Big brew day completed

Yesterday I brewed 10 gallons of a completely new recipe that I came up with after researching stouts, chocolate additions, etc. From what I can tell, it turned out as well as expected. My end gravity ended up being lower than I expected, but by how much I’m not sure. I use an Iphone app called BrewPal, which works very well. If I go by their numbers, I hit my number right on at 1.056…but I’m not confident that’s correct with the additions I made. Either way, here is a general idea of what I did and how things went down.

Everything started great, I milled my grain:

17lbs of Pale Malt
1.8lbs of Chocolate
5oz of Roasted Barley
1lb of CaraPils

While milling my grain, I was heating my mash water. I ended up mashing 7gallons in at 165, coming to 156 in the mash tun. Over the hour of mashing, I lost about 2-3 degrees of temperature, ending at about 153. I mashed off about 4.67 gallons of wort before sparging. I sparged 8 gallons at about 179-180, coming to about 174 or so. I sparged off about 7.34 gallons, giving me 12 gallons into the brew pot.

The sweet smell of mashing wort

The color looked to be very dark brown but not quite black and smelled great. I was going for a roasted smell but didn’t want a strong coffee scent, even before my boil additions.

Close to black, but definitely dark brown

Close to black, but definitely dark brown

After running off a total of about 12 gallons, I collected a sample…which was later spilled as a friend grabbed a beer from the fridge. So…no pre-boil sample ended up being my first small issue.

Before I even started my boil, I mixed my baker’s cocoa. I wanted to prevent lumps, so I decided to mix 12oz of baker’s cocoa with about 1/3 of a gallon of COLD water. I decided to do this for a couple of reasons: 1) I’ve read about people having big issues with adding bakers cocoa to the boil…tons of lumping 2) after reading about these issues and others, I wanted to find a way to make it into a syrup type substance, so I decided to treat it like I would flour…mix with cold water…mix the water into the powder. Overall, the mixing went as well as it could. I slowly mixed the water into the bakers cocoa and came out with a very thick substance that looked and smelled almost exactly like a ready to go brownie mix.

Smelled great...tasted like garbage

After preparing the bakers cocoa, I measured out my hops:

.6oz of Magnum at 60min
1 oz of Willamette at 30 min

Now onto the boil. Once I got the wort boiling rapidly, I added my Magnum hops first and foremost. About 5 minutes into the boil, I added my chocolate bars…5 small bars of Moser Roth 85% Dark Chocolate. The 5 bars totaled 4.4oz…which I broke into very small pieces and added to the boil while stirring (to prevent any scorching on the bottom of the boil pot). In addition, I added 1lb of cane sugar to reduce some body a bit and add a bit of alcohol.

This says 70%, but I used 85%...I'm eating this 70% as I write

During my 25 minute off time (until my next addition), I measured out my lactose…22oz total. I followed that up with another beer and an ultra competitive game of bags with some friends.

My neighbor Krista...whose team was losing about 12-0 at this point

At the 30 minute mark, I added my 1oz of Willamette hops while continuing to stir occasionally in case any chocolate from the bars settled to the bottom of the brew pot. At 15 minutes I added 2 TSP of Irish Moss followed by my bakers cocoa mass at 10 minutes. I slowly poured the bakers cocoa into the brew point…which works rather well as I stirred. Once the bakers cocoa was mixed in, we all simultaneously agreed that the wort smelled of chocolate heaven if there is such a thing. At about 8 minutes, I mixed in my 22oz of lactose, making sure it didn’t clump.

At that point, my process was the same as always…crash cool the brew with my copper wort chiller, siphon into my fermenters (2 plastic ale pales in this particular case), pitch my re-hydrated yeast (Nottingham dry yeast), and close the buckets up with air tight lids with an airlock.

Overall, I must say the day went well. The wort smelled excellent and tasted very chocolatey without being too bitter. A few things that didn’t work out well:

-My pre-boil gravity reading was spilled all over my fridge…thus no reading taken
-My wort chiller hose melted to my brewpot, which was easily fixed
-The ending gravity came in at 1.056, much lower than expected with the additions I made
-My brewpal software somehow didn’t save my full notes (I found that out as I started this post)…which were pretty detailed. I’m happy I decided to write about my brew day while everything was fresh in my mind.

