I have some gigayeast gb150 sour cherry funk and gb122 berliner blend. I would like to do one 12 gallon batch and split it into 2 fermenters. What would be an acceptable malt bill for both ? Maybe 65 % pilsner, 25 % wheat, and 10 % crystal ? And what crystal ?
Back to the OP's question about keeping crap out his plate chiller.
I quit using one, it was to much of a pain in the ass. For the last couple of years I've been using a Chillzilla, it's a lot easier to keep clean. It does take a little longer to chill, but it will never clog.
So I just ran 23.5 lbs through the mill. No problem with container over filling. I let it fill without touching it. For larger grain bills I might have to give it a shake.
I did some quick checking, looks like I'm in right at 700, complete with kettle, controls, and pump. Note, I had wire, connecters, and tools already.
I'm sure some crafty people could do it cheaper with enough hunting for better deals.
I hear you, those are premium sets. I built mine. I bought a 25 gallon bayou kettle. All weldless fittings from brewhardware.com and built a auber pid control panel. I'm not sure of the final cost, but it was over time and less than 700.
Have you considered e-biab ? I haven't touched my 3 vessel e-herms since I built the e-biab system.
You can build it yourself or buy one ready to go.
http://www.brew-boss.com/default.asp
http://www.cobrewingsystems.com/products/single-vessel-electric-brew-system-ebiab
I use Ahtanum, Amarillo, and Nelson together in a pale that I have done a few times. People seem to like it, even got a best in show at our county fair a couple years ago.
Several members have built them. Mine is a 25 gallon kettle with PID control. I use a false bottom and a bag, although I have been thinking about going to a mesh filter basket.