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Ben Caya Carl Czajka

Milwaukee’s Best Brew Stand. Ben Caya Carl Czajka. Background. Spike Brewing LLC Started Summer 2011 Produce 10 to 25gal stainless steel home brewing kettles Welded couplers. Background. Need for manufactured brew stands…. Background. Very little competition

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Ben Caya Carl Czajka

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  1. Milwaukee’s Best Brew Stand Ben Caya Carl Czajka

  2. Background • Spike Brewing LLC • Started Summer 2011 • Produce 10 to 25gal stainless steel home brewing kettles • Welded couplers

  3. Background • Need for manufactured brew stands…

  4. Background • Very little competition • Blichmann – ‘Top Tier’ - $1000+ • BrewSteel – ‘BadAss’ - $1850+ • Sabco – ‘Brew Magic’ - $6000 • Our design: • Off the shelf design • More affordable Blichmann – Top Tier

  5. Brew Process – Step 1 • Sanitize, Sanitize, Sanitize (Star San) • Crush Grain • Activate yeast

  6. Brew Process – Step 2 • Heat water in HLT so mash tun is about 162°

  7. Brew Process – Step 3 • Sparge from HLT to mash tun • ~60 min process

  8. Brew Process – Step 4 • Mash out • 170° to stop starch conversion • Drain until clear liquid comes out then pour back into Mash Tun • Checking for sediment in liquid

  9. Brew Process – Step 5 • Drain Mash Tun into the Boil Kettle • 5 gallons batch will have about 2 gallons

  10. Brew Process – Step 6 • Add liquid from HLT to Mash Tun until you fill grain bed • Sit for ~10 min

  11. Brew Process – Step 7 • Add enough liquid from Mash Tun to Boil Kettle to get desired amount

  12. Brew Process – Step 8 • Start boil (60 min) • Add bitter hops • Other flavors • 15 min later add aroma hops

  13. Brew Process – Step 9 • Chill to 70 deg F • Carboy (ferment) (3 weeks – months)

  14. Voice of Customer • Polled home brewers on HomeBrewTalk.com (largest online home brew forum) • Price • Collapsibility/Storage Footprint • Mobility • Modular/Use with Existing Equipment • On Board Storage

  15. Initial Design Frame • Total weight • Kettles, pumps, burners, propane tank, frame material, plate chiller • ~250lb • (3) 25gal kettles filled with water/grain • ~600lb • Safety factor 2 (people store things on cart) • 1700lb (1 ton) • Material Choice

  16. Initial Design Frame

  17. Initial Design Frame • Auto Cad Inventor

  18. Initial Design Frame - FEA • Design Load 800lbs distributed across the top

  19. Frame Deflection

  20. Frame FOS • FOS = 4.54 Minimum

  21. Design Components • Kettles • Thermometers • Valves • Burners • Regulator • Pumps • Heat Exchanger • Castors • Tubing

  22. Design Components Kettles: • Capabilities • 10 to 25 gallon kettles • Our Design • 15gal kettles → 10gal final product Thermometer: • 20-240 °F • Glass dial • ± 1.5% accuracy Ball Valve: • 5/8” Full Port Design

  23. Design Components Burners: • Bayou Classic – SQ14 • 55,000 BTU • ~35mins 10gal water to boil Regulator: • Bayou Classic – M5HPR • 10 PSI

  24. Design Components Pumps: • Chugger - SS Inline (Donation) • Max Flow 7.3 GPM • Max Head 18.9 FT  • Power .05 HP 

  25. Design Components Heat Exchanger: • Duda Diesel - B3-23A 30 (Donation) • 30 Plates • 12" x 2.9“ • Chills 10gal @ 212°F to 75°F in 10mins

  26. Design Components Castors: • Northern Tool • 6” Pneumatic • Easier for terrain • 400lb capacity

  27. Design Components Tubing: • U.S Plastics – Silicone Tubing • 0.5” ID • -100°F to 500°F  temperature range • 10PSI working pressure, 30PSI burst pressure at 70°F • FDA & NSF-1 approved as food safe

  28. Manufacturing Frame • Fixtureing • Stainless MIG Welding • Stainless 308 Wire

  29. Manufacturing Frame

  30. Manufacturing Frame

  31. Manufacturing Frame

  32. Pricing

  33. Future Design • PLC Unit • Ignition System • Flame Sensing • Temperature Control • Push Button/ Programmable Pumping • Dumpable Mash Tun • Easy grain removal • Post Brew Improvements - TBD

  34. Question?

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