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Looking to yield 6 gallons of finished 110 proof whiskey to fill a small new oak barrel. I’m doing my stripping runs right now as I ferment out these batches one by one. My low wines are running about 75 poof on average.

I’m thinking my spirit run of the low wines will keep about 60% of the cuts. So I’m thinking I’ll need the equivalent of 10 gallons of 110 proof in order to get 6 gallons after cuts. If my low wines are 75 proof then my math puts me at needing 14.67 gallons of my low wines in order to yield 10 gallons of 110 proof in order to make my cuts to end with 6 gallons of whiskey to barrel.

Does this sound about right to you?

Truthfully that isn’t something that can be answered. Some can fill a 5 gallon barrel with 100 gallons of ferment. Some use a little more. The health of the ferment can also affect how much beer is needed to make a barrel. Yield varies from person to person and recipe to recipe.

Yes, you’re correct.

To get 10 gallons of 110 proof (55%ABV) would require (10 x .55) / .375 = 14.67 gallons at 75 proof (37.5%ABV).

Also, in the event you have more than 6 gallons after cuts, then you can keep the extra to backfill the cask as it ages and evaporates. Or, if by some mistake, you happen to pull a bottle off once in a while.

I think your estimate of 6 gallons of product from a 10 gallon collection is conservative. Sure, you’ll have some for the feints, but I doubt it will amount to 40% of the collection. Regardless, 15 gallons of 37.5%ABV low wines will give you enough to fill the cask, and a little extra.
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110 proof is quite low for aging whiskey. 130 proof is more commonly used as it pulls different flavors from the wood.

75 proof is quite high for low wines and leaves useful flavors and alcohol in the backset. Good if you are adding fresh wash to the low wines for the spirit run.

I suspect most of us calculate the amount of wash needed rather than the amount of low wines. I've seen quotes from members of 50% to 60% of the initial alcohol ending up in their barrels. From experience, I know what I can expect to get, so I use that to calculate the volume of wash needed.

Thank you all!