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Burned my last beer--why?

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I can't say for certain, of course, but I really don't think this is what happened--but it definitely points out the importance of not trying to recirculate over the top too quickly. And also of checking the level (my kettle has etched volume markings on the inside) to make sure it isn't increasing, which would indicate this is happening.
So I have the same spike kettle and was never able to see the markings through the bag, and now that I have the stainless mesh basket I can't see them at all. You're able to see the markings through your bag?
 
The folded-back ripple elements can trap particles (hops, grain, LME) between them. I suggest unbending the fold so that there is no trap there. The ripples I used were very bendable. I had the incoloy elements (dark gray) - not sure about SS if that's what you have.

I've brewed electric for a long time. I've definitely had a few smokey batches when stuff collected in there and burned.
I have to ask at what point of the brew process was stuff able to collect between the element folds? I've brewed probably 60+ batches on mine so far and I just can see a part of the brew process where stuff could collect and sit between the element folds AND the element be on constantly and hot enough that it could burn something. The only part of my process where anything comes remotely close to building up and touching the element is during my chilling cycle where I'm recirculating wort through my CFC and back into the kettle (element is obviously off at this point). After chilled, I let it sit for 10-15 minutes to allow all the big stuff to fall out of solution/settle on the bottom before finally racking pretty clear wort to the fermenter. When I'm done racking there is most definitely stuff settled on and around the element, but for that whole process the element is off so I'm failing to see where what you're saying is even possible.
 
I have to ask at what point of the brew process was stuff able to collect between the element folds?
It's possible I'm not understanding your comment, but I'll do my best here.

If any solid material is added to the boil kettle while the elements are on, that solid material could settle into the folds of the element.

If the hop sack that is hanging in there sits on the elements, it can burn during the boil.

Anyone who has brewed with an electrical element know that "gunk" collects on the element. If that gunk gets thick enough, it can burn. For this reason, I'd advise to look at them if you're doing back-to-back brewing sessions without cleaning between.
 
It's possible I'm not understanding your comment, but I'll do my best here.

If any solid material is added to the boil kettle while the elements are on, that solid material could settle into the folds of the element.

If the hop sack that is hanging in there sits on the elements, it can burn during the boil.

Anyone who has brewed with an electrical element know that "gunk" collects on the element. If that gunk gets thick enough, it can burn. For this reason, I'd advise to look at them if you're doing back-to-back brewing sessions without cleaning between.
I don't use hop bags and use a stainless mesh basket for mashing. I've done many back to back batches and even with a thin layer of whatever is on the element, I've never had scotching ever. Maybe my stainless ripple makes the difference, I don't know, I'm just saying if there's liquid in the kettle and it's covering the element, I've never had it scotch ever. Again, anecdotal evidence but at least 10 back to back batches and a total of at least 60 batches is my sample size. Maybe if I got 3 or 4 batches with out cleaning something might happen, but that's the Brewers fault, not the element.
 
From an IPA I made. You can see where the ripple element (Camco 2963 ULWD) did a job on it. The bag o' hops smothered the element such that the water in the kettle didn't remove the heat fast enough. Can happen in other scenarios.

1701741627661.png
 
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