Fixing the stuck sparge. (Mash and Boil)

Waaay last year, I mentioned that one of the upcoming articles would be the stuck sparge issue on the Brewers Edge Mash and Boil. Here it is finally!

If you are a new Mash and Boil owner, go back and check out my previous post on fixing some of the units slight issues.

Even now after a few years of being in circulation,, one of the biggest complaints about the Mash and Boil (M&B) is the slow or quite often the stuck sparge. The M&B mash tube (or basket) is designed with drainage holes only at the very bottom. This poses a major problem for the suggested method of lift and drain.
Everything gets slammed to the bottom during the lift and plugs mesh bottom, then no drain.

When this happens you normally see your drainage is quite slow. And then grow even slower as the finer particles start settling out, and eventually onto a full on stuck sparge with no draining at all.

When this happens you need to get in and stir it up to open the drain holes,, while letting more and more of the fine grain thru into the wort.. this is almost always not what you want.

I see a lot of people mentioning that this is a grain crush problem. This is the same grain crush that I have used forever in my mash tun. Well.. several mash tuns. There is no reason or no way I’m going to make a less efficient crush just for this simple problem.

There are basically three things you can do to minimize the stuck or slow sparge.
(I say three, but two are the most viable, and one being the easiest)

-The first thing I did when this happened during my first couple runs was to simply leave the basket in place and drain off the wort thru the valve into another kettle, remove the basket after it was drained and poured the wort back into the unit for boil.
I do not recommend this method, however it does work well as the bottom grate does not seem to plug as easily when it is drained off like this.
-Second, and much better method. Rice hulls. Always a good idea to throw in a few handfuls of the hulls for mashes that are prone to sticking.
This certainly helps here for sure. But,, its mostly helping the wort drain thru the grain bed. The holes in the basket are still prone to plugging before the grain bed get a chance to set up and start filtering. So I started using the third method.

The third method and the one that I found to be the best,, is to use a mash bag INSIDE the mash basket.

This keeps the nice barrier between the grain and those holes at the bottom and let’s the grain bed drain from the sides as well.
Even a 70% oat flake beer with no rice hulls drains as fast as an empty basket would.
And because it’s inside the tube, the elements won’t scorch or burn it.
The basket handle comes right off so you can pull or dump the bag out with no snagging. Then the bag is washed and dried out till next brew. I’ve got a few years with the same bag.

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Using the bag allows for a better/faster way to do a vourlaaf for greatly reduced grain powder gunk in the boil and ultimately, into the fermenter.
And pump users get an extra comfort in knowing that they are less likely to stick during recirc so nothing burns up.

This $5.00 bag saves a lot of grief, give it a shot and be amazed.

Patagonia Porter

I won a pound of this Perla Negra roast grain a few weeks back so I figured I’d use it all in one blast to see what we get out of it.

All of the descriptions I’ve seen on it seem to make it out to be a “softer” roast. One of the huskless roasts, so should not have the bitter burnt aspect.

Other notes I’ve seen mention coffee and chocolate. It’s 340L so a pound shouldnt make it blacker than night, but we will see.

I also won a bag of Vienna with this, so I will use that as the base. I dont wanna hide the Perla profile so just a smidge of Crystal and I’ll call it good.

Before I got this into the fermenter I gave it a tatse. Very mild roast with bigger than expected chocolate and coffee. I can’t wait to get this one in a keg!

Mash and Boil Adjustments

To follow up on my previous Mash and Boil post, I’m gonna post up some of my notes, fixes, changes and thoughts after using this thing for 5 months.

In the next few weeks I am gonna address the concerns I and other have had or have heard about, and what I did to help get my Mash and Boil dialed in.

Some of the points are going to be..

  • Heat Loss
  • Temp Fluctuation
  • Lack of pump
  • Stuck Mash
  • General design

Today its going to be the biggest concern I and other have or had when looking at the Brewers Edge Mash and Boil…

Temp Fluctuation

When I was looking at the MB and deciding if I should get it, the big concern on almost every forum temp control.

  • huge temperature fluctuation
  • Losing heat very quickly.
  • The controller overshooting set temps, and dipping too low before turning on the heat.

