In this series of articles examining homebrewing with electric we have looked at BIAB (Brew In A Bag) in Part 1, HERMS (Heat Exchange Recirculating Mash System) in Part 2, and in Part 3 we examined RIMS (Recirculating Infusion Mash System).
In this article we are going to examine conversion possibilities for our existing 3-tier Sanke keg-based system from propane gas to electric. We will investigate how much it would cost and how you would go about modifying the system into a BIAB, HERMS or RIMS type of system…
Please note that prices are taken from the supplier’ web sites and are subject to change.
Conversion
Having looked at various BIAB, HERMS and RIMS systems there are a variety of possibilities that could be built using my existing three tier brewing system which comprises of the following:
- 7.75 gal keg for HLT (Hot Liquor Tank).
- 15.5 gal keg for Mash Tun which includes a false bottom and is insulated with Reflectix aluminum bubble-wrap.
- 15.5 gal keg for Boil Kettle.
In addition to the above there is a Chugger pump, various fittings, hoses and valves plus a home-made brew stand that could also be re-purposed to keep the build costs down.
One thing that was noticeable from the HERMS and RIMS systems is that they fill the Boil Kettle from the Mash Tun in a bottom-up rather than top-down manner which is to help avoid Hot Side Aeration of the wort that can cause off flavors such as oxidation. This is one change that would be needed if something other than a BIAB system was to be built.
There are some other options that are not covered in this article but could be considered as a way of brewing inside, these include the use of an Induction Stove. We examined this alternative during the winter of 2013 and wrote an article about our experiences – see Homebrewing inside using Induction stoves.
The prices of these start at around $100 for a 1300w version which we found to be too low in power because for even a 5 gallon batch it was a struggle to reach a boil and resulted in a prolonged brew day. There are however more powerful and professional grade versions which might be worth considering such as the following:
- Max Burton 6530 ProChef 3000-Watt Commercial Induction Cooktop (3000w) – $266
- SPT SR-1262B-1 2600W Commercial Built-In Induction Range (2600w) – $402
- Vollrath 59500P Mirage Pro Countertop Induction Range, 14-Inch (1800w) – $454
One word of advice we would offer is should you want to try an Induction Stove then ensure it is returnable for a full refund in case you are not fully satisfied with how they perform. Also if you reside within the USA then check whether the voltage of the stove to ensure you have the correct supply e.g. some are 240v.
The following sections are going to look at each of the three types of systems from a conversion perspective.
*** IMPORTANT ***
Please note that all components and builds should be double-checked and ideally verified with the relevant retailers prior to making a purchase and starting an assembly. Also note that these systems are electricity-based and therefore dangerous and that extreme caution should always be taken. If you are unsure about how to proceed then it is advisable to engage the services of, or seek advice from, a qualified electrician.
BIAB
In order to build a BIAB system the following components are needed:
- Stand – reuse existing homemade brew stand. Cost = $0.
- Brewing vessel – one of the 15.5 Sanke kegs can be reused for this. Cost = $0.
- Grain basket – to fit inside the brewing vessel and to avoid the issue of a meshed bag sitting on top of the heater element. Cost = $130 (Brew-In-A-Basket 400 Micron Stainless – 10″ x 13″ with 5″ feet & handle).
- Meshed bag – not needed if the grain basket solution is adopted otherwise some sort of false bottom would be needed in order to avoid the potential problem of a meshed bag touching the hot heating element and melting. Cost = $0.
- Crane – given the size of the brewing vessel it would make sense to target 10 gallon batches which means lifting a bag or basket full of wet grain. This would require a handle on the basket itself plus a hook, rope and non-slip ratchet. Cost = $20 (Rope Ratchet 3/4-in x 8-ft Ratcheting Tie Down plus joist bracket needed).
- Controller – to regulate the temperature, control the recirculation via the pump, and accept a temperature probe. Can utilize the 220v 30amp service that the dryer in the basement uses as this can be made available on brew days which will save on electrician charges. Automation would be an added benefit if available e.g. to step mash if possible. Cost = $495 (High Gravity EBC SV – manual only step mashes) or $650 (Brew Boss Controller – allows automated step mashes).
- Temperature probe – to monitor the temperature of the liquid being recirculated within the brewing vessel. Cost = $0 (Probe for EBC-SV and EBC III included with High Gravity EBC SV controller) or $0 (Brew-Boss Plug-in Temperature Probe included with Brew Boss Controller).
- Temperature probe cable – to connect the temperature probe to the controller. Cost = $0 (Temperature probe cable for EBC-SV and EBC III included with High Gravity EBC SV controller), same goes for Brew Boss controller.
