'Brew-Magic' Methodology
The original design for the Brew-Magic Pilot Brewing System evolved after
five (5) years of research along with the creation of four progressively
engineered prototypes. The project intent in simple terms, was to 'design
away' those brewing characteristics previously determined to be less than
repeatable during small batch brewing operations. Procedural as well as
mechanical aspects of beer production were each considered and in turn
're-developed' to eliminate inconsistencies. These included wort handling
technique, temperature control, stratification (heat layering) issues, hot-
side aeration, caramelization, stirring effects and brewer recipe recall.
The system employs specific RIMS ( recirculating infusion ) techniques but
these are modified to limit brewer input and less than repeatable activities.
Once again, the Brew-Magic System recirculates the liquid wort (not grain)
from and back to the mash. A specific design pump is used for this
purpose. Pump impeller design, rpm, flow rate and tube diameter are all
necessary considerations for the control of the smooth wort handling
characteristics of this system.
During this perfectly managed mash temperature cycle, the system's
circulation action has 'spent' the grain without stirring, foaming, or adding
other unwanted variables. There is virtually no stratification of heat within
the mash tun due to Brew-Magic's smooth flow design. The grain bed
remains undisturbed throughout the mashing procedure and acts as a static
filter for circulating wort. This creates an amazingly clean finish runoff.
The sparge operation is similar to that of the mash.
The original design for the Brew-Magic Pilot Brewing System evolved after
five (5) years of research along with the creation of four progressively
engineered prototypes. The project intent in simple terms, was to 'design
away' those brewing characteristics previously determined to be less than
repeatable during small batch brewing operations. Procedural as well as
mechanical aspects of beer production were each considered and in turn
're-developed' to eliminate inconsistencies. These included wort handling
technique, temperature control, stratification (heat layering) issues, hot-
side aeration, caramelization, stirring effects and brewer recipe recall.
The system employs specific RIMS ( recirculating infusion ) techniques but
these are modified to limit brewer input and less than repeatable activities.
- Milled grain is suspended in the mash kettle above a false bottom.
- Prepared water is added in a unique fashion to place the grain into a
state of equilibrium with the same quantity of liquid above and below.
- Control valves are positioned to allow flow of liquid from under the
false bottom through the system pump and on-board electronic heat
exchanger.
- Liquid is returned to the top of the mash bed in a controlled gentle
whirlpool that insures a smooth, uniform distribution of heat without
aeration.
Once again, the Brew-Magic System recirculates the liquid wort (not grain)
from and back to the mash. A specific design pump is used for this
purpose. Pump impeller design, rpm, flow rate and tube diameter are all
necessary considerations for the control of the smooth wort handling
characteristics of this system.
- The wort liquid temperature is monitored by a Unitronics V350 color
touch-screen controller as it flows from the mash kettle.
- Sabco's 'patent-pending' MagicSoft programming, monitors and
records temperature, temp settings, brewer notes, time intervals,
pump activations, graphic temp. rises, etc., and allows the brewer to
save the data file as a recipe for future playback with full self control.
- Kettle liquid temperatures are assisted by efficient ring style burners
located under each kettle. Each has its individual control valve.
- System kettles have a convex bottom along with a centrally located
siphon. This provide a constant directed motion of liquid without hot-
spots within the vessel unlike flat bottomed design kettles. Potential
caramelization effects from heated surfaces are eliminated.
- Final precise acquisition of the desired mash temperature is achieved
without the use of the burner. The Brew-Magic's fully flooded and
vented electronic heat exchanger is automatically brought into play by
the MagicSoft programming. The V350 controller locks and holds the
temperature during the mashing process. Desirable step mashes are
easily accomplished.
During this perfectly managed mash temperature cycle, the system's
circulation action has 'spent' the grain without stirring, foaming, or adding
other unwanted variables. There is virtually no stratification of heat within
the mash tun due to Brew-Magic's smooth flow design. The grain bed
remains undisturbed throughout the mashing procedure and acts as a static
filter for circulating wort. This creates an amazingly clean finish runoff.
The sparge operation is similar to that of the mash.
- Heated sparge water is directed to the pump for re-distribution back
to the top of the mash kettle in the form of a gentle whirlpool.
- As clean liquid descends from the top through the grain for a final
rinse, the richest wort under the false bottom is then directed via
siphon, into the boil kettle. Yield efficiency is excellent and typically
exceeds other brewing system designs.
- As wort is being boiled, the brewer can set up and begin another
mash. This feature is a great advantage when consecutive batches
are desired.
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