Why don't you scale your batches up and do 5.5? I do 10.5 for most standard batches and 11 gallons for big IPA's with a lot of dry hopping. This way I ensure I end up with two full 5 gallon kegs.
$0.72 for an AG pale ale? You must be including equipment depreciation expenses. :cross:
Just the things I said, and of course, propane. I'm being realistic about product losses too. I brew a 5.5G batch by the time I factor in equipment, kettle, fermenter and sample losses, and that first pint in the keg that's mostly yeast... I end up with about 4.5G to drink. Dryhops absorb beer too, and I DO factor that in.
I just checked my numbers. That number is about right. Some will say that I'm counting too much for losses, but I find kegging increases losses somewhat, and I try to be realistic about the number of pints I actually pull from a batch.
I'm 175 gallons into my brew career, and I have to say, I'm being very honest about my results. I'd love to engage in the one upmanship that is: I can make beer cheaper then you, but I can't compete.
As an addendum, I tend to brew with leaf hops which also accounts for way more in losses then pellets do.