Saturday, June 15, 2013

Home Brewery Upgrade--the New Setup

Well, unfortunately, I failed to take pictures when I punched holes and installed the inlet valves in my mash tun and boil kettle.  Guess I got excited and jumped right in.  It was a bit stressful, but I feel a LOT better now that it's finished and everything turned out well.



View of inlet from inside kettle.  5' of
silicone tubing coils around to the
bottom of the kettle to help with
whirlpooling.
Kettle inlet valve installed 2" from top.
Blichmann Thrumometer installed inline
to monitor wort temps into kettle















Mash Tun inlet valve for sparging

So, now that the modifications are behind me, it does seem much simpler than it did when I was in the planning stages.  The only real equipment modification was the addition of the inlet valves.  Two big additions were the March pump and the Blichmann floor burner.  Other than that, all the fittings are now quick disconnect and I replaced all my flimsy 1/2" vinyl tubing with thermoplastic tubing, which makes a pretty badass looking hose when it's rockin a QD fitting on each end.





Tomorrow I plan to brew my first batch on this new setup, a Scottish 70/- that I'm calling No Pence.  It will be a 5 gallon extract batch made with Marris Otter LME from Northern Brewer.  This will be my first extract batch in over 6 years; thought I'd keep it simple as I get used to the pump, etc.

From kettle to pump, through chiller, back into kettle!

Today, I set up the BK, pump, chiller circuit and ran some One Step cleanser through it.  This was meant not only to clean but more importantly to test run the setup before brew day tomorrow.  Worked great!  I couldn't be more thrilled.  The test run did expose some leaks, but after tightening up a few spots I think I'm ready.  Got some nice whirlpool action inside the kettle, too, and I dropped an extra tablespoon of One Step powder into the kettle which didn't take long to find its way into a tidy little pile in the center.

Maybe difficult to see, but there's a nice whirlpool going.


Can't wait for brew day tomorrow!

Wednesday, June 12, 2013

Home Brewery Upgrade--The Plan

So, now that the problems have been outlined, let's talk about solutions.

All the parts for the upgrade are in.  I have 10 stainless quick disconnects, several feet of thermoplastic tubing and some silicone tubing, three stainless ball valves, two street elbows, a March pump, and a Blichmann floor burner.

I also picked up a used Barley Crusher with 7" rollers and a 15# hopper.  This should make it much easier to mill my grain than it is on my current Grain Gobbler with 2" rollers and plastic funnel for a hopper, which holds maybe 2#.  More importantly, the Barley Crusher should improve the consistency of my crush, which will help me hit my efficiency more consistently.



Now, lets tackle each limitation in order, and talk about what all this stuff is going to do about it:

1.  Fly sparging with the lid off = massive heat loss.  I need an inlet valve about 1" from the top of my mash tun.  This should allow me to add sparge water above the grain bed while keeping the lid on, retaining much more heat. One ball valve, street elbow and some silicone tubing--along with the right size hole punched at the appropriate place on my cooler--should do the trick.  I've seen two configurations that I like.  The simpler one, and the one I plan to use, comes from The Electric Brewery build.  A length of tubing simply rests on the grain bed supplying sparge water at a single point.  Shouldn't really have a problem with channeling, but if I don't get good results with this, I can try the other configuration, which employs a T to form the tubing into a circle which hovers above the grain bed.  Holes punched in the tubing allow sparge water to be "sprinkled" evenly across the surface, similar to my current sparge arm.  Either way, the significant improvement is the addition of the top inlet valve--allows me to sparge with the lid on, and combined with the March pump, will allow me to retire my two pitchers and do a proper vorlauf.

2.  Can't fire the BK until runoff is complete.  So the addition of the Blichmann burner should do the trick here.  My summer batches will be done on the patio, HLT and MLT on the patio table, BK on the burner a foot below.  Shouldn't have a problem firing that puppy up during runoff, at least to maintain temp in the BK, if not to raise it, without fear of kettle caramelization.

3.  Stovetop boiling is no good.  Blichmann burner.  Done.

4.  Added a plate chiller; created issues.
       a.  Cold break ends up in the fermenter
       b.  Gravity is not the best way . . .