But because I mostly planned on mashing in my regular mash tun, this did not concern me…much.
But when I did start to use the MB to mash as per the instructions, oh yea, there was a bit of concern.

There are a few issues working against the MB here. The metal design, false readings, mechanically poor mash instructions for this system.
But the big temp swings, the heat loss and the controller issue are all related and easily fixed or adjusted out.

Heat Loss

While the MB is described as being double walled, the two thin sheets of metal have little effect on heat loss or heat retention. Having used my other electric kettles, and collecting data on temps and times,, insulation is the key here.

Adding a Reflectix wrap (double wrap) is a 100%, no brainer, requirement. Without a wrap you can literally stand 3 feet away and feel the heat radiating off from it.

And even though the lid is clamped on, pay attention to the top. Most people have been finding an enclosed “cap” or dome of reflectix over the top is most effective. I have also been using a blanket in the winter, but this may or may not needed.

You will immediately notice a difference in both heating times and how little heat loss you have once you have some proper insulation.
Heat loss recap:

  • Insulation is absolutely a must
  • Double wrap reflectix body
  • Reflectix dome for top

False readings.

“False” readings may not actually be the right term here, but the general concern is that the temp probe doesn’t trip the heat element on until it reads 6 degrees below the set temp. But then over shoots the set temp by quite a bit.

Yes. Factually this is exactly what happens. But why?

Two things. A poor temp probe placement, and no circulation.

The temp probe, which is directly on the bottom on kettle, gets covered in grain dust/sludge that settles to the bottom. This sludge insulates and separates the probe from the true temp of the mash. This is easy enough to see when you give the mash a stir and the onboard temp display shoots up even though the heat is not even on.

Then the other thing happens. The element kicks on to heat because the covered up probe thinks the mash temp is low! There is no circulation, so now the mash heats unevenly and quickly ramps up and over the target temp before the probe can get an accurate reading!

Ok,, all that sounds bad and probably a lot to fix, but…

Remember our first priority up there in the beginning? Insulation!
When you have the kettle insulated properly, the temps DON’T really drop, But the dang sludge covered probe thinks it did.

So once my mash temp where I want it and stable,, I turn the control panel off so it wont kick the element on, because the now insulated kettle holds the temp just fine.

Another thing I have started to do now to help stabilize the temp, is to do almost full volume mashes. The more water mass you have the less your temps will drop.

I say “almost” full volume because I hold back a gallon or so because I wanna do a small sparge. I know some people scoff at the big +1.85ish:1 mash ratios, but BIABers (that’s what this system actually is) and myself have found this to be just fine.
So to recap the False Reading points:

  • Particles from the mash have settled to the bottom, covering the temp probe. This causes the probe to cool faster than the rest of the mash and mistakenly turn on the heat element.
  • Once mash temp has settled, shut off the controller and use only hand held thermometers.
  • Your insulation and max volume mashes will keep temps steadier temps, and not usually need extra heat applied.
  • As with any form of brewing, anytime you are checking temps and/or applying heat, stir and stir to get accurate reading.

So while the reports of temp control problems with the Mash and Boil are sorta valid, they are neither tragic, nor completely true.

After insulating and moving to the largest volume mashes, my temps only drop 1 degree at 30 min when I normally open it up to stir. I’m not really sure that it would drop any further than that over 60 min. But I never let it go that far without the midway stir.

Lack of pump

Wouldn’t just adding a recirculating mash pump keep temps under control?
I am not certain that it would. It certainly would keep temps even throughout the system, and stop the false readings and accidental ramping, But..

Pumps lose quit a bit of heat. And normally that would not be a problem on a auto-temp controlled system. But as of right now, on this system there is no way to adjust the 6 degree variance that the controller is set to.

For us old schoolers, watching a pump constantly cycle our wort up and down 6 degrees just isn’t gonna cut it.
Leaving it wrapped up without no pump and a steady temp just feels better to me. (I do have a pump though just in case my feeling changes)

I hope helps those thinking about picking up the Mash And Boil but have concerns.

:next time: Stuck Mash!