Speaking of batch size, I plan on doing a lot of split batches. Basically a pretty generic wort and the. Change up the flavoring hops in dry hopping stage. I have 5 gallon kegs but still need one more and wonder if it would be better to get a 3 gallon keg so there is less headspace? Or does that matter?
It won't matter...if you think of it, as a keg empties the headspace increases. Doesn't harm the beer.
However, you'll use a lot of CO2 purging that much headspace. Let me suggest a procedure that will get you a virtually oxygen-free keg into which you can rack your beer.
Fill the keg you're going to rack the beer into with 5 gallons of Star-San. Attach the gas line, then purge the headspace 10 times or so. At that point, very, very little O2 left in the keg.
Then, use CO2 pressure to push that Star-San out into either a bucket or the next keg that you'll use (I store that Star-San always in the next keg to be filled with beer). As the Star-San leaves the keg, what replaces it is CO2--and no oxygen.
When the keg is empty of Star-San, then rack your beer into a QD connected to the OUT post. That allows the keg to fill from the bottom rather than the beer splashing in. Open the PRV to allow the CO2 to exit. Once you've filled the keg with your 2-3 gallons, you now have a virtually pure headspace above that beer, and can release the PRV and proceed to force carb or whatever you want to do.
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When I push out the Star-San from one keg to the next I use a jumper,
such as here, but I made my own out of a couple QDs and a piece of tubing.
I'll crack the lid of the keg receiving the Star-San, and when the originating keg is empty of Star-San, you'll start getting bubbling in the bottom of the receiving keg. Immediately remove one of the QDs unless you want Star-San all over your floor. Then I'll continue to connect and disconnect that QD a couple of times until I have bubbles and foam coming out of the opening. I'll put the lid on, and guess what? All that foam and bubbles are filled with what? CO2! So now I have a keg filled with Star-San whose headspace is completely CO2. No purging required at that point.
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I've included a pic below showing how I do a closed-loop racking of the keg, recovering the CO2 and feeding it into the top of the fermenter. I use a cutoff airlock because it fit the tubing I had, but you can use any short piece of tubing. Friend of mine uses a piece of a ballpoint pen.
See that tubing connected from the fermenter to the keg?
I use that to purge any last Star-San from the keg I've just purged of Star-San. I'll tilt the keg toward the pickup tube (or if it's centered, let it sit square), put on that racking QD, and it'll blast out any remaining Star-San. Not a big deal, but it clears everything.
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Some of the above, I'm sure, could be written better or sounds confusing, but it works, and works very well. It'll get oxygen out of your system as much as you can, and it's pretty easy.
