Ben Caya Carl Czajka

Ben CayaCarl Czajka

Milwaukee’s Best Brew Stand

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– Blichmann – ‘Top Tier’ - $1000+– BrewSteel – ‘BadAss’ - $1850+– Sabco – ‘Brew Magic’ - $6000

• Our design:– Off the shelf design– More affordable

Blichmann – Top Tier

Brew Process – Step 1

– Sanitize, Sanitize, Sanitize (Star San)– Crush Grain– Activate yeast

Brew Process – Step 2

• Heat water in HLT so mash tun is about 162°

Brew Process – Step 3

• Sparge from HLT to mash tun– ~60 min process

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

Brew Process – Step 5

• Drain Mash Tun into the Boil Kettle– 5 gallons batch will have about 2 gallons

Brew Process – Step 6

• Add liquid from HLT to Mash Tun until you fill grain bed– Sit for ~10 min

Brew Process – Step 7

• Add enough liquid from Mash Tun to Boil Kettle to get desired amount

Brew Process – Step 8

• Start boil (60 min)– Add bitter hops– Other flavors– 15 min later add aroma hops

Brew Process – Step 9

• Chill to 70 deg F• Carboy (ferment) (3 weeks – months)

Voice of Customer

• Polled home brewers on HomeBrewTalk.com (largest online home brew forum)

PriceCollapsibility/Storage Footprint

•Mobility•Modular/Use with Existing Equipment•On Board Storage

Initial Design

•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

Frame

Initial DesignFrame

Material Pro Con

Carbon Steel • Inexpensive• Strong

• Heavy• Rusts

Stainless Steel• Aesthetically Pleasing• Corrosion Resistant

• Strong• Expensive• Heavy

Aluminum• Light

• Corrosion Resistant• Aesthetically Pleasing

• Expensive• Strength

Initial Design

• Auto Cad Inventor

Frame

Initial Design

• Design Load 800lbs distributed across the top

Frame - FEA

FrameDeflection

• FOS = 4.54 Minimum

FrameFOS

• Kettles– Thermometers– Valves

• Burners– Regulator

• Pumps• Heat Exchanger• Castors• Tubing

DesignComponents

Kettles:• Capabilities

– 10 to 25 gallon kettles• Our Design

– 15gal kettles → 10gal final productThermometer:• 20-240 °F• Glass dial• ± 1.5% accuracyBall Valve:• 5/8” Full Port Design

DesignComponents

DesignComponents

Burners:• Bayou Classic – SQ14– 55,000 BTU– ~35mins 10gal water to boil

Regulator:• Bayou Classic – M5HPR– 10 PSI

DesignComponents

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

DesignComponents

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

DesignComponents

Castors:• Northern Tool– 6” Pneumatic• Easier for terrain

– 400lb capacity

DesignComponents

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

ManufacturingFrame

•Fixtureing•Stainless MIG Welding•Stainless 308 Wire

ManufacturingFrame

ManufacturingFrame

ManufacturingFrame

PricingName Quantity Price Ea Total

Frame - Stainless 1 - $600Burners 3 $10 $30Regulators 1 $20 $20Pumps 2 $120 $240Castors 4 $14 $56Kettles 3 $85 $255Thermometers 3 $26 $78Valves 3 $20 $60Piping 1 $40 $40Heat Exchanger 1 $120 $120Pump Wiring - - $30Gas Lines - - $40Labor 6hrs $80/hr $480 Total: $2,040

Included Blichmann Spike Brewing BrewSteel Sabco

Frame Steel/Al Extrusion Stainless Stainless Steel

Burners 210,000BTU 55,000BTU 210,000BTU 65,000BTU

Gas Piping Braided/Steel Steel Steel Steel

Regulator 40PSI 10PSI 40PSI 10PSI

Castors 4" Polyurethane 6" Pneumatic 4" Polyurethane 4.5" Polyurethane

Pumps - Chugger March -

Heat Exchanger - Duda Diesel - -

Kettle Storage No Yes No No

Propane Tank Storage No Yes No No

Kettles Included No Yes, 15gal kettle No Yes, 15.5gal keggle

PLC Controlled No No No Yes

Cost = $2,000

Profit Margin - 40%

Price: $994 $2,800 $2,843.79 $5,995

Future Design

• PLC Unit– Ignition System– Flame Sensing– Temperature Control– Push Button/ Programmable Pumping

• Dumpable Mash Tun– Easy grain removal

• Post Brew Improvements - TBD

Question?