2-month lurker, first time poster.
I just thought Id chime in because Ive just started in this hobby (2 x 5.5ish gal batches only). Ive not yet even tasted the results (one batch fermenting, other just bottled) but I can say Im very pleased with my wort chilling processboth in how quickly it works and how little water I feel like Im wasting. Its quite similar to what others have said.
My chiller is made from 50ft of copper tubing with dual (i.e. inner and outer) coils. I think this part is important, to get as much surface area in contact with the wort as possible. Admittedly, I kind of duffed the fabrication/bending process of the copper tube--the thing looks like total crapbut it drops neatly into my kettle and it sure does seem to work.
- Drop cooler into wort
- Fill chest-type cooler with hose water
- Drop submersible pond pump into the cooler, connect it to inlet of immersion chiller
- Let outlet of coil drain onto the driveway (if you can capture this water and use it for something, all the better), with a hose backfilling the water into the cooler (dont let the pump run dry!)
- Regularly swirl the chiller around in the wort (without splashing) to keep the wort moving over the coils a bit. I didnt time it, but for me, this got my temperature down to sub-100F in what felt like no time at all. The swirling motion really helps speed it along; every time I do it, I feel a burst of heat flowing out the outlet of the chiller
- As I approach 90F, I shut off the hose and go closed loop, routing the outlet of the chiller back into the cooler such that it just keeps recirculating the same water
- To chill the water in the cooler, I fill up used beer/soda cans with water and freeze them. Not sure if this is better than plastic bottles or not; I thought the metal cans might help transfer heat better, but I have not tried plastic so I cant compare.
- It seems to work because using a 24-pack of frozen cans, Im easily able to get the wort down to pitching temperature in, again, what feels like no time at all (Im guessing 10 minutes, but definitely no more than 15 minutes). Again, regular swirling of the wort chiller is important to get the quickest chill times.
- During clean up, I fill up the spent cans with water out of the cooler, and re-freeze them. Note, some will have split due to the freeze/thaw cycle, and those get returned to the store for deposit.
Your hose water is probably hotter than mine so youd probably need more ice than I do, but this method has worked very well for me and I dont plan to change it any time soon. For my first batch, I was prepared with (3) cases of 24 frozen cans, and I only ended up needing one case.
Cheers
Matt