Actual Recipe:

Recipe Type: All Grain
Yeast: Nottingham
Yeast Starter: no
Batch Size (Gallons): 10
Original Gravity: 1.056
Final Gravity: ?
IBU: 21
Boiling Time (Minutes): 60
Color: 31 SRM
Primary Fermentation (# of Days & Temp): 28 @ 68F

Ingredients
Brewhouse Efficiency: 70.00%

17lbs Pale Malt (3.0 SRM) Grain 80.6 %
1.8 lbs Chocolate Malt (350.0 SRM) Grain 8.50 %
5 oz Roasted Barley (500.0 SRM) Grain 1.40 %
1lb CaraPils (1.50 SRM) Grain 4.7%

.6 oz Magnum [13.00 %] (60 min) Hops 14 IBU
1 oz Willamette [5.8%] (30 min) Hops 7 IBU

12 oz Cocoa Powder, mixed with 1/3 gallon of water (Boil 10.0 min)
22.0 oz Milk Sugar (Lactose) (0.0 SRM) (Boil 8.0 min)
1 lb Cane Sugar (0.0 SRM) (Boil 55 min)
4.4 oz Moser Roth 85% Dark Chocolate Bars (? SRM) (Boil 55 min)
2 TSP Irish Moss (15 min)
2.5 TBSP PH water corrected into mash and sparge water

2 Pkgs Nottingham (Danstar #-) Yeast-Ale

Mash Profile

Single Infusion
60 min Mash In Add 7 gallons of water at 165 F 155.0 F
collected 4.67 gallons on mash out
Add 8 gallons of water at 179 F 171.0 F for sparge
collected 7.33 gallons of sparge runoff

As I type this, the airlocks are going crazy, meaning fermentation has been started. I am contemplating letting the fermenters sit for as long as 4 weeks since most of my research has led me to think that the aging may help the flavor profile. In addition, I am thinking of adding some ‘Creme de Cacao’ into the secondary to give a stronger chocolate aroma and add a bit of alcohol since I anticipate this batch coming a bit low.

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My Crown Valley Brewery experience

For those that weren’t aware from a previous post, I had the pleasure of working at a 15BBL commercial micro-brewery called Crown Valley Brewery in Ste. Genevieve, MO. The experience was definitely positive and I plan to go back frequently. I want to thank Mr. Carl Wiersma and his assistant brewer Jim.

After setting the visit up, I had no idea what to expect. I was told that 7AM was probably a good time to arrive, which I thought would be easy enough…I couldn’t have been more wrong. If you’ve never been on B highway in Ste. Genevieve, its windy and pretty dangerous. It’s roughly about 9 miles to the brewery on B, which I knew before looking up directions since I’ve been to the brewery previously. The problem I hit was some unplanned road construction about 5 miles onto B, where the road was completely shut down. Logically, I took the only turn available at the time thinking it was a detour…20 minutes later, I realized this road wasn’t a detour after pulling into a man’s driveway at the end of the road. So, with this glorious start, I pulled into the brewery around 7:45 after driving countless miles to find a different route.

When I arrived, it appeared as though they weren’t going to be able to brew as the mash tun agitator was acting up. The mash tun agitator is important because as the grain is soaking in the ~152 degree mash water, the agitator spins the grain and water, resulting in a higher efficiency and an easier conversion. After about an hour or so of watching a few guys try and fix the agitator, we were finally able to get started.

The brew plan was simple enough…30 barrels of their house pilsner. The most I’ve brewed at once is 10 gallons, which is about 1/4 of 1 barrel. The recipe was pretty simple, 2 types of grain in obvious large quantities (over 1000 pounds of standard 2 row) with a white labs yeast which started as a normal vial…one that I would use in my beer. They take that yeast vial, make a starter (wort/yeast in an Erlenmeyer Flask), and then use their yeast propagator to create a pitchable (the amount needed for a particular batch) amount of yeast.

