10+ batches of Efficiency Blues

[mforsman]

I'm trying to weed out of there is something wrong in my process or if it's really just the crush. I've brewed 10-12 all-grain batches now and each time using both NB & my LHBS crushes I ended up right around 60% efficiency. I finally picked up a Corona mill, but this last one (using that) ended up at 50%. Clearly, I need to dial that in a bit more. I'm using a straight braid (bazooka screen) that I picked up from my LHBS.

The grist was
12 # 2-row
8 oz Caramel 10L
8 oz Caramel 20L

I used this calculator:
http://www.brew365.com/mash_sparge_water_calculator.php
I've attached a screenshot of the results

Pre-heated mash tun using hot tap water (130-140&#730
Add 5.2 to HLT
Mashed in 4.3 gallons of water at 166˚ which leveled at 152˚
Recirculated around 1.5 gallons
The first runnings were 1.077
Fully drained the mash tun.
Collected around 2 - 2.5 gallons (rough estimate, should have measured)

Add 5.2 to HLT
Batch sparged with 4.75 gallons of water at 185˚ which leveled at 167˚
Mixed very very very well
Waited 15 minutes
Recirculated around 1.5 gallons
The sparge runnings were close to 1.022
Collected until 6.5 gallons

Pre boil gravity was 1.044
BeerAlchemy calculated that it should be 1.055 @ 60% efficiency.

Because of that low number, I boiled for an hour before beginning my hour boil.
I ended up at 1.060

Am I missing a step? Doing something wrong? Or just crank that corona to the point of fear?

Thanks, I know these kinds of questions get asked all the time, I just can not find a solution in any of those threads that work for me.

 

[abrew2u]

Crush crush crush and more crush.I use a corona style mill dialed way down getting 85% effiecentcy lately my first few brews was only getting 50 % then I made it a finer crush and were good to go
Hope that helps.

 

[mforsman]

I'm going to pick up some rice hulls next time so I won't be so scared of grinding so fine.

 

[nickharbour]

There is any number of things that could be the problem but for me it was dough-in.

I experienced very inconsistent and somewhat crappy efficiency when I first switched to AG. After a while I realized I really wasn't stirring effectively enough at dough-in to break up grain balls. So if you're doing like I used to do by pouring in water and giving it a half-assed 10 second stir, that may be the problem. Now I stir for a few minutes and really try to feel out and crush grain balls.

 

[mforsman]

I stir the crap out of it, but will probably pickup or make a mash paddle and stir even more. I've been using one of the big stainless spoons.

 

[Golddiggie]

I stir the crap out of it, but will probably pickup or make a mash paddle and stir even more. I've been using one of the big stainless spoons.

Get, or make, a mash paddle. If you make one, make sure it has at least a few holes in the paddle part. Look at the designs of what others are using.

Mash paddle porn shot...

I've been using the one on the right, since the other is a bit too large to work well in my current mash tun. The one on the right is about 3' long.

 

[ajf]

You could take a look at http://braukaiser.com/wiki/index.php?title=Troubleshooting_Brewhouse_Efficiency for some excellent information on how to diagnose efficiency problems.

-a.

 

[diS]

Kaiser did a great job about explaining efficiency factors and how to predict/change your efficiency, it is a great read for anyone struggling with it.

If you really want to pick a nickle and calculate how much of sugars didn't unconverted, how much sugars stays in MLT after sparging etc. you can use efficiency calculator and measure all this values on brewday.. it requires some more work but I found it helpful to optimize my process.. and it is pleasure to do it form time to time.. weird I know, but I like numbers

 

[chuckstout]

Ill put my money on your crush, do you look at the crush and run your hands through it. If you find grain uncrushed your just wasting grain. Also maybe try mashing longer. I batch sparge and only stir at mash in and before recirculating and have dialed the crush in on our stone grinder to 76-80 eff with multiple brewers using the same equipment.

 

[helibrewer]

According to Kaiser's chart you max conversion number would be 1.090, you got 1.077, that's 85% conversion efficiencry but you should be able to get into the mid to high 90's. The crystal throws that off a bit since it's not a big contributor, but even figuring 1.43 ratio without it leaves you just barely hitting 90%.

Based on that, I'd say your issues are in the MLT and would agree with others that crush is the place to look.

 

[duboman]

According to Kaiser's chart you max conversion number would be 1.090, you got 1.077, that's 85% conversion efficiencry but you should be able to get into the mid to high 90's. The crystal throws that off a bit since it's not a big contributor, but even figuring 1.43 ratio without it leaves you just barely hitting 90%.

Based on that, I'd say your issues are in the MLT and would agree with others that crush is the place to look.

Not nit picking.......OP stated first runnings were 1.077 but pre-boil was 1.044.
I too believe the crush is the first thing to look at as without a good crush all the other suggestions won't garner much.

If the OP has the mill then get a set of gap feelers at the hardware store and dial the rollers down to .035-.039, that should help a lot! Rice hulls for the first batch would be a good idea but IME not really necessary at that gap unless there's a lot of wheat.

I will also add that it is important that you are using calibrated instruments to measure as in your thermometer and hydrometer/refractometer. Which are you using to measure your pre-boil and are you correcting for temperature if using a hydrometer?

How much wort was left in your tun after you sparged? If there was a lot left then you left a lot of sugar behind decreasing your efficiency as well.

+1 to reading the links above, very informative and educational