My big fat shiny American Keg brewery build with pics

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setmash

My big fat shiny American Keg brewery build with pics

Post by setmash » Fri Jan 03, 2014 8:49 pm

At last the American 15.5 Gallon, 59 liter, American Sankes have arrived. After months of planning my new electric brewery is getting off the ground.

The spec:

3 x Sank kegs - 59 liters (so i can pre boil my liquor for a double corny batch of 38 liters)
Inverted - to make cleaning as easy as possible, and ZERO dead space :-)
BCS driven - I want to reduce brew time and improve consistency and the Brewery Control System will help me do this.
Front end will be 10 inch Android tablet (after debug) with compact control box (initial debug will be done via laptop)
5500W ULWD in Kettle and HLT, 4500W ULWD in RIMS - 38 Amp system budget , PWM managed via BCS
2 x Chugger with stainless steel heads
High throughput Quick Disconnects - first phase using hose, second phase hard piped in copper (because it looks great) - many tests needed me thinks
Initial stage no RIMs (one step at a time ..)

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Zero dead space

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Playing around with positioning stuff

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I will let you know how i get on and post more pics !!!

setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Fri Jan 03, 2014 9:10 pm

Brew stand is made from old oak post and rail fencing from the garden that Ive cleaned up.

Not a single bit of wood was square....it was a begger of job to get it level and square, looks very rustic though and it cost nearly nowt (better still)

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setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Fri Jan 03, 2014 9:18 pm

Base plate for the control box is now drilled....took me nearly a fecking day to do this, Q max, Starret , cobalt drills...not had this much fun since metal work class at school. It does look like the flight deck of a spitfire !!

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mysterio

Re: My big fat shiny American Keg brewery build with pics

Post by mysterio » Sat Jan 04, 2014 5:13 am

Great work, will be following this.

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far9410
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Re: My big fat shiny American Keg brewery build with pics

Post by far9410 » Sat Jan 04, 2014 7:30 am

Hi, how did you seal off the top of the keg, which is now the bottom?
no palate, no patience.


Drinking - of course

darkonnis

Re: My big fat shiny American Keg brewery build with pics

Post by darkonnis » Sat Jan 04, 2014 10:29 am

Tri-clamps. You just need to file down the gasket a bit on one side so it fits.

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far9410
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Re: My big fat shiny American Keg brewery build with pics

Post by far9410 » Sat Jan 04, 2014 11:56 am

darkonnis wrote:Tri-clamps. You just need to file down the gasket a bit on one side so it fits.
I'll come back to you on this later!
no palate, no patience.


Drinking - of course

rossi74

Re: My big fat shiny American Keg brewery build with pics

Post by rossi74 » Sat Jan 04, 2014 1:21 pm

Liking the look of this

setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Sun Jan 05, 2014 6:59 pm

All my kit has turned up from the states. Paid full duty on one package and partial duty on the other. not complaining overall. Have to say the quality of the kit is outstanding. I managed to get my BCS working over the wireless network today and successfully accessed it via my laptop and tablet. Will do some work on this when i get time.
The 2 inch tri clamps and gaskets arrived with the packages. I ordered two types of gasket, the normal silicone tri clamp gasket with one half already smoothed off and also 3 o rings in case the gaskets didnt work. I tried the gaskets first, to my horror they make the overall mating too thick and the tr-clamps struggle to make it around the whole neck. I then tried the o rings. They worked, however they are tricky to put in place and i actually severed one whist playing around....kack. I decided to give the gaskets another go. I applied a fair bit of pressure to the tri clamp and it eventually fitted. Seemed to seat the gasket very nicely even though the tr-clamp itself does not mate perfectly around the keg neck...time for a wet test.

Here you can see how i attach to keg neck

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Here is the broken O ring with the tri clamp in place. (looking down through the top of the keg) You can see the drop in aperture from 2 inches to 0.5 inches. I have spent hours pondering whether to use 2 inch tr-clamp valves to aid cleaning (give me a larger aperture output). The cost would be quite high so i decided for the first build to stick to half inch as this baby is bankrupting me already....i tested it later with grain - see below

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Start of wet test - filled with 59 liters of water - not a single drop leaked, excellent. Output from the keg is simply astonishing. with zero dead space left in the bottom.