       The addition of the March pump and an inlet valve on the boil kettle will take care of both of these issues.  The pump pulls the wort through the plate chiller and recirculates it back into the BK as I see fit, and finally pumps it into the fermenter.  And of course the whirlpool attachment on the interior of the inlet will help to chill the wort inside the BK, at a rate I decide, controlled by the ball valve on the exit end of the pump.  This allows all lengths of whirlpool/ hop stands at temps I control, for any number of fun aromatic additions.  Meanwhile, cold break is pumped back into the BK, where the whirlpool action deposits it neatly in a cute cone in the center of the kettle with the rest of the trub, far from the output valve.  When this process is complete, the pump moves the chilled wort into the fermenter.

So that's it!  My next post, hopefully soon, will include pictures of the modifications as they were made.  Can't wait until this is complete and I can brew on it.

Thursday, May 16, 2013

Home Brewery Upgrade--Limitations of my Current Setup

I have been brewing on the Morebeer B3-200 since I started brewing all grain.  It's the most basic setup:  two orange coolers, a brew kettle, and some tubing.  The bulkheads, the spigots, and the fittings are all original--which makes them 10 years old.  I have replaced tubing, of course, and I added a 1/2" stainless ball valve spigot and bazooka screen to the brew kettle about 18 months ago but that's about it.


"Three tier Brew Stand"
Sparge arm that came with the setup.
I think it was manufactured by Listerman
or Fermentap--not even sure they're
still in business...

Original stainless steel ball valve with
a plastic barb fitting.

Runoff into the BK













Stovetop boiling.  What a mess.


This setup has served me very well up to now, but I am beginning to feel its limitations, so I know it's time to update it.  Some of the limitations I need to address:

1.  Fly sparging with the lid off = massive heat loss.  As seen in the above photo, I have no way to fly sparge with the lid on the mash tun under this current setup.  You may well imagine that after 45-60 minutes with the lid off, the temperature of the mash drops significantly (down to about 140 or below, in fact).  It's been ok up to now--just a minor inconvenience--but if I hope to improve my beer, I need to figure out a way to keep the lid on during the sparge.

2.  Can't fire the BK until runoff is complete.  Because my setup is 100% gravity driven, and because I don't have a proper 3 tier brew stand, my BK sits on the floor during runoff.  This means that I can't apply heat to it until after I've collected my full volume of wort and moved it to the stove top.  I imagine I could easily shave 60-90 minutes off my brew day just by maintaining temp during the sparge and firing up the kettle sooner.

3.  Stovetop boiling is no good.  I have gone through a few different iterations of kettle setup, but since we moved into this house 10 months ago, I've been boiling on this glass topped stove.  No good.  Can't attain or maintain a good rolling boil without the lid on the kettle, and I'm pretty sure I'm destroying this stove, which certainly was not designed to boil 10 gallons of anything for 60-90 minutes.  I need a proper heat source for my kettle, I need to get this kettle off the stove before I have to explain to my wife that I broke it, and I need a configuration that eliminates the need to carry my full kettle from one place to another.

4.  Added a plate chiller; created issues.  A few months ago I replaced my immersion chiller with a Shirron plate chiller.  Love the fact that I got the IC out of my wort, but the addition of a plate chiller without any other modifications to my process has caused two issues:
   
     a.  Cold break all ends up in the fermenter.  I understand that a little bit of break
          material in the fermenter is a good idea since it contains nutrients for the yeast, but
          I'd like a way to leave most of it behind in the kettle.

     b.  Gravity is not the best way to move wort through the plate chiller on its way to the
           fermenter.  It is possible, but tricky, a big pain in the ass.  I need a way to move wort 
           through the plate chiller that is more reliable and consistent than gravity.

That's the basic outline.  I would also like to add the ability to whirlpool after flameout.  I have already planned out my upgrades and purchased the parts and equipment that I need in order to hopefully overcome these limitations.  In the next post or two, I will lay out the plan.










Thursday, May 9, 2013

Hop Sprouts!

