Operating the Brewhouse

Stacking the Kettles

  1. Level the brew stand base using the leveling feet on each leg
  2. Place the boil kettle on top of the base
  3. Place the brew stand collar on top of the boil kettle
  4. Place the mash tun on top of the brew stand collar
  5. Attach a hose from the boil kettle valve to the pump inlet
  6. Attach a hose from the pump outlet to the mash tun inlet (top valve)
    1. Fasten a hose to the corresponding valve outlet inside the mash tun
  7. Attach a short hose from the mash tun outlet valve and direct it into the centre of the boil kettle

Brew Day Prep

To save time on brew day, prepare a few things the night before. A checklist ensures everything is in place for an easy operation.

Adding Water

  1. Close all valves
  2. Add half of the water to the boil kettle
  3. Add the other half to the mash tun

Staging the Control Panel

Before turning the panel on, ensure the element and pump are switched off. Check that all cables are securely connected and that the temperature sensor is properly installed.

  1. Insert and turn the key to arm the panel
  2. Check the emergency stop button; disengage if on
  3. Check and set the PID to automatic mode:
    1. Press and hold the SET button until panel 1 (PV1) displays SET
    2. Press SET repeatedly to cycle through the options to find A-M mode (resembles A – Π)
    3. Use the ▲ button to change from value ‘0’ to value ‘2’. The panel automatically exits ‘set’ mode.

Heating the Water

  1. Open all valves
  2. Turn the pump on
  3. Turn the element on and set the PID to strike temperature
  4. Recirculate the water while it heats to strike temperature
  5. Crush grains
  6. Add the brewing salts as per the recipe; recirculate the water a few times to dissolve them
  7. At strike temperature close all valves
  8. Turn the element and pump off

Mashing In

IMPORTANT: No pump; no element during mash-in! Pushing grains through the pump is a bad thing for a lot of reasons.

  1. Add the grist to the mash tun, stirring while adding
  2. Let it sit for about 10 minutes to absorb the water, settle and release any pockets of trapped air

Beginning Recirculation

  1. Once the mash-in is complete, open all valves
  2. Turn the pump and heating element on
  3. Adjust the outlet valve on the pump to balance the flow through the system. Aim for approximately two inches of liquor above the grain bed

IMPORTANT: The heating element must always be submerged! Carefully monitor volumes between the mash tun and boil kettle. Manage flow only on the pump’s outlet side. Restricting flow to the inlet can shorten the life of the pump.

During the Mash

After about 10-15 min all the liquor has been recirculated and should have an even and consistent temperature. If the temperature gauges between the control panel and two kettles are within a degree or two, everything is fine. If not, use the mash tun gauge as your guide and calibrate the thermometers before the next brew and/ or run auto-tune on the control panel.

  1. Take a sample (2 tbsp) out of the kettle and cool to room temperature. Chilling the sample in a bowl of ice water drops the temperature in about 1-2 minutes
  2. Take a pH reading. The pH sample should be in the 5.2 – 5.4 pH range at room temperature, or 5.4 – 5.6 pH at mash temperature
  3. Add acid or minerals to balance the chemistry for your recipe

DATA POINT: Take measurements and fill in the section called Mash on the brew and batch log sheet

IMPORTANT: Occasionally stir the top third of the grain bed, leaving the bottom two-thirds to continue compacting and filtering.

Mashing Out

At the end of the mash the sweet wort needs to be transferred to the boil kettle.

  1. Set the PID temperature to 168°F (75.5°C)
  2. At 168°F, hold the temperature for 10 minutes to lock the starch conversion process
  3. Turn the pump off
  4. Close the valve on the boil kettle but leave the valve on the mash tun open
  5. Slowly drain the mash tun into the boil kettle. Dragging this out for 45 minutes is rumoured to improve efficiency.
  6. Close the valve once all sweet wort has been collected
  7. Transfer the spent grains into a bucket for disposal
  8. Remove the drain tube and hose from the mash tun
  9. Remove the mash tun from the brew stand; place it out of the way

IMPORTANT: DO NOT boil the wort with stacked kettles.

Boiling

The boil is done without recirculation so the temperature sensor does not take a reading to govern the element. The heating element needs to be controlled manually which is achieved by setting the PID to manual mode. In manual mode the element functions more like a stove dial than a precise instrument (Auber Instruments).

  1. Press and hold the SET button until panel 1 (PV1) displays SET
  2. Press SET repeatedly to cycle through the options to find A-M mode (resembles A – I I)
  3. Use the ▼ button to change from value ‘2’ to value ‘0’. The panel automatically exits ‘set’ mode.
  4. Use the control panel to set the value to for the desired boil vigour. We boil at 75% and evaporate ~2.2 gallons per hour.
  5. Wait for the boil to begin

Adding Ingredients

Add ingredients at the times described in your recipe.

  1. Use the boil time to rinse and sanitize the wort chiller, hoses, fermentation vessels and hydrate dry yeast.
  2. At the end of the boil, turn the heating element off at the control panel

Chilling the Wort

  1. Use hoses to connect the kettle out valve to the pump inlet;
  2. Connect the pump outlet port to the chiller in connection;
  3. Place the chiller out hose in a sanitized carboy. Alternately you can redirect it to the boil kettle to recirculate chilling (we do).
  4. Turn on the source water

Transferring to Fermentor(s)

  1. Direct to carboy
    1. Open the kettle valve and fill the carboy(s).
  2. Recirculation chill
    1. Wait until the wort is cooled to yeast temperature, usually 60° F – 70°F or (15.5°C – 21°C).
    2. Close the kettle valve
    3. Disconnect from the pump in port; put the hose end in the carboy(s)
    4. Open the kettle valve and fill the carboy

DATA POINT: Take measurements and fill in the section Into Fermentor on the brew and batch log sheet

Fermentation

  1. Aerate the wort with your preferred method, such as recirculating chilled wort through the boil kettle
  2. Pitch the yeast into the carboy
  3. Install an airlock or blow off valve
  4. Relocate the fermenter to a cool, dark place or lager fridge
  5. In the case of a lager fridge, set the temperature controller to match the yeast strain
  6. Ferment as per recipe instructions, tracking progress and notes in sections Fermentation, Packaging and Notes on the brew and batch log sheet

Cleaning the Brewhouse

  1. Compost all organic material
  2. Rinse, scrub and/ or dishwash all tanks, hoses, fittings and utensils
  3. Cycle clean water through the pump and chiller (buckets come in handy for this)
  4. Dispose of grey water
  5. Refill kettles and add Powdered Brewery Wash (PBW)
  6. Recirculate through the pump and valves for 10 minutes
  7. Turn the pump off and close all valves
  8. Leave the water and PBW in the tanks to soak overnight
  9. The following day, drain all water
  10. Recirculate clean water through the entire system, twice
  11. Drain the kettles

Storing Equipment

  1. Disconnect and hang all hoses
  2. Open all valves
  3. Place tanks on the brew stand as storage
  4. Dry and store remaining accessories and tools in their designated locations