The Draymans' Brewery Build

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The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 12:53

Hope it's okay to do this but I'm copying my brewery build thread from 'another place' and placing it here (as I feel more comfortable here). So, as it was quite a long thread I'll cut out the bits' that are not relevant and post the 'best-of' here (I'm including the original dates of posting so you get an idea of the timescale of the project). Later I'll bring-across the other related pieces about the legal hoops I had to jump through to be able to produce small batches of beer fro my local from my terraced house. Here goes...

25-05-2013
SWMBO and I bought our first house last December (after 30+ years in a Disabled Persons Council House; mother was disabled and I had been her carer since I was at school). Married SWMBO on St. Georges Day 2010 and never looked-back. I've been full-mash home brewing for over 35 years now and, after mum passed away, and we bought this property the opportunity arose for me to have a dedicated brewing set-up (rather than keep using the kitchen). The brewing kit was purchased a while ago and has already produced some good ale so I know it all works well (as do my recipes) all I need to do now is prepare the brewing area (man cave?). So, here we go then...

Photos show the room just being used as a store but I'm now in the process of stripping one wall back to brick to prepare it for painting with white paint. The other walls are okay and can just be undercoated and painted over. Kingspan Therma insulation board has been placed in the ceiling between the supports and I intend to cover it with the white uPVC cladding used in bathrooms. When the painting is done and the ceiling fitted, I've got an electrician drinking buddy who is going to fit the strip light and 6 double-gang sockets. Then it'll be a case of laying some lino/vinyl floor covering and fitting a double-sink unit (there is already a drain in the corner of the room).

SWMBO is a 'rock'. She is from Thailand and loves our British real ales so she is very supportive of my hobby. I say 'hobby' but I've been approached by a couple of local pubs to supply them with beer so I'm also starting the process of contacting all the relevant authorities to register as a brewer so that some of the output from my hobby can be drunk in local hostelries. My current 100l set-up allows for an 18 gallon brew of around 4%.

I'll keep you updated as and when things happen.

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 12:58

25-05-2013

Have now removed the tatty plasterboard from the wall opposite the brewing equipment. Don't intend to replace it, just going to go for the white masonry paint look (as with the other walls). Messy bit now with wire brush, cold chisel and scraper to tidy it up. Stopped for lunch break (which has been hi-jacked by SWMBO so we're going to do the shopping...). Time for a shower now, that dust gets everywhere...

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08-06-2013

Finished the first of (hopefully two only) primer coats this morning on the bare brick wall. Second coat tomorrow.

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23-06-2013

Here is the 'brew-table' wall in undercoat. The window is handy as I can keep an eye on SWMBO in the kitchen. :) ....or she can keep an eye on me in the brewery

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Last edited by thedrayman on Thu Apr 16, 2015 20:07, edited 1 time in total.
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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:00

05-07-2013
Thanks to a helping hand from SWMBO, the uPVC ceiling cladding went up today.

Next step is to get the vinyl floor covering down, followed by getting the electrics done (just sockets for now, I'll be designing and building a custom control panel at a future date), and the plumbing. We're getting there!

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19-07-2013
Have now got the vinyl floor down and it's starting to look (almost) like a brewery... Just waiting for my electrician friend to finish playing with the Cub Scouts (he is an 'official' not a friend of Jimmy Saville) and he can sort out the power and a light. Then a double sink unit to be fitted underneath the boiler at the end of the brewery table. I'm going to fit a uPVC cladding wall/separator at the end of the brewery table so you won’t be able to see the poo-pipe or boiler/washing area.

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Last edited by thedrayman on Tue May 20, 2014 21:22, edited 3 times in total.
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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:06

17-08-2013
Update! Now have a ring-main installed in the brewery with 8 double-sockets (probably still won’t be enough) and a six-foot fluorescent light. At last I can see in there when its' dark and MY does that light reflect off the white walls wonderfully! Just the sink unit and water to be fitted and then I can start re-testing the equipment in-situ (at last). I've also installed a webcam for security (records to a server during silent hours) and I intend to stream BrewDays when I can. I'll let you know passwords and stuff later.

Here is a snapshot taken from the webcam. This is not the final layout (I've got to move stuff again to install the plumbing); the copper will be at the far-end (so I can use trunking to let the steam out of the double-doors). The boxes on the lower shelf will be going and will be replaced with two 100l fermenting vessels and the cooler (currently on the top shelf) will join them to keep the ale at the right temperature during the ferment.

Eventually (hopefully?) next year I will be building a control panel (using The Electric Brewery http://theelectricbrewery.com/ specs) and it is hoped to be able to fix it to the wall where the light switch currently is.

More details, and photos, when the plumbing is installed!

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01-12-2013
Apologies to all as I've let this topic slip a bit as the brewery-build has slowed-up and I'm still waiting to get a few things in-place (but we're getting there).