The machine that makes yeast faster than the Dugger's make babies

The process itself was very similar to that of home brewing…just much nicer equipment, much greater batch sizes, and a much more quick and efficient system. The brewery itself looks great, but after helping for a full day, Mr. Wiersma filled me in on some of the “not so nice” parts of the brewery design. Although it isn’t perfect, the 3 year old equipment and design still works very well and looks like it will for quite sometime.

The actual brewing itself took place in one small area:

The place were "the man" makes the brew

If you look closely, you can see a stair way leading up to the different tanks, that’s the way to the command center for lack of a better term. When up the stairs, the brewer has access to the brew computer, the mash tun hatch, the lauter tun hatch, and the kettle. In the picture you can see a total of 5 tanks…from left to right there’s the hot liquor tank, the mas tun, the lauter tun, the boil kettle, and the cold water tank. I haven’t mentioned anything in previous posts about the use of a hot liquor tank and cold water tank so let me expand a bit on those two things and use. The hot liquor tank is a tank that holds water, obviously, but the tank heats the water up to a designated temperature. In this case, the water was heated 3 different times to infuse into the mash since this particular brew did a triple mash infusion (3 different water additions at different temps into the mash tun). The tank is able to heat water down to 1 degree, which makes the mash and sparge process incredibly easy and much more efficient. The cold water tank utilizes glycol which cools the tank rapidly. The water in the tank was kept at about 34 degrees and was used to cool the boiled wort as rapidly as possible through the plate heat exchanger.

Every single part of the brew process was automated through the computer system. The system allows the head brewer the ability to control all aspects of the process through the use of pumps and steam. Here is a shot of the computer, which is touch screen controlled:

The brewer's mainframe

Once the wort was finished boiling and cooled, it was transferred into a 30 barrel fermenting tank which was pre-loaded with yeast slurry from a previously fermented lager. The yeast we transferred was done through the bottom of the tank on the left, through a large hose, and pushed its way into the fermenter on the right. The pressure from 30 barrels of beer in the full and fermented tank on the left forced the yeast through the hose and into conical on the right. I would guess we pre-loaded about 15-25 gallons of mostly pure yeast slurry into the fermenter to turn the 30 barrels of wort into beer.

These fermenters each hold 30 barrels of beer

We did the entire process two times in order to fill a full 30 barrel fermenter. As a 15 barrel brewery, it takes two brews in one day to fill a fermenter pictured above.

Overall, my first day was great. Carl and Jim were fun to be around and very informative through the entire process. I was inundated with information throughout the day and can say I learned quite a bit. I am scheduled to head down again on Wednesday to help brew their ‘Worktruck Wheat’ which is one of their most popular offerings. Thursday I will be there to learn the ins and outs of the bottling process. I’ll post an update about both days.All in all, if you’ve never been to the Crown Valley Brewery, I suggest taking a trip and visiting. The brewery has an excellent atmosphere and an amazing outside patio in addition to their excellent beers and any time brewery tour.

Here are some other various pictures:

60 barrel fermenters

15 barrel fermenters

Seconadary fermentation tanks

Larger secondary tanks..

Progress, plans, and news

The Friday Brew Update

After brewing on Friday (March 26th), the A peTit APA is moving along nicely. Since I used previously washed yeast, I expected for fermentation to really begin at around the 48 hour mark like it did with my blonde beer. The APA got started a little earlier, starting activity around 36 hours. Here is what my carboy looked  like this morning:

A decent size krausen and nice activity

I have yet to take a reading but expect to sometime Friday to check the gravity reading. With the S-05 yeast that I used, I expect it to be ready to secondary and dry hop on Friday or Saturday. After dry hopping for 7 days, I plan to bottle at least half, maybe more. If I bottle, I feel like my carbonation is more manageable and meets expectations regularly in comparison to kegging…which I have yet to truly master (more on that later). Overall, I have pretty high expectations for this brew but not as much as I had previously. With what will end up being a rather high ABV of 7.1%, I’m not very confident in the aroma dry-hopping will impart. The last hoppy beer I brewed was an IPA with an ABV of 6.8%. I dry hopped that beer with 4oz of cascade hops for 7 days and ended up being incredibly disappointed in the hop aroma. I guess we’ll see, and I’ll continue to write about what I end up with.

