The No Boil Corn Mashing Method
Posted: Sun Oct 16, 2011 2:20 pm
I had originally posted this in another thread but WalkingWolf pm’d me and suggested that I put it in a new thread.
I have been experimenting for a while on a methodology for mashing corn, primarily focusing on reducing the labor involved but also on reducing the likelihood of scorching. I’ve tried a number of different approaches, garnering bit and pieces of information from other posts and finally came up with this method. To give credit where credit is due, it was one of Dnderhead’s posts that got me thinking of this particular approach.
No boil doesn’t mean no cooking. It is the application of heat for extended periods that accomplishes the gelatinization of the corn. It is still necessary to spend time stirring but the amount of time is significantly reduced. I have used this method with six mashes (7 lbs corn/2 lbs wheat/3 lbs malted red wheat) so far and with each mash I had an OG of 1.062 (potential abv of 7-8%), which is pretty good for an all grain mash.
Here's the procedure I've developed for a 12 lb grain bill with 6 gal of liquids (I'm using backset and sparge from a previous wash)
1. Pre-soak: Boil 1.5 gal backset and add to all grains except malt. Add enough cold water to reduce temps to 150-155F (about 4-5 cups) and add 1/2 teaspoon alpha. Stir well and seal the bucket. Let set for 2 days. I've done the pre-soak with both backset and plain water and there is a definite benefit to using the backset. I think the acid helps to break loose the starches and I know it also helps the enzymes in saccrification. The addition of alpha keeps the corn from becoming a solid mass but instead it's a thick, gooey porridge that can be easily removed from the bucket.
2. Bring 4 gal of sparge water to a boil and turn off heat. Add 2 teaspoons gypsum and a pinch of Epsom salt, these help the enzymes do their thing. Add the pre-soaked grains stirring well. Temps will drop to around 150F. Add 1 lb malted grain and stir well (I have used alpha here but the malted grains do a better job). Let rest for at least 30 minutes so malt can convert the available starches. This will keep the mash from getting real thick, it really helps in keeping it from sticking to the pot and virtually eliminates any problems with scorching and it makes stirring much, much easier. You can't include this lb of malt in the bill for ultimate conversion because most of the starch hasn't gelatinized yet, so it's sacrificial.
3. The key now to good gelatinization is time at elevated temps. I'll bring the mash up to 200F in two steps, first to 165-175, rest for 30-45 minutes and then to 200F with another rest of 30-45 minutes. Corn has a gelatinization range of 144-168 so boiling is really not necessary, but time at the higher temp is. During the rest stages I'll stir every 5-10 minutes or so to keep the corn suspended and off the bottom of the pot. My stove has a 2700 watt element and it generally take about 18-20 minutes to raise the temps at each step. The pot that you use can also make a big difference. When I first started distillation I was using a cheap SS pot and had a terrible time with the corn sticking and with scorching. I finally broke down and bought an 8 gal Megapot from Northern Brewer and it has made a significant difference. The SS is much thicker and the bottom is 3 layers and around 1/4 in thick. The mass distributes the heat much better. Another aid is to use a stirring spatula instead of a spoon. It allows scrapping the entire bottom to keep it clean while cooking.
4. Now I'll transfer my mash to a 6 1/2 gal bucket, add 3 cups cold water to make a total of 6 gal liquid. Gelatinization will continue as the mash cools and will thicken considerably. At 156-158F I'll add 1 tablespoon alpha to thin the mash, making it easier to stir in the malted grains. At 150F I add the malted grains and insulate to hold temps above 140F for a minimum of two hours. When temps drop below 130F I'll separate off the grain and cool to pitching temps.
It is a long process but it sure beats standing and stirring for an hour or more.
Big R
I have been experimenting for a while on a methodology for mashing corn, primarily focusing on reducing the labor involved but also on reducing the likelihood of scorching. I’ve tried a number of different approaches, garnering bit and pieces of information from other posts and finally came up with this method. To give credit where credit is due, it was one of Dnderhead’s posts that got me thinking of this particular approach.
No boil doesn’t mean no cooking. It is the application of heat for extended periods that accomplishes the gelatinization of the corn. It is still necessary to spend time stirring but the amount of time is significantly reduced. I have used this method with six mashes (7 lbs corn/2 lbs wheat/3 lbs malted red wheat) so far and with each mash I had an OG of 1.062 (potential abv of 7-8%), which is pretty good for an all grain mash.
Here's the procedure I've developed for a 12 lb grain bill with 6 gal of liquids (I'm using backset and sparge from a previous wash)
1. Pre-soak: Boil 1.5 gal backset and add to all grains except malt. Add enough cold water to reduce temps to 150-155F (about 4-5 cups) and add 1/2 teaspoon alpha. Stir well and seal the bucket. Let set for 2 days. I've done the pre-soak with both backset and plain water and there is a definite benefit to using the backset. I think the acid helps to break loose the starches and I know it also helps the enzymes in saccrification. The addition of alpha keeps the corn from becoming a solid mass but instead it's a thick, gooey porridge that can be easily removed from the bucket.
2. Bring 4 gal of sparge water to a boil and turn off heat. Add 2 teaspoons gypsum and a pinch of Epsom salt, these help the enzymes do their thing. Add the pre-soaked grains stirring well. Temps will drop to around 150F. Add 1 lb malted grain and stir well (I have used alpha here but the malted grains do a better job). Let rest for at least 30 minutes so malt can convert the available starches. This will keep the mash from getting real thick, it really helps in keeping it from sticking to the pot and virtually eliminates any problems with scorching and it makes stirring much, much easier. You can't include this lb of malt in the bill for ultimate conversion because most of the starch hasn't gelatinized yet, so it's sacrificial.
3. The key now to good gelatinization is time at elevated temps. I'll bring the mash up to 200F in two steps, first to 165-175, rest for 30-45 minutes and then to 200F with another rest of 30-45 minutes. Corn has a gelatinization range of 144-168 so boiling is really not necessary, but time at the higher temp is. During the rest stages I'll stir every 5-10 minutes or so to keep the corn suspended and off the bottom of the pot. My stove has a 2700 watt element and it generally take about 18-20 minutes to raise the temps at each step. The pot that you use can also make a big difference. When I first started distillation I was using a cheap SS pot and had a terrible time with the corn sticking and with scorching. I finally broke down and bought an 8 gal Megapot from Northern Brewer and it has made a significant difference. The SS is much thicker and the bottom is 3 layers and around 1/4 in thick. The mass distributes the heat much better. Another aid is to use a stirring spatula instead of a spoon. It allows scrapping the entire bottom to keep it clean while cooking.
4. Now I'll transfer my mash to a 6 1/2 gal bucket, add 3 cups cold water to make a total of 6 gal liquid. Gelatinization will continue as the mash cools and will thicken considerably. At 156-158F I'll add 1 tablespoon alpha to thin the mash, making it easier to stir in the malted grains. At 150F I add the malted grains and insulate to hold temps above 140F for a minimum of two hours. When temps drop below 130F I'll separate off the grain and cool to pitching temps.
It is a long process but it sure beats standing and stirring for an hour or more.
Big R