Ouch. Worst. Brewday. Ever.
I tried this one as a BIAB batch, and just about everything went wrong other than the bag ripping. I have never done anywhere near this much grain in one batch before, and it definitely does not work the way I normally do things.
Problem 1 was that my calculated volume fit into my mash tun nicely. I have a 15 gallon mash tun and do 7 gal batches. I calculated the water at 11.85 gallons, which should fit nicely. But when I started measuring out the grain, and it took my biggest bucket to hold the uncrushed grains, I knew I was going to have a problem. And sure enough, with the volume of grain, it wouldn't fit in the mash tun. This was easily fixed by getting out another vessel and splitting the mash. From then on, things went well. RIMS tube held temps perfectly, I was able to mash out, etc. THen I tried to lift the bag. It turns out, that 29.41 lbs of grain in a bag and soaking wet, weighs a LOT more than 29.41 lbs. And my equipment is quite high off the ground (top of the mash tun us about 5' up). I couldn't hold the bag for more than about 5 seconds before dropping it back into the mash. So the only thing I could do was haul it out as fast as I could with one big jerk and transfer it to another container that was lower so I could attempt to hold it up that way, as opposed to above my shoulder level. As you can imagine, wort was dripping out quite fast and it went EVERYWHERE. I was covered in wort (HOT wort, mind you!) as was the floor all around me. Great.
From then on things seemed great. I got tons more liquid out of the bag, got the boil going, added all the hops at the right places, and recirculated through my chiller to sanitize it. Then I added whirfloc and some pellet hops. I have a homemade hopstopper, and I have used it with pellets and whirlfloc before. but this was a disaster. When I started the chill, I got about 1/2" into the fermentor and then nothing more. THe homemade hop stopper was clogged, and try as I did to scrape, move it around etc, I couldn't get it to unclog. I even tried blowing backwards into it to see if there might be a chunk stuck in the dip tube. No dice.
So, I tried pouring the whole lot into the fermentor and making this my first no chill brew. Again, this is 100 lbs that has to be lifted up and gingerly poured into the fermentor through a strainer. Well, again, I got hot (this team REALLY hot) wort on everything, but this time was more careful and didn't get any on myself. And the strainer got plugged instantaneously. ULtimately I had to split the batch between 2 buckets, then go clean out my kettle, and pour the buckets back in, and finally I was able to get the stuff chilled.
So, I am hoping, as I have read, that hot side aeration is a myth, because I just poured 7 gallons of hot beer back and forth like separating an eggyolk from the white, with LOTS AND LOTS of sloshing around.
Also, my efficiency was quite low- normally I get 80%, but on this batch I only got 64%. I knew it would be low, but I calculated for 70%. Used 1 lb of light DME and 6 oz of brown sugar to make up for the low efficiency. I will have to try this again and hope it is not as miserable.
The only positive was I did this partigyle style, and the second batch went very smoothly.