Just a quick update:

I came home this evening to find three tiny sprouts pushing their way through the soil to sunlight!

They look like this...

See my Hops Page for the full photo documentary of my first year of hop "farming."


Sunday, May 5, 2013

Growing Hops

This weekend I planted three Centennial hop rhizomes.

I'm apparently planting late in the season, and I definitely don't have a green thumb.  But, I like the thought of brewing up something this fall using fresh hops grown in my own back yard, so I thought I'd give it a try.


I planted the rhizomes in a 30" pot with a tomato stake, along with several other produce items in their own pots.  Our family decided to plant a vegetable garden this year, but since this is only our first full summer in our new house, we decided to keep it simple with a container garden.  So on the patio we now have five pots, one each of strawberries, tomatoes, zucchini, rosemary, and of course Centennial hops.


It was such a great afternoon with the kids--so much enthusiasm, not just for going elbow deep in dirt, but genuinely for handling plants that they realize and trust will yield some of their favorite foods in a few weeks and months.

I hope my hops take off, and I am fully prepared to add structure and support as they hopefully climb far beyond the 36" of this tomato stake framework.

I will update here as things progress.

Wednesday, April 10, 2013

2013 Strategy

It's been quite a while since my last post.  Work's been busy, and I've had plenty at home as well to keep me distracted--building a guest bedroom in the basement (a project still only halfway complete).  Fortunately I have managed to brew two batches since the new year:  A Tripel and an American Pale Ale.  The Tripel is absolutely delicious, although I missed my efficiency and my attenuation so it’s much fuller and sweeter than intended.  The Pale Ale--hopped with 100% Cascade hops—just kicked last night (wish I would have waited longer to start drinking it; the past two nights’ pulls were amazing).

Anyway, I think now may be a good time to set the focus of my brewing, and perhaps of this blog, a little better.  Until now, my brewing has been kind of random, and that’s probably reflected in my posts up to this point.  It has always been my goal to learn as much as I can about home brewing, to continue to grow as a brewer and someday to produce amazing beers that can stand up to the best commercial examples.  I think I finally understand how to achieve that, and in 2013, I’m narrowing the focus of my brewing and setting a strategy for my own improvement.  You’ll read about it shortly.

WHERE I STARTED:

I brewed my first batch in 2001, but I wouldn't say that I've been brewing that long since I took a six year hiatus when my kids were born.  In the first stint (pre-kids), I probably brewed about 8 extract batches, none of them repeats, each of them a complete mess—but at least I was making beer.  And of course I had no idea that it sucked (my family and friends are very supportive; they “love” all my beer).  Like so many other new homebrewers, I wanted to brew everything, and to brew with everything.  A fresh strawberry "wheat," an oaked IPA, a Belgian wit, and a chocolate stout were all among this first round of brews.  After a few years, I invested in a basic 3-vessel all grain system (two 10 gallon converted coolers and a 15 gallon kettle) from MoreBeer.  I thought (incorrectly) that this was the best thing I could do to improve my beers.  I stumbled around two or three all grain batches before my wife had twin boys in 2005, at which time my burgeoning hobby was shelved.

WHERE I AM NOW:

I picked up brewing again right around this time in 2011, on the equipment I bought in 2003, that had been collecting dust since 2005.  The cool thing—as I would discover—was that equipment had not changed in that time, but the quality of information available to me seems to have improved tremendously.  In the past two years I've brewed 12 all grain batches—mostly not repeating any style or recipe more than once, and my results have been varied to say the least.  I now have a fermentation chamber (able to control fermentation temps to within 1 deg F anywhere from 30-80).  I cold crash, and I fine with gelatin and my past few batches have looked and tasted great.  But I still know I have a lot to learn.