Since the electrics have gone in I've been doing a bit more work in the brewery at night...amazing what can be achieved when you have illumination :party:

Today I be mostly fitting a 'solar-pump-in-a-box' to the wall near the HLT. This will be my recirc pump and will also double for sparging via my (new) perspex-lidded MT; thanks for the inspiration BarnsleyBrewer :thumb:

I've also decided that, as I'd prefer to boil all my wort for each 18 gallon brew (rather than have to boil part of it then liquor-back to achieve the gravity required) I'll be needing a bigger copper. I managed to sell some collectible Italian cycle parts and the £200 I got for them will be going towards a 200L pot from MrLard at http://www.homebrewbuilder.co.uk. When I get my hands on the new copper I'll insulate it and get it put in-place on the table ready for a test brew.

Here is the latest web-cam snap-shot taken today. The current copper (at the far end of the table) will be moved to the lower-deck and will, probably, become FV3. Will keep you posted as to any other developments when they happen.

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:09

03-01-2014
Just another small update for the new year.

The sink unit is now installed (thanks Ralph) and, over the Christmas holiday I put in the separator 'wall' between the end of the brew table and the sink. Awaiting delivery of a 200L copper to replace current 100L one (shown with extractor hose) then I can brew an 18 gallon test batch. Getting-there...slowly.

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09-02-2014
'Big Bertha', the 200L copper from Mr Lard @ Homebrewbuilder, is now on the brewing table and has been 'lagged' with twin layers of loft insulation foil with a foil-backed camping mat sandwiched in-between. I'm in the process of calibrating the sight-glass and wiring-up the two 3Kw elements. I'll lag the lid after my engineer friend has cut and made an opening hatch in it (for viewing the boil and adding additional hops) - it will be impossible to lift the lily-pad-like lid during a full boil, so an inspection hatch will be essential.

I've also realised that I've now got to get a work platform so that I can reach inside of BB and be able to touch the bottom when cleaning out the spent hops (a chair just isn't high enough)! It's certainly a Big MUTHA!

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19-03-2014
Have temporarily rigged-up the steam outlet and am now bringing-up 100litres of Adams' Ale to the Test boil to see how long two 3Kw elements will take to get 'steam-up'.

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:15

22-03-2014
Another update. Owing to the lack of funds I decided against the all-singing-all-dancing control panel A-La 'Electric Brewery'. I looked at what I currently had (an STC-1000 with solar pump for recirculating the HLT) and what I needed (an easy way to control two 3Kw elements in the boil) and decided just to build a control panel for the boil.

The idea is much like that used by others on the forum, two elements bring the wort to the boil and then one is switched off. As I would be concentrating on cleaning out the mash tun as the copper comes to the boil I'd be needing an alarm to tell me when the boil had been reached, so I included one of those in the plans. Today my friendly engineer mate brought back my enclosure with all the holes cut and pieces fitted as per the plans I gave him (see below). One thing he did forget, though, was to drill some vent holes in the top to let out the heat from the two SSRs so I'll be popping out to get a stepped drill bit later.

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The power to the panel for the two elements comes from two separate sockets on a ring main (so as not to over heat a double-socket) and the panel will be attached to the brewery wall just behind the HLT (see below). So my task for this week is to wire it all up then calibrate the PT100 with the PID and do a test boil to try it out.

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18-04-2014

My first 18 gallon brewday http://forum.craftbrewing.org.uk/viewtopic.php?f=5&t=883.

It's taken a long time to get to the stage where I can now brew to my capacity in a dedicated area, and doesn't it make a difference. It's been well-worth the time-and-trouble getting it to this stage and now, the next stage, after a couple more test brews, will be to register with HMRC as a brewer so I can start producing ale for the locals at my nearest boozer.
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Re: The Draymans' Brewery Build

Postby EvansTheSteam » Mon Apr 21, 2014 13:16

That's some brewery, I remember the thread on the other place, pleased you've brought it over!

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:22

EvansTheSteam wrote:That's some brewery, I remember the thread on the other place, pleased you've brought it over!


Thanks, Evans, yes I thought I'd transfer across all the stuff that people may find interesting. Over the course of this week I'll be bringing-across the info about my contact with the local council Planning and Environmental Health departments.

One thing I did notice when conducting my test brew though, when I want to brew stronger beers than the regular bitter I'll be doing (around 3.8%) I'll have to replace the 80L thermal-insulated MT as its' just not big-enough to take much more grain. Looks like MrLard@homebrewbuilder will be getting an order for a 160L version. :-) (Don't tell SWMBO)
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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 13:25

The changing faces of the 'lean-to'...

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Re: The Draymans' Brewery Build

Postby BarnsleyBrewer » Mon Apr 21, 2014 13:38

Another good thread salvaged............ Looks great, I'd be well proud. :clap: :clap: :clap:

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Pints brewed in 2015.. 624
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Re: The Draymans' Brewery Build

Postby EvansTheSteam » Mon Apr 21, 2014 14:06

I take it you don't use the double doors!

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 14:12

EvansTheSteam wrote:I take it you don't use the double doors!


The brown ones into the dining room. no. Although having said that I'll have to move the cupboard and use them in a week-or-so' time to take turf through to the garden, as we don't have rear access.

The double doors at the garden end of the brewery are open when I'm boiling to let the ducting vent out the steam, which is alright at this time of year, but will probably be a bit chilly in the winter.
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Re: The Draymans' Brewery Build

Postby EvansTheSteam » Mon Apr 21, 2014 15:22

I brew in the garage with the door open!
If I wear a hat and coat in the winter. I never notice the cold (much).

