When we finished our meals, we headed over to the home of Freixenet Cava, where we got a tour of the wine cellars and learned the process of how the sparkling wines were made and the development of the process over the years. From what I can remember, the cava starts with 3+ types of top-quality grapes (for different types of cava) that are grown in this region. The different types of grapes are best grown at certain altitudes in the region, and the soil helps largely in the development of the quality of grapes, with the amount of clay helping contain the rainwater. They mentioned that they don’t irrigate the fields and just let nature do its work. They pick the grapes in the later summer months, although due to global warming and increasing temperatures, the times for harvest have been premature, with the last 2 years being the earliest on record.
The next step in the cava making process is to crush the grapes (now industrially) in large containers where the first big squeeze produced 60% of the “grape juice.” This is the top-quality stuff they use for wine making, with the aromas and flavors they are looking for. The next squeeze gets most of the rest of it, which isn’t as good quality, so they sell it to distilleries and other companies for making alcohol and other drinks. The next step is adding sugar and their own yeast to the large containers and letting it sit for a while to ferment.
To make sparkling wine however, they put the liquid in the bottles, and let it sit again for some number of months to let the yeast do its thing allowing no air to escape. The yeast will eventually collect and clump together, creating “lees” (a sediment) which has to be taken out before they can sell the bottles. They have a shaking/shifting/rotating process to separate it out from the liquid keeping it at the end near the lid of the bottle while the liquid is in the bottom. They have an automated process now done by machines that can do a hundred bottles in only 3 hours per machine when it used to be a few days or weeks for 2 bottles done by hand.
The part of the bottle with the lees are then suspended in ice water until it freezes and then (also automated now and less tedious than by hand) the bottle is opened, and the lees are removed, then it’s recapped without losing any of the cava. Also, the wine was previously stored underground because it has a constant temperature required for optimal fermentation, which is about 50-55 degrees Fahrenheit.
They make several million bottles a year and were the first sparkling wine to sell internationally. Freixenet is a big supplier to the the US as well, and I assume it’s popular. After the tour we got to taste two of their most popular Cavas. I’m not a fan of alcohol so I didn’t particularly like it, but learning the process was interesting.