WHERE I’M HEADED:

Over about the past year, I've been reading voraciously on Home Brew Talk Forums (while not posting much) as well as in books from Brewers Publications, and also listening to podcasts (current and archived) from the Brewing Network trying to gain as much knowledge as I can.  My 2013 strategy follows advice offered repeatedly by Jamil Zainasheff on “Can You Brew It” and probably elsewhere.  This year I am focusing on:
  • Repeatability 
  • Understanding yeast

Specifically, I have chosen just a few beer styles to focus on and will brew those over and over—hopefully with identical results--in order to really understand my system and process, and in order to “nail” those styles (“clone” my own brews).  Styles I’ll be working on this year are:
  • Scottish 80/-
  •  American Blonde Ale
  • American Pale Ale 
  •  Imperial IPA
  •  Patersbier
  • Tripel

Six styles may seem a bit much for the strategy I just laid out, but I love them all so much . . .  And my goal is to brew twice a month starting in May.  I chose these styles also because they can help me with my second goal:  understanding yeast.  I will brew everything on this list with one of only two yeast strains, so that I can really begin to understand them, how they behave, what they like and don’t like, etc.  I will be able to ferment the Pale Ale and IIPA using slurry (WLP001) from the Blonde or 80 /-, and I will be able to ferment the Tripel using slurry (WLP550) from the Patersbier.

For the 80/-, the Blonde, the Pale, and the Tripel, I simply pulled the recipes from Brewing Classic Styles.  The Patersbier is based on the kit recipe from Northern Brewer, and the IIPA will probably be an amped up version of my Columbus IPA.

I might join a local home brew club, and I’ll probably also enter a few of my brews in competition before the year is through.  Having my beer evaluated by strangers trained to do so will no doubt reveal flaws I don’t detect, refining my process and my palate (my friends and family are not helpful; they “love” all my beers—they’re all just impressed that it is beer).

This blog itself is another strategy toward my overall goal of developing myself as a home brewer.  From the beginning, I've meant it as a tool to chronicle my progress.  I’m sure I will someday look back at my early posts and chuckle at the silliness.  Those early posts will no doubt expose some of my limited understanding, misinformation, misinterpretation, and otherwise general noobdouchery.  I’m ok with that.  They will stand as they were written, as what they are:  points on the map showing where I was as I continue my journey to where I’d like to be.

Friday, November 16, 2012

I Brew Better Beer

Sound arrogant?  Well what I mean is:

I have brewed some really crappy beer in my time.

Luckily, with experience I continue to get better and better.  A few changes over the years in my equipment, setup, and process have resulted in my ability to brew much better beer.

I'm not done yet--my beer still has plenty of room for improvement, but here's where I've gotten so far . . .

WORT AERATION
Yeast need oxygen to develop healthy cell walls, which are key to their surviving the rigors of fermentation.    Unfortunately, boiling actually drives off oxygen, so a well aerated post-boil wort is a must for healthy yeast.  I use a small plastic aeration tip at the end of my hose while transferring my cooled wort to the fermenter.  A small cone in the tip spreads the wort into a thin sheet as it exits the hose, introducing lots of oxygen along the way.  I also rock the fermenter for about a minute after pitching, just to make sure.

Aeration Tip:  possibly the best $2.59 I've ever spent on a
home brewing gadget



YEAST STARTER
Pitching the right amount of yeast will greatly improve your beer.  You can grow your cell count by pitching your yeast into a small amount of 1.030-1.040 unhopped wort a few days before brew day.  There are several means available for determining the amount you need based on yeast type and gravity of your beer.  Popular online pitch rate calculators can be found at mrmalty.com and yeastcalc.com.  Some beer design software packages also include pitching rate calculators.

I enter all my beers into BeerSmith, whether designing my own or simply inputting a popular recipe I'd like to try.  The "starter" tab in the software tells me how many billion yeast cells are ideal for the given beer's starting gravity, yeast strain and age, and also tells me what size starter I need in order to achieve the required cell count.  This is a very good thing--the less "math" I have to do, the better off my beer will be, I'm sure.

These days, all of my starters go on a stir plate.  This device creates a vortex or whirlpool effect in the starter, which helps the yeast grow healthier and more plentiful, more quickly, by constantly aerating the wort (remember how much yeast love oxygen in the growth phase?) and by keeping them in suspension for maximum exposure.
Magnetic Stir Plate:  It's because of stuff like this
that my kids think I'm a mad scientist.
My wife just thinks I'm nuts.

