After 4 and a half years of service (it was planned as a stop-gap to last a year tops) our old ramshackle malt hopper and mashing in regime has been replaced!
The old one was knocked up quickly to get us brewing but, due to never having enough time or money, we've never got around to replacing it... until now. We'd become aware that the bottom of the chute, made from marine ply, was becoming increasingly rotten and looked as if it may give way mid-mash depositing up to 300kg of expensive grain all over the floor (and probably Gazza too) so once we'd acquired the old Waen Brewery hopper and hydrator - the device which mixes the grain with hot water - it was time to swap over!
Only, it wasn't.... the new hopper sat in a corner for 6 months until the condition of the old one dictated that we really, really needed to replace it PDQ.... so, the start of 2018 was declared "new mashing in week" and we prepared for the headaches such a project inevitably brings on. Fortuitously, a Screwfix has recently opened just behind us, so we were confident we could buy any bits needed, making things a lot easier.
In the end, luckily, we got the whole thing done in 3 days and that's including rebuilding the hydrator from scratch! there are still a few bits and bobs to tidy up, but the upshot of this work is that we now have a completely piped-in pump under the hot liquor tank which can recirculate the tank to mix it and pump water below to the mashing in process at the turn of a lever, not as before where multiple disconnecting and reconnecting of flexible hoses was the order of play.
The big improvement, however, is in the time saved mashing in - we estimate that the complete process with the old setup would take anything up to 45 minutes, whereas with the lovely new kit it takes 15 minutes maximum! This saving of 30 minutes on the brewday will be extremely welcome. plus the new hydrator mixes the grain really well making one-man mashing a distinct option now! The hopper also does something the old one never managed to do which is empty itself without any brushing or goading of grains which is yet another enormous improvement, and finally the hydrator is much lower in the pipe meaning the marine ply of the hopper won't get wet and rot like the old one...
So, win-win all round and a great start to the year for us!
|the hopper and chute being bolted together|
|The completed (nearly) setup with the grain hopper and hot liquor tank|
|Gav sawing pipe for the new hydrator|
|looking inside the grain chute|
|New valve on the sparge arm (which we don't actually need!)|
|The new grain chute and hydrator in situ with the liquor hose attached to the hydrator|
|almost done! Nice pipework....|