Upcoming Competition and Beer Fest

The St. Louis Microfest is coming up at the end of April. I previously haven’t been to the Micro Fest but have been told that it’s the best beer fest of the year. I have ended up going to the Forest Park Heritage Festival the last two years which I’ve really enjoyed…so if the MicroFest even comes close to the Heritage Festival, it will be something I’ll be excited to attend. In addition to the 60+ beers at MicroFest, they’re sponsoring a homebrew competition that I plan to enter. Right now, I don’t have a variety of beers to enter, so it appears I’ll be entering my first APA which I finished in December. I ended up bottling 5 gallons and kegging 5 gallons and luckily saved 3 bottles in case a competition came up. They require two bottles for competition, leaving me with one to try to make sure the beer has aged well in the last 2+ months. Once I decide for sure on whether to enter, I’ll post my recipe on here for critiquing or just to satisfy the curiosity of anyone interested.

Other Random Info

It looks like tomorrow I’m going to be helping the brew master of a commercial brewery brew two different batches of beer. I’ll be waking up early to make sure I’m able to show up at Crown Valley Brewery at 7AM to help/watch Brewmaster Carl Wiersma turn water and grain into something special. I’ll probably make a post about the experience in the very near future.

Upcoming Plans

So after brewing my SNL Parody A peTit APA, I’m already looking to the future. After doing a bit of research and what not, I have decided to branch off some by trying to brew a stout. To this point, I have yet to brew a stout or porter but am looking forward to the challenge and the result. While I’m still unsure as to my exact recipe, here is an idea of what I’m thinking:

Recipe Type: All Grain
Yeast: Nottingham
Yeast Starter: no
Batch Size (Gallons): 10
Original Gravity: 1.052
Final Gravity: 1.011
IBU: 22
Boiling Time (Minutes): 60
Color: 42 SRM
Primary Fermentation (# of Days & Temp): 14 @ 65F

Ingredients
Brewhouse Efficiency: 70.00%

16lbs Pale Malt (3.0 SRM) Grain 75.7 %
1.8 lbs Caramel/Crystal Malt – 80L (87.0 SRM) Grain 9.70 %
1.8 lbs Chocolate Malt (350.0 SRM) Grain 9.70 %
14.0 oz Roasted Barley (500.0 SRM) Grain 4.90 %

.8 oz Magnum [13.00 %] (60 min) Hops 18 IBU
0.60 oz Cluster [5.00 %] (30 min) Hops 4 IBU

1.2 oz Chocolate Extract (Bottling 0.0 min)
14 oz Cocoa Powder (Boil 0.0 min)
22.0 oz Milk Sugar (Lactose) (0.0 SRM) (Boil 5.0 min)

2 Pkgs Nottingham (Danstar #-) Yeast-Ale

Mash Profile

Single Infusion
60 min Mash In Add 7 gallons of water at 168 F 156.0 F
10 min Mash Out Add 7 gallons of water at 176 F 168.0 F

My obvious plan here is to try and get this upcoming beer to taste as close to actual dark chocolate as possible. I’ve researched stouts, chocolate addition, etc quite a bit and have decided this is probably the way to go. There is still a slight chance I use the trifecta of cocoa nibs, cocoa power, and chocolate extract…I guess we’ll see. I’m leaning toward adding to the SNL series and calling this: Turd Fergeson’s Dark Chocolate Stout.

Upcoming brew plans

As I stated earlier, I mentioned I’ll be brewing an APA (American Pale Ale) next Friday at my place. I’ve thought about what I’m wanting to go for and have made a few decisions regarding this brew.

1. I’m going with 10 gallons…I could make up some cool reason but I think everyone knows that 10 gallons of kick ass APA is better than 5. That alone seems to be reason enough to double output.

2. I’m going to use Chinook and Cascade hops, with a first wort hop of Chinook to dial down the harsh bitterness (first wort hop=adding the hops into the wort before the boil). This should make the bitterness a bit more smooth rather than an “in your face” type of hop flavor.