WHIRLFLOC, KETTLE SCREEN, A 15 MINUTE REST
With a strong rolling boil, certain proteins and other compounds will separate out of your wort as solids. Don't worry, you don't need them in your finished beer or even in your fermenter, so this is a good thing.  Boil strong.  While we're on the subject, there are also plenty of volatile nasties that you don't want--good news is these will evaporate away with a good rolling boil as long as you let them, so leave the lid off.  As for the solids separating out of the boil--"hot break" is what it's called--there are a few clarifiers that you can use in the boil to help prevent it from transferring to the fermenter with the wort.  I use whirlfloc, just a little white tablet that goes into the boil 15 minutes before flameout.  It dissolves into smaller particles that bond with the hot break and drag it to the bottom of the kettle like a bunch of evil little mermaids.  This, along with a long, strong stir at flameout (trying to emulate a whirlpool) and a 15 minute rest afterward seem to do a great deal toward depositing all the solids in a tidy pile at the bottom of the kettle.  With the help of a kettle screen, I am able to leave much of it behind when I transfer.
Kettle Screen:  This bad boy gets quite dirty during transfer.

FERMENTATION TEMPERATURE CONTROL
My beer quality took a solid jump forward when I gained the ability to control fermentation temps.

I used to just chill it down as much as possible post boil (maybe mid 70s to mid 80s), then pitch, throw it in the basement, and let it naturally drop to whatever it would drop to (maybe 70-75ish). What's the worry? We're in the ballpark, right? Wrong. Stressed out yeast.  Bad things happened.  Bad beer, actually.

Then, last year as a most awesome Christmas gift, my wife bought me a 7 cubic foot chest freezer and a Johnson temp controller.  The true purpose for this was and is to be converted into a keezer for my draft home brew.  That will happen someday. In the meantime, I'm content to lift the lid and pour a pint from my picnic tap, and the freezer doubles as a fermentation chamber.  Now with every batch, I pitch my yeast at the low end of its temp range, then as the most vigorous period of fermentation comes to an end, I gradually ramp it up a few degrees to facilitate attenuation.  Much happier yeast; much better beer.

DIALING IN

REPS
Besides possibly fermentation temp control, this is probably the most important factor contributing to my journey toward better home brew.  Practice.  Repetition.  The more I brew, the more comfortable I become with the process and the better I understand the effect each decision has on the finished beer.  When I first started out, I did things a certain way because the directions said to, or because I read in a book that I should do it that way.  When I stopped making decisions based on what I "knew" based on reading in favor of what I truly "understood" based on experience, my brewing rose to a whole different level.

WATER TREATMENT
This is the latest development in the evolution of my brewing.

When I began the hobby, I just used straight tap water, whatever the fine Borough of Hanover saw fit to send through my kitchen faucet. Eventually, I migrated to carbon filtered tap water, then more recently to store bought spring water.

I finally feel consistent enough in my process that I've decided it's time to sweat the water profile.  Still brand new at it, so I can only work from "knowledge" I've gained through reading, or through listening to interviews of experts like Gordon Strong.  No real understanding yet--that can only come with experience.  Only after enough reps will I begin to understand the effect that small adjustments in water chemistry might have on the finished beer, and which might play best to my own preferences.

For now, I'll have to rely on published wisdom, and the consensus seems to be that a good basic water profile can be achieved by starting with a distilled or reverse osmosis water (either one effectively a zero value, neutral baseline), adding 1 tsp calcium chloride per 5 gallons brewing water, and adding 2% acidulated malt to the mash.  So that's what I did.  My first brew using treated water is in the fermenter now, a 60 minutey IPAish kinda thing, so I also followed the guidance for hoppy beers and added half a tsp of gypsum.  Don't know why, just that its what others who do understand brew water chemistry better than I do suggest to add.  We'll see how it turns out--hopefully a bit brighter, cleaner, and more flavorful, with a hop presence that just pops.

So that's it.  Pay attention to your yeast; give it what it needs. Get some reps in; practice practice practice. If you're a beginning home brewer looking to take your brew quality to the next level, I'd say those two things would be the best place to start.