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Introduction

Steps to System
Construction

1. Frame
2. Burners and Gas Lines
3. Heat Shielding
4. HLB, Mash Tun,
and Kettle
5. Heating Chamber
6. Immersion Chiller
7. Counterflow Heat
Exchanger
8. Pumps
9. Plumbing for both
Chillers
10. RIMS Control System
11. Electrical Plan
12. Controller

Brewing

Brewery Construction Guide

HLB Mash Tun and Kettle

Materials
3 “Sanke” Kegs - with handles & cylindrical sides, 23”x15.5”, capacity 15.5 gal
6  Stainless Steel Couplings, 1/2”ID
Several Stainless Steel Welding Rods (#304) for the welder to use on couplings     
--- Available from Welding Supply stores
1 Mash Screen, Model: “Keg folding on legs”, approximately $75
--- Available from: Precision Brewing Systems, 718 667-4459
1 Stainless Steel Folding Vegetable Steamer
3 Pot lids, Stainless Steel is best.  But I've used Aluminum and have had no problems.

Special Equipment
Sawz-All (Carbide blade) or Jig Saw
Various Metal Files
TIG Welding Equipm
   
                         
Procedures                                                                                         
Obtain three 15.5 gallon “Sanke” style kegs as shown above.                   
They are available through Brewer's Warehouse, Pico and Sabco.
Cut 12” centered holes into the top of each with a Sawz-All (Carbide blade).
Be precise on the hole size.  The 13” pizza pan lids fit onto 12” holes.
File the openings to remove sharp edges.
Determine the proper location for the couplings as shown above.
Warning: The coupling cutout holes on the sides of each keg should be close but not cut into the existing welds.
To do so would weaken the keg and risk leaks.
Cut coupling holes the same diameter as the coupling so that it may be inserted 1/8” to 1/4” into the keg.
Your welder may prefer that the holes be the cut to 1/2”, the coupling interior diameter, so that he may weld the coupling directly to the outside of the keg.  Caution: If any of the weld material drips into the keg, it may obstruct usage of the interior coupling threads.  Also, If the welder uses a threaded pipe to hold the coupling during welding, it must be of a material that will not accidentally weld to the coupling.
TIG weld the couplings with stainless steel (grade # 403) rods. Other metal/grades may be toxic.
Place the kegs, now called the HLB, mash tun and kettle, into position.
Build or purchase a primary mash screen.  If a mash screen is purchased from Precision Brewing Systems, reverse the handle and legs so that the hinge will be on the bottom.  I discovered that with the hinge on the top, the screen will shift down during the mash-in process thereby allowing grain to pass through and jam the pump.
Additionally, reinforce the hinge with 12 small stainless steel nuts & bolts.  The heat may warp it and form an opening.
Purchase a secondary mash screen.
It will stop any grain that happened to pass the primary screen.

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This page designed and produced by Donald S. Chrzan
Site last updated: 21-jun-05 22:44