How McLaughlin Distillery Built One of America’s Most Distinctive Grain-to-Glass Operations

(Photos: McLaughlin Distillery)

Exclusive for our readers: Use code DailyMD for $10 off your first online order!

Grain-to-glass distilleries have become more common over the past decade, but very few follow a playbook similar to the one McLaughlin Distillery uses. Tucked into the wooded hills of Sewickley, Pennsylvania, the small operation produces everything on-site, works with a lean staff and relies on methods that often run counter to large-scale whiskey production. The result is a portfolio that ranges from traditional bourbons to experimental blends and an unusually deep lineup of flavored spirits, all tied together by an approach that favors clarity, simplicity and hands-on craft.

An Unconventional Distillation Method

One of the first things visitors learn on a McLaughlin tour is that the distillery separates its grain before distillation. Most whiskey makers run the entire mash through the still with solids included. McLaughlin does the opposite.

Removing the grain adds extra steps but creates a softer, cleaner spirit before it’s even aged. This technique is rare in the American whiskey scene, and it gives McLaughlin’s base distillate a noticeably bright, smooth profile. Everything is done by a small team that spends the majority of the year in active production.

A Simplified Mashbill With a Clear Intent

Rather than building whiskeys around complex mash bills, McLaughlin keeps the recipes focused and straightforward. The distillery’s bourbons and whiskeys use 100% corn, a rare choice that pushes grain harshness out of the way and keeps the character light and approachable. When the distillery does step outside of that framework, it does so with purpose. That would be Blackburn Rye, which uses a split of five-year cask-strength bourbon and unaged rye whiskey to land somewhere between classic rye and a high-proof smooth American blend.

Small Casks, Bigger Flavor

Barrel aging is where McLaughlin’s production choices start to show their impact. The distillery relies heavily on small cooperage: mostly 10-gallon casks, along with 5-gallon and 2.5-gallon barrels. All are heavily charred (#4), which gives the spirit rapid access to toasted and caramelized wood layers.

Smaller barrels means less surface area and more whiskey-to-wood contact. This increased wood-to-liquid ratio can produce color and complexity quickly, but it demands close monitoring. With a small team tasting regularly throughout the year, the distillery adjusts age ranges and release timing batch by batch.

These decisions and attention to detail have paid off at the prestigious San Francisco World Spirits Competition. The distillery’s Cask Strength Baby Barrel Bourbon earned a Double Gold medal at the San Francisco World Spirits Competition, while its Mario’s Creamy Limoncello has taken Double Gold in consecutive years, a rare feat. For a distillery using rustic equipment and small-batch methods, the awards have helped spotlight the technical precision behind the folksy aesthetic.

While the distillery remains compact in size, its catalog is anything but. McLaughlin produces traditional bourbons and whiskeys alongside a growing collection of experimental releases. Its flavored spirits program is particularly robust, with more than 23 varieties of moonshine, plus cream liqueurs and seasonal bottlings that rotate throughout the year. Every product comes from the same site, and nothing is sourced.

Open-Door Culture and Year-Round Activity

McLaughlin is open seven days a week, and its tour program gives visitors a close look at how the spirits are produced, from fermentation to barrel aging to bottling. The team participates actively in the local community, showing up at events, festivals and classes throughout the region. As the distillery heads toward its 10th anniversary in February 2026, it continues to balance a casual, welcoming atmosphere with a production schedule that surpasses 300 distillation days per year.

Shop McLaughlin Online

For those outside western Pennsylvania, the distillery ships its full lineup to most states through its online store. New customers can take advantage of our exclusive offer: use code DailyMD to get $10 off your first online order!