Mellow Corn is not categorized as a bourbon primarily because it is aged in once-used barrels, rather than new charred American oak barrels. This distinction in aging process is one of the key factors that sets bourbon apart from other types of whiskey, including corn whiskey like Mellow Corn.
To be considered a bourbon, a whiskey must meet certain legal requirements set by the U.S. government. These requirements include being made from a grain mixture that is at least 51% corn, aged in new charred oak barrels, distilled to no more than 160 proof (80% alcohol by volume), entered into the barrel for aging at no more than 125 proof (62.5% alcohol by volume), and bottled at a minimum of 80 proof (40% alcohol by volume). Mellow Corn meets most of these criteria, with its 80% corn mashbill and 100 proof bottling strength, but falls short in the aging process.
The use of once-used barrels in the aging of Mellow Corn is what sets it apart from bourbons. Bourbon regulations specifically require new barrels, as the charred oak contributes to the flavor profile and character of the whiskey. By using once-used barrels, Mellow Corn deviates from this requirement and therefore cannot be classified as a bourbon.
The choice to use once-used barrels in the production of Mellow Corn may have been made for a variety of reasons. It could be a cost-saving measure, as new barrels can be expensive. Additionally, using once-used barrels may impart different flavors and characteristics to the whiskey, providing a unique profile that sets Mellow Corn apart from traditional bourbons.
It's important to note that while Mellow Corn may not be classified as a bourbon, it is still a corn whiskey. Corn whiskey, like bourbon, must have a mashbill that is at least 51% corn. However, corn whiskey is not subject to the same aging requirements as bourbon, allowing for some flexibility in the aging process.
In terms of personal experiences, I have had the opportunity to taste Mellow Corn and other bourbons side by side. While Mellow Corn may lack the traditional bourbon characteristics imparted by new charred oak barrels, it still offers a distinct flavor profile. The once-used barrels may contribute different oak flavors and allow other aspects of the whiskey, such as the corn sweetness, to shine through. It's a unique and enjoyable experience, albeit different from what one might expect from a traditional bourbon.
Mellow Corn is not considered a bourbon due to its use of once-used barrels in the aging process, which deviates from the requirement of new charred oak barrels for bourbon. Despite this distinction, Mellow Corn is still a corn whiskey and offers its own distinct flavor profile.