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How do you dump the trub w/o losing beer?
Well you're always going to lose a little, but after several days the heavier trub definitely drops and makes a nice compact cake in the bottom. I just open the dump valve slowly until you get liquid and quickly shut it off. We probably only lose about 1/2 a pint this way.
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Same question with when you are bottling/kegging. I assumed you pulled from the main triclover/NPT connection, and when done you dropped the trub out the bottom.
I dump once towards the end of fermentation while it's still blowing off a little to prevent pulling vacuum from the lost liquid. This takes care of almost all of the trub. After that, I generally dump once more after several days of cold-crashing to get the rest of the yeast that flocc'ed out. The beer isn't perfectly clear at this point, but it's good enough for most styles.
After that we keg out the racking port. I semi-checked last time and I think we left about a pint or two in the bottom of the cone. It was super, super yeasty though, so you won't feel bad about dumping it. I would say from kettle to keg, we lose about 1 gallon after factoring in yeast dumps, gravity samples, random urges to taste the progress, etc.
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I've been doing primary/secondary in same fermenter, then dry hopping in keg. In your experience should I dry hop in secondary and then keg?
If you use pellets, you could just dry hop straight into primary, wait for that to drop then siphon off above the trub. Dry-hopping is fine in the keg as well and I did the same for a while. I was really just pointing out how easy it is in a conical.
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Can I come check these things out some weekend?
Sure. I'll shoot you an e-mail next time we're brewing.