Why McLaughlin Distillery Keeps Its Spirits Small, Simple and In-House

(Photo: McLaughlin Distillery)

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In an era when many smaller whiskey brands rely on sourced spirits and outsourced production, McLaughlin Distillery has built its business around doing the opposite. The Pennsylvania producer operates year-round, makes every product on-site and follows a deliberately narrow set of production principles that shape everything from mash bills to barrel selection.

Rather than chasing rapid expansion, McLaughlin has focused on full control — of ingredients, equipment and process — resulting in a portfolio that reflects consistency and intention more than scale.

Distilled Off the Grain by Design

One of McLaughlin’s defining production choices is separating grain solids before distillation. While distilling on the grain is common for the sake of efficiency, McLaughlin removes the grain first, reducing particulate carryover and producing a cleaner base spirit.

The added time and labor limit output, but McLaughlin isn’t prioritizing mass production. This approach allows more precise control over texture and flavor before the spirit ever reaches a barrel. For McLaughlin, that tradeoff is central to its identity.

A Simple Mashbill With Complex Results

Instead of rotating mash bills or chasing complexity through grain variety, McLaughlin keeps its whiskey foundation intentionally simple — all its bourbons are distilled from 100% corn, emphasizing brightness and natural sweetness over spice or grain sharpness.

That consistency gives the distillery a stable base for experimentation elsewhere in the process. The only whiskey with another mashbill is Blackburn Rye, which blends 5-year cask-strength bourbon with unaged rye whiskey to create a hybrid profile that doesn’t fit neatly into standard categories.

Barrel Size as a Tool

McLaughlin relies heavily on small-format barrels — primarily 10-gallon casks, with smaller 5- and 2.5-gallon barrels used selectively. All much smaller than your usual 53-gallon size. The smaller barrels accelerate interaction between spirit and wood, deepening color and pulling oak-driven flavors earlier in the aging cycle.

Small cask aging requires constant monitoring, and batches are evaluated individually rather than by fixed age statements. This allows the distillery to release spirits based on readiness rather than timelines.

A Portfolio Built Through Hands-On Production

Every product in McLaughlin’s lineup is made under the same roof using the same core equipment. That includes bourbons, American whiskeys, experimental blends, cream liqueurs and more than 23 flavored moonshines.

This variety reflects a willingness to apply the same hands-on approach across different styles.

Recognition Rooted in Process, Not Scale

Several McLaughlin releases have earned top-tier competition results, including Double Gold medals at the San Francisco World Spirits Competition for Cask Strength Baby Barrel Bourbon and Mario’s Creamy Limoncello, which has won in consecutive years.

The recognition highlights how a small operation using rustic equipment can still deliver technical consistency when process discipline remains the priority.

A Salt-of-the-Earth Business Built Without Outside Capital

Founder Kim McLaughlin brought an agricultural background to distilling after more than 25 years in dairy farming. That experience shaped the distillery’s emphasis on efficiency, adaptability and self-reliance. When a career change coincided with final permitting, the distillery shifted from a planned hobby into a full-time operation with no external funding.

That constraint continues to inform production decisions, reinforcing a preference for manageable batch sizes and hands-on oversight rather than rapid growth.

Year-Round Production

McLaughlin operates more than 300 distillation days each year, keeping production consistent. This steady rhythm supports a broad release schedule while allowing the team to maintain quality control across categories.

It also reflects a philosophy rooted in consistent work — not sporadic output tied to marketing cycles.

Accessing the Lineup

McLaughlin Distillery’s full portfolio is available through its online store, with shipping to most states. New customers can apply the promo code DailyMD for $10 off your first online order. Shop now!