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So I fitted the false bottom to the wet test keg. It fits beautifully (note there is no hole for a dip tube , so it is perfect for my application)

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I decided to add some grain, i was really keen to see how much flow would get through the grain and also just how easy this bottom draining 'MT' would be to clean. I added about 6Kg of grain (so not an exact test but would give me an idea). OMG i was not disappointed. The flow through the grain bed was simply astonishing (see the pic below - no thats not a silicone tube its the water pounding from the MT)...I couldnt get enough water back in to the MT (hose pipe on full bore) to keep up with the outflow from the MT through the grain bed. Here is a pic of the output going in to a bucket at full bore - this is going through the grain bed :shock:
It also emptied with zero dead space, nada liquid present :D

I then cleaned the MT by scooping out the grain and then flushing out of the bottom in to a bucket (see pic of my basic test). It took me about 5 mins to thoroughly clean the MT. Any worries i had about only having a half inch aperture for cleaning were unfounded. It was an utter dream to clean. Initial tests have proved very very encouraging, so far, im delighted and now very excited.....

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darkonnis

Re: My big fat shiny American Keg brewery build with pics

Post by darkonnis » Sun Jan 05, 2014 7:43 pm

Good stuff, I knew myself as soon as we got our FV's made of kegs and did a wet test we'd made a mistake and should have used them for the entire hotside as well. Looking good!

setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Sun Jan 05, 2014 8:13 pm

Many thanks Darkonnis, it was your comments on earlier threads and the work you have done that convinced me this was the right way to go. I was so happy today with the throughput and how easy it was to clean without moving the keg an inch !! ....just drain in to a bucket.

Plenty of work to do on this build yet - its going to take some time, and time is hard to find...the Mrs is already asking a lot of questions lol....

setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Tue Jan 07, 2014 7:39 pm

Base plate connector position test - wow i cut that one fine. These connectors are lovely though. The black one on the right is 32A (8Kw rated to drive my 5.5 Kw elements) rated and the one on the left is 20A rated. I will have 2 x 32A for HLT and Kettle 5.5KW elements, 4 x 20A for 4.5KW RIMs element, 2 x chugger pumps and an output to FV heater. I also have 8 x 5 pin DIN for all the temp probes and various inputs - HLT, Kettle, RIMs OUT, Mash, float safety switches on kettle and HLT, RIMs flow safety switch and Emergency stop button. There are a few spares for expansion. Im not too keen on the DIN connectors, they look a bit 80's - should of gone for something a bit nicer - not that it will matter when everything is plugged in !

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Here is the bottom panel populated with all the connectors. Its not yet painted and I may change the screws to something nicer. You can see how dense it is though.

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themadhippy
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Re: My big fat shiny American Keg brewery build with pics

Post by themadhippy » Tue Jan 07, 2014 7:50 pm

. Im not too keen on the DIN connectors, they look a bit 80's - should of gone for something a bit nicer
horrible connectors the cable connectors are paain to solder "nicely" ,there non locking so tend to disconnect if you look at em funny,at this early stage why not change them to some nice xlr 5 pins,if the budgets tight http://cpc.farnell.com/pro-signal/psg01 ... dp/AV15043 or if your feeling flush and want the rolls royce http://cpc.farnell.com/neutrik/nc5fd-lx ... dp/AV19358
Warning: The Dutch Coffeeshops products may contain drugs. Drinks containing caffeine should be used with care and moderation

setmash

Re: My big fat shiny American Keg brewery build with pics

Post by setmash » Tue Jan 07, 2014 8:12 pm

I agree they look awful. Im not too bothered about the soldering Ive a lot of experience on that side so I will get by. They seem to mate fairly snuggly right now but I agree if I could I would swap them out but the problem is Ive already drilled my panel base plate !!! Looks like Im stuck with them as it doesnt look like they are panel cut out compatible..yuk #-o

Fil
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Re: My big fat shiny American Keg brewery build with pics

Post by Fil » Wed Jan 08, 2014 3:06 pm

xlr sockets should fit in a similar sized hole?? looking good....
ist update for months n months..
Fermnting: not a lot..
Conditioning: nowt
Maturing: Challenger smash, and a kit lager
Drinking: dry one minikeg left in the store
Coming Soon Lots planned for the near future nowt for the immediate :(

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