- Temperature sensor fitting – to connect the temperature probe to the brewing vessel. Cost = $0 (for High Gravity temperature probe) or $35 (Direct Contact Weldless Temperature Sensor Fitting for Brew Boss controller).
- Quick connects, hoses and clamps – existing parts can be reused for this purpose. Cost = $0.
- Pump – existing Chugger pump can be used to recirculate the liquid. Cost = $0.
- Heating element – 4500w or higher. Plugs into controller that supports 240v supply. Cost = $89.95 (Heating Element – 4500 Watt SS Twist-lock Plug for the High Gravity controller) or $69.95 (Heating Element – 4500 Watt SS for the Brew Boss controller).
- Heating element connector – may need to widen the existing thermometer hole and add a different connector so the heating element can fit. Cost = $19.95 (Weldless Heating Element Kit – needed for the 4500w element but not the 5500w version).
- Lid bulkhead – needs to include a spray nozzle and fittings for hose and temperature probe. Cost = $19.95 (Lid Input Assembly with Sprinkler for BIAB with existing available lid) or $0 if existing Fly Sparge arm is reused (may not be workable due to clogging from small particles in the mash, this arm is really meant for sparging with water only).
- Hop dispenser – this would be an optional extra to allow timed additions such as hops. Estimated cost = $175 (attached to Brew-Boss Controller) or $250 (separate to Brew-Boss Controller).
This system takes a similar approach to the Braumeister so is arguably a RIMS system due to using a basket rather than an actual bag.
Estimated starting costs = $774.85 (excluding taxes, shipping & Hop dispenser)
HERMS
In order to build a HERMS system the following components are needed for our three vessel system:
- Stand – reuse existing homemade brew stand. Cost = $0.
- Controller – to control the temperature of the HLT and Mash Tun as well as control of the pump. Can utilize the 220v 30amp service that the dryer in the basement uses as this can be made available on brew days which will save on electrician charges. Cost = $799 (EBC III with Infinite Power Control)
- HLT – one of the 15.5 Sanke kegs can be reused for this. Cost = $0.
- HLT heat exchanger – this raises the heat of the mash and can also be used for cooling the wort after the boil. Reuse the existing 50 foot copper wort chiller. Needs modification to be supported on the bottom of the HLT so it does not sit on the heater element or consider the use of a Blichmann BoilCoil which goes round the edge of the kettle rather than across this middle. Cost = $0 (may need so parts or add to the cost of the heater element).
- HLT heat exchanger connectors – existing plastic garden hose connectors need replacing with metal connectors and attaching to the HLT lid or side. Cost = $11.96 (2 x Gilmour Metal Quick Connector Set with Overmold)
- HLT heating element – 4500w or higher. Plugs into controller that supports 240v supply. Cost = $89.95 (Heating Element – 4500 Watt SS Twist-lock Plug) or or $169.99 (Blichmann BoilCoil for 20 gallon).
- HLT heating element connector – may need to widen the existing thermometer hole and add a different connector so the heating element can fit. Cost = $19.95 (Weldless Heating Element Kit – needed for the 4500w element but not the 5500w version).
- HLT temperature probe – to monitor the temperature of the liquid being recirculated within the brewing vessel. Cost = $0 (Probe for EBC-SV and EBC III using existing 1/2″ NPT fittings – probe is included with the High Gravity controller).
- HLT temperature probe cable – to connect the temperature probe to the controller. Cost = $0 (Temperature probe cable for EBC-SV and EBC III which is included with the High Gravity controller.
- Pump – existing Chugger pump can be used to fill the Mash Tun with strike water from the HLT, recirculate the liquid between the Mash Tun and through the heat exchanger in the HLT plus move the liquid from the Mash Tun into the Boil Kettle during sparging. This would require the appropriate opening and closing of valves at the right time if not automated. Cost = $0.
- Pump fittings, ties, hoses and connectors – various needed for plumbing. Cost = $50 (estimated).
- Mash Tun (MT) – one of the 15.5 Sanke kegs can be reused for this together with existing false bottom and dip tube. Cost = $0.
- MT AutoSparge – AutoSparge to govern the flow rate of liquid entering the top of the Mash Tun over the grain bed. Cost = $69.99 (Blichmann AutoSparge)
- MT temperature probe – to monitor the temperature of the liquid being recirculated within the brewing vessel. Cost = $0 (Probe for EBC-SV and EBC III using existing 1/2″ NPT fittings – probe is included with the High Gravity controller).
