I usually take the rough estimate and double or triple it. Our Pro series and signature equipment agitators are around 3 time more hp than our competitors and our pro series condensers have around 4 times the condensing capacity on the average. We typically go with thicker steel and copper than our competitors on the pro series and signature series stills. Our prices are lower because of our low over head and lower mark ups. I built the business with no debt.
For the standard series the condensers are plenty large enough as are the agitators. We test all jackets to 3 times the operation steam pressures. My team leaders have long check lists concerning quality control testing and inspection. Every distilling vessels goes through a 30 point inspection by me personally before it leaves here. We work really hard to make sure that no issues arise. By using the methods above we have been very successful with our designs. Now, all of our distilling equipment designs have been proven by years of use in the field.
We have found that the fastest and most efficient way to crash cool mash with a heat exchanger, is a cooling coil in the mash tun. We maximize the heat exchange surface area with the coil so that our mash tuns with crash cooling coils, crash cool in 1 hour. Even our 2,500 gallon mash tun will crash cool in one hr with the coil.
Because our pro series agitators are so heavy duty, you can leave 25% of the water out of the corn mash recipe and add it directly as cold water to crash cool from 190F down to the yeast throwing temp in less than 5 or 6 minutes in a 300 gallon mash tun. Keep in mind that this will shorten the lifespan of the agitator and that the cooling coil in the tun is the best way to go. Also you can steam inject and use the jackets of our tuns for crash cooling. Even with our insulation jackets, crash cooling with the jacket is not as efficient as the coil in the tun. Used properly, our tube and tube heat exchangers work great as well. We currently quote all of our on the grain in mash tuns with crash cooling coils.