bold, woody flavors to tequila, along with intense vanilla and spice notes. The charred interior of new barrels also adds a smoky depth, which can enhance the agave’s earthy and herbal qualities.
For tequila producers looking to create a bolder, more robust flavor profile, new barrels are often the go-to choice. The result is a tequila that stands out for its intensity and complexity, appealing to those who enjoy the punch of a well-aged bourbon.
Used Barrels: Subtle and Refined
Used barrels, especially ex-bourbon or ex-whiskey barrels, bring a different dimension to tequila. Since these barrels have already been “broken in” by their first tenant, they impart subtler, more integrated flavors. Think of it as the difference between a roaring campfire and the lingering warmth of embers.
Tequilas aged in used barrels often showcase softer notes of caramel, vanilla, and maple, with a smoother, more mellow finish. For bourbon drinkers, this can feel like a natural progression—a spirit that’s familiar in its depth but distinct in its agave-driven character.
Most tequilas are aged in used bourbon/whiskey barrels, including Four Roses, Woodford, Jack Daniel’s, Jim Beam, Buffalo Trace, and others.
The Flavor Playground
The choice between new and used barrels allows tequila makers to experiment and create a wide range of flavor profiles. Some distilleries even use a combination of both to strike the perfect balance between boldness and refinement.
For example, the famous Clase Azul reposado is aged in new American oak barrels, which lends it a robust, woody character with notes of vanilla and spice, perfectly complementing its smooth agave base.
Another standout is the equally well-known Don Julio 1942, which spends time in new oak barrels to achieve its iconic richness and depth.
Craft tequila brand Insólito embraces new American oak for both its reposado and añejo expressions, delivering bold, smoky profiles with hints of caramel and toasted wood—ideal for bourbon drinkers looking for a familiar yet distinct experience.
I made a delightful single-barrel Insólito añejo last year that was frighteningly quaffable.
Then there’s the rare but exciting use of new French oak barrels. French oak brings a different flavor profile compared to American oak, with more subtle tannins and notes of baking spices, dried fruit, and even a hint of floral sweetness.
While this is less common in tequila production, it’s gaining traction among innovative producers. Casa Dragones Joven is one example that blends tequila aged in new French oak barrels, resulting in a smooth, elegant spirit with layers of complexity.
Another notable example is Volcan de Mi Tierra, which uses new French oak for its reposado and X.A. expressions, creating refined and nuanced tequilas with hints of citrus, vanilla, and a silky finish.
Use of new French oak is a bit of a high-wire act, however, as the flavors can get very strong, very quickly.
I collaborated with craft brand Primo on a single-barrel reposado aged in barrels with new french oak staves and American oak heads. After just 35 days, we pulled it out because the flavors were already very prominent.
Why Bourbon Fans Should Care
If you’re a bourbon or whiskey enthusiast, tequila aged in barrels offers a natural bridge to explore. The familiar flavors of vanilla, caramel, and oak are there, but they’re layered with the distinct sweetness and earthiness of agave. It’s a chance to experience something new while staying grounded in the comforting warmth of barrel-aged spirits.
Sustainability and Efficiency
Beyond flavor, there’s a practical side to using barrels. Repurposing bourbon and whiskey barrels is both cost-effective and environmentally friendly. New barrels can cost upwards of $750 (and new French barrels well over $1,000) while used ones are significantly cheaper, often around $200. This allows tequila producers to invest in other areas, like sourcing high-quality agave or expanding their offerings.
Reusing barrels also aligns with sustainability goals, reducing waste and promoting eco-conscious practices.
An Invitation to Explore
The world of tequila is evolving rapidly, and barrel aging is at the heart of this transformation. Whether you’re sipping a tequila aged in new American oak or one that’s taken on the subtle nuances of a bourbon barrel, you’re experiencing the artistry of a distiller who knows how to harness the power of wood.
So, bourbon fans, it’s time to venture into tequila territory. You might just find a new favorite that bridges the gap between the familiar and the extraordinary.
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Jay Baer is a tequila educator and a marketing and business consultant to tequila brands. He and his business partner, Maddie Jager, produce 20+ videos per month about all things tequila on Instagram (@tequilajaybaer) and TikTok (@tequila.jay)
Get their list of 83 top recommended tequila brands at JayTequila.com