- MT temperature probe cable – to connect the temperature probe to the controller. Cost = $0 (Temperature probe cable for EBC-SV and EBC III which is included with the High Gravity controller.
- Brew Kettle (BK) – new 20 gallon kettle to enable safe boiling of full 12-13 gallons volume for a 10 gallon batch. Cost = $454.99 (Blichmann BoilerMaker).
- BK heating element – 4500w or higher. Plugs into controller that supports 240v supply. Cost = $89.95 (Heating Element – 4500 Watt SS Twist-lock Plug) or $169.99 (Blichmann BoilCoil for 20 gallon).
- BK heating element connector – may need to widen the existing thermometer hole and add a different connector so the heating element can fit. Cost = $19.95 (Weldless Heating Element Kit – needed for the 4500w element but not the 5500w version).
Estimated starting costs = $1605.74 (excluding taxes & shipping)
RIMS
Whilst a HERMS brewing system applies heat to the mash liquid being recirculated indirectly via a Heat Exchanger in the HLT, a RIMS system applies the heat directly and this is usually by one of the following methods:
- By heating the liquid that is in the bottom of the Mash Tun and then recirculating it up to the top of the Mash Tun.
- By recirculating the liquid into the Boil Kettle for heating then back up to the top of the Mash Tun.
- By recirculating the liquid through a tube containing a heating element and then back up to the top of the Mast Tun.
With all three methods the most important thing is to recirculate the liquid at a high enough flow rate so as not to scorch or caramelize it and introduce undesirable color and/or flavors.
Our BIAB conversion solution takes the option #1 approach with a single vessel so our RIMS conversion will use option #2 for heating the mash with two vessels:
- Stand – reuse existing homemade brew stand. Cost = $0.
- Controller – to control the recirculation via the pump as well as the heater element in the Boil Kettle to ensure the correct temperature in the Mash Tun. Can utilize the 220v 30amp service that the dryer in the basement uses as this can be made available on brew days which will save on electrician charges. Automation would be an added benefit if available e.g. to step mash if possible. Cost = $495 (High Gravity EBC SV – manual only step mashes) or $650 (Brew Boss Controller – allows automated step mashes).
- Mash Tun (MT) – one of the 15.5 Sanke kegs can be reused for this together with existing false bottom and dip tube. Cost = $0.
- MT AutoSparge – AutoSparge to govern the flow rate of liquid entering the top of the Mash Tun over the grain bed. Cost = $69.99 (Blichmann AutoSparge)
- MT Temperature probe – to monitor the temperature of the liquid being recirculated within the brewing vessel. Cost = $0 (Probe for EBC-SV and EBC III included with High Gravity EBC SV controller) or $0 (Brew-Boss Plug-in Temperature Probe included with Brew Boss Controller).
- MT Temperature probe cable – to connect the temperature probe to the controller. Cost = $0 (Temperature probe cable for EBC-SV and EBC III included with High Gravity EBC SV controller), same goes for Brew Boss controller.
- MT Temperature sensor fitting – to connect the temperature probe to the brewing vessel. Cost = $0 (for High Gravity temperature probe) or $35 (Direct Contact Weldless Temperature Sensor Fitting for Brew Boss controller).
- Brew Kettle (BK) – one of the 15.5 Sanke kegs can be reused for this. Cost = $0.
- BK Heating element – 4500w or higher. Plugs into controller that supports 240v supply. Cost = $89.95 (Heating Element – 4500 Watt SS Twist-lock Plug for the High Gravity controller) or $69.95 (Heating Element – 4500 Watt SS for the Brew Boss controller).
- BK heating element connector – may need to widen the existing thermometer hole and add a different connector so the heating element can fit. Cost = $19.95 (Weldless Heating Element Kit).
- Quick connects, hoses and clamps – existing parts can be reused for this purpose. Cost = $0.
- Pump – existing Chugger pump can be used to recirculate the liquid. Cost = $0.
- Lid bulkhead – needs to include a spray nozzle and fittings for hose and temperature probe. Cost = $19.95 (Lid Input Assembly with Sprinkler for BIAB with existing available lid) or $0 if existing Fly Sparge arm is reused.
This system takes a similar approach to the Blichmann BrewEasy system by using the Boil Kettle to heat the mash liquid.
Estimated starting costs = $694.84 (excluding taxes & shipping)
If you have any questions, suggestions, or comments on this article I’d really like to hear your thoughts on converting or re-purposing brewing equipment to work with electric!
In Part 5 of this series we will be examining the results of our investigation into electric brewing…