3. I think I’m going to name it ApeTit APA. This will be somewhat comical to anyone that has seem the Jeopardy spoof on SNL. I’m going with ApeTIt because it brings a little laugh, should be rather bitter (not that I would expect an ape tit to be bitter…ugh), and is a play on the word appetite (the show suggests a-petit but I’m going my own route) which seems to sound positive when talking about anything food or drink related.

Check out the video: http://www.milkandcookies.com/link/12178/detail/

4. On brew day, I should have a small amount of people over who are interested in brewing. If you’re around and want to come by, just let me know. It looks like it’ll be Friday around 1 or so.
Other brews on the horizon:

I guess I’ll just say, A LOT. Why? Because I’m now brewing beer for the annual rib fest, held on July 31st. I expect I’ll need to have a minimum of 120 bottles brewed and ready to rock, with a goal of 200. In addition, I’ll be brewing for my wedding weekend (July 9th weekend), as my parents are wanting to have some homebrew at their place for family, friends, strangers, etc. My goal for that weekend is going to sit at 125. So overall, it seems that I’m going to be brewing over 30 gallons of beer in the upcoming months (will need to be all bottled by the end of June), and probably more as I have to keep my own tongue wet for the spring/summer season. As I get a better idea of a brew plan, I’ll make sure I keep this up to date with recipes, my process, and reviews of the finished beers.

The next brew day, etc

So right now I’m in Florida watching baseball, scouting players, helping with video taping, etc for the website ProjectProspect.com. It’s going well currently, although I’m already both wind and sun burnt. As of yet I’ve seen the Astros, the Phillies, and the Blue Jays, with another 6-8 teams left to see. So…I obviously can’t brew until I’m back in Festus. I’m currently scheduled to be back sometime next Wednesday night.

The night before I left for Florida I bottled my “Rachel’s Blonde,” and ended up with 52 total bottles. The sample I tasted was light, somewhat grainy, but overall pretty satisfying. I think this is going to be a great summer beer once it’s carbonated. On a side note, I brewed 10 gallons of this particular beer and split the batches. The first 5 gallons, I fermented for 2 weeks,racked to a secondary, added gelatin, crash cooled, and bottled. The second 5 gallons, I fermented for 2 weeks before changing some things up. I decided to pasteurize 3.25lbs of previously frozen strawberries, lightly smashed them in water, and added them to the secondary. I have let the secondary sit untouched for about 1.5 weeks thus far and plan to let it sit for another 1.5 weeks before adding gelatin and crash cooling. I’ll make a post with the recipe and the results of the two beers.

With it being about 3 weeks since my last brew day, I’m getting the itch (which seems to be coming more and more often these days). I’ve already been trying to find a great day to brew and it seems that the next big day will land on Friday, March 26th. It seems that I may have a small group over to watch the process to see if they want to jump headfirst into this very addicting hobby. So, if you’re around the STL area and want to hang out, brew, have couple of beers, and maybe even grill, let me know.

My current plan is to brew another American Pale Ale. I started working on my recipe last night and this is what I have so far:

Target Style 		American Pale Ale
Volume 		        10 gallons
Efficiency 		        70%

Recipe Statistics (Cat/StyleRange/Est)
Pre-Boil        1.045
OG		1.055
FG		1.008-1.011
IBU		47
SRM		7-9
ABV		5.60%		

Ingredient Name		        Amount		%
2-Row Base       		10 lbs   	42.0%
Pale Ale         		9 lbs		37.8%
Honey Malt          	        12 oz		3.2%
Munich (Light)         	        2 lbs		8.4%
Malted Wheat                    1 lb            4.2%
Crystal 40L                     12 oz           3.2%
Crystal 80L                     5 oz            1.3%

Cascade, Pellets 6.3%AA	        3.7 oz @ 60 mins
Cascade, Pellets 6.3%AA 	2.3 oz @ 10 mins
Cascade, Pellets 6.3%AA 	1.5 oz @ flameout (end of boil)

Safale US-05, washed yeast