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Re: The Draymans' Brewery Build

Postby thedrayman » Mon Apr 21, 2014 15:57

EvansTheSteam wrote:I brew in the garage with the door open!
If I wear a hat and coat in the winter. I never notice the cold (much).


What don't kill you makes you stronger, me duck. I really must get back 'home' to Nottinghamshire to visit my Uncle Eric (and try out some of the 'new' Shippos bitter). He used to work at Holes' Castle Brewery, Newark. I also had another uncle who used to work in one of the many maltings in Newark. Mother was also a barmaid so I suppose with all those beery connections it was inevitable I became a brewer. :D

As the Czech saying goes, 'Blessed is the mother who gives birth to a brewer'..... :pray: Thanks, ma.
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Re: The Draymans' Brewery Build

Postby EvansTheSteam » Mon Apr 21, 2014 18:44

I wonder how blessed the brewer himself is? :lol:

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Re: The Draymans' Brewery Build

Postby thedrayman » Wed Apr 23, 2014 08:47

Here is the copper control panel now resplendent with labels supplied by Steve of Swift Tag Ltd. http://swifttag.co.uk/

Steve is also a home-brewer and has supplied many members of 'the other place' with labels for their control panels. I have no hesitation in recommending him for his excellent, and reasonably-priced, service.

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Re: The Draymans' Brewery Build

Postby thedrayman » Wed Apr 23, 2014 09:44

Happy St. Georges Day to fellow English brewers. Thought I'd post a 'related' image in this thread (note the colours I chose to identify my casks).

The casks are clean and ready for casking the Good Friday brewday beer in the next day-or-two.

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Re: The Draymans' Brewery Build

Postby EvansTheSteam » Wed Apr 23, 2014 10:29

Your labels look great, what about the plugs and sockets?

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Re: The Draymans' Brewery Build

Postby bobsbeer » Wed Apr 23, 2014 10:38

Looks great, all finished and beer on the move.
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Re: The Draymans' Brewery Build

Postby Swift Tag » Wed Apr 23, 2014 21:23

Nice to see it in place, happy brewing :cheers:

Thanks for the plug. :thumb:
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Re: The Draymans' Brewery Build

Postby mixbrewery » Thu Apr 24, 2014 20:20

Glad to see you've now got beer in cask.
I'm still bottling with an occasional cornie going into one restuarant.

Might have to get some swift tags done for my control panels - very smart.
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Re: The Draymans' Brewery Build

Postby thedrayman » Tue Dec 23, 2014 12:54

Just another, and I suppose 'final', update to this 'build' thread. A couple of weeks' ago I finally had a visit from the Environmental Health lady who, on first viewing my equipment (oo-er!), was 'surprised' it was so 'professional-looking'. I imagine she was expecting plastic fermenting bins and general home-brew kit everywhere :-)

The outcome of the visit was that EH where very happy with my cleaning set-up (two sinks, one for equipment and one for hands) and stainless steel table for the main equipment. The lady said she would need to check back at the office to see if I would be entitled to a certificate, which would be for the highest rating of 5 stars :thumb: The emailed reply from EH was "I have checked with our guidance and your business is exempt from the food hygiene rating scheme as you do not supply the final consumer directly and your business is classed as manufacturing." So (although EH would have given me a 5-star rating and a certificate had I needed to be registered) I actually got no certificate, just the satisfaction of knowing that another hurdle had been jumped.

Test brews of the 1036 bitter are going well and a final recipe has been chosen. In the new year I'll be investing in a dozen plastic casks and some very expensive saccharometers (UKAS tested to HMRC standard) before registering with HMRC.

Images below are of the brewery in it's current state. I won't say it's finished as we can always find something else to add can't we? In my case I'll need to find some room for a couple more 100L FVs and associated Cornelius coolers...oh and maybe a larger plate-chiller and mag-pump... :whistle:

Happy Christmas and a Prosperous New Year to all members of the forum and, indeed, brewers' (of all capacities) everywhere.

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Re: The Draymans' Brewery Build

Postby thedrayman » Tue Dec 23, 2014 13:05

This year I didn't brew a 'seasonal' ale for Christmas however I did revive a best bitter recipe which went down well two years' ago when I last brewed it. This time the recipe was up-scaled to 18 gallons and Danstar Nottingham ale yeast used instead of Windsor (last time it just never cleared). This version, at 1050og, was crystal clear with a great head retention and a robust flavour, owing to the addition of extra-dark crystal, and biscuit malts. [url]http:\\newtownbrewery.co.uk\beer\blockhouse.htm[/url]

Blockhouse Recipe details
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Re: The Draymans' Brewery Build

Postby Raptor » Tue Dec 23, 2014 13:59

Great reading these build threads. Good luck with your brewing.
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Re: The Draymans' Brewery Build

Postby johnsaunders » Tue Dec 23, 2014 16:50

LOL. A 18 gallon brew. Just fantastic. :clap:

What a brilliant build. Well done. :notworthy:

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