For my last brew I decided to insulate my mash tun because the projected temperatures were below 20 degrees Fahrenheit and we needed to hold our temps very well without doing HERMS.
After some research on the homebrew talk forums I found that a lot of home brewers have success with Reflectix wrap. This stuff is essentially just bubble wrap with an aluminum backing, but it provides a simple and easy to apply insulating layer. It comes in rolls of 24” wide which is almost perfect for my keggle. I picked up a 25ft roll along with two rolls of reflectix aluminum tape. I would definitely recommend getting the tape because it helps bind multiple levers together very well.
Creating the complete wrap took a few hours but was well worth it.
Getting Started
You will need the following items for this project
- Scissors
- 24” x 25ft roll of Reflectix Insulation
- 2 rolls of Reflectix aluminum tape
- Sharpie for tracing
- 2 hrs of time
Step 1 – Cut the first Wrap
Wrap the insulation around the kettle and cut to length giving yourself plenty of extra. Next, cut the width of the wrap so that the handles of the keggle are free to grab, this is about 4-5 inches off the 24” wide piece. Next, cut all your gaps and holes to enable it to fit around all your fittings. After that it should be easy to mark the length while around the keggle so that you have a seam in the front of the keggle.
Step 2 – Cut Remaining Wraps
This really depends on how much wrap you have and how much insulation you think you need. I created 4 wraps, so during this stage I created 3 more. To save time, use your first wrap as a template for your remaining wraps. Though make sure that every wrap you add gets a little longer because the diameter is getting bigger. If you don’t your outer wraps will be too short. I just eyeballed it, but if I was doing it again I would just do the math. I’m guessing each wrap adds at least 3/8 inch in diameter, so with 3 wraps this will add up. If you make a mistake, you can always hide it with the outer wrap. The outer wrap is the most important one to size because it’s the one everyone will see. Cut the holes and gaps last and do them each by hand to make sure they line up with everything. Note that simply drawing outlines from your first wrap on the later wraps won’t work because the circumference is changing with each wrap. Make sure all the seams line up in the same place at the front.
Make the last wrap 4-6 inches longer than the rest. You will use this to keep the wrap closed with Velcro. Plus it will cover the seem with insulation but still make it easy to remove the wrap for cleaning.
Step 3 – Bind Wraps Together
Next put all the wraps in place around the keggle. Line all the seems to the same place in the front middle of the keggle. Use the tape to bind all the layers together while they are in place. This will ensure the proper curvature is maintained. Once you have tacked it together on the top, take the piece off and finish tacking on the bottom and any bare spots so that you have one big wrap.
Step 4 – Apply Velcro
If you didn’t get Velcro, I would recommend it. Apply the grabbing portion of the velcro to the underside of the last wrap on the shorter side (left side for me). On the longer part that overlaps, apply the fabric side of the velcro. Make sure that when you position the strips, that you do so with the wrap held and stretched tight. This will ensure you have a nice tight seal when closing the wrap.
Step 5 - Make a Lid
This is real easy. Take the remaining 4-5 inch strips that you cut off for the width and start wrapping them around the top of the keg with the main wrap in place as a guide. Bind where reflectix touches itself with tape. When the strip is done grab another and start it where the other left of, binding with tape. Do this until you have the same number of wraps as your main wrap. You should have just enough length to do it. While in place, bind the layers together at the seams using the tape, similar to how you did for the main wrap. Do this on the top and bottom and make sure its solid before continuing. Next, cut a square piece that fits over the top of the keggle. Place it on top and cut off the edges. Make sure to leave a bit of overhang. Something like a 1/4 inch will work fine. Tape the lid shut on all sides of the top so there are no places for heat to escape.
I only used on layer for the lid, but you could do more. You would just need to make the lid a little higher to accommodate the extra padding at the top
Step 6 – Brew some beer
The high for the day in which I first used this wrap was 19 degrees F. What I observed is that the wrap did an awesome job, only really losing 1 degree after a long time once the mash temperature had stabilized. In my opinion well worth it. If I ever switch to electric I will certainly do the same thing for my HLT and BOIL kettle.