1. What's your usual batch size?
I target ~3 gallons at the end of the boil and package in 2.5 gallon kegs. I am considering cutting this down on some batches to use the smaller kegs in the 1.5-1.75 gallon range as well. When I am testing out new hop varieties, I start with 1 gallon preboil and end up with about 3 quarts in the fermenter.
2. Why do you brew small batches?
I have a couple of reasons. First of all, I'm a kitchen brewer and this allows me to brew full-boil, all-grain batches on my stovetop. Secondly, I only drink 3-5 pints of beer in an average week. I enjoy the brewing process just as much as the actual drinking, so brewing small batches allows me to brew more often. It also lets me have a variety of beer on tap at a given time without ending up with a huge backlog of beer to drink. And finally, I like to experiment a lot. By brewing smaller batches, it's not as big of a deal to dump a batch that didn't work out as well as I had hoped.
3. Do you brew, extract, partial mash, all grain?
I mainly brew all-grain, but I brew a handful of extract batches every year.
4. What's your basic process? I.E., BIAB, tiny cooler (😉), just stir in the extract, etc.
I consider my process a cross between BIAB and no-sparge. I was going to BIAB when I started brewing all-grain, but I was concerned with maintaining mash temps, especially with smaller volumes of liquid. My solution is to line a 5-gallon beverage cooler with a BIAB bag, and mash in that. The 2-vessel approach works for me in my kitchen, and holds temps as well as I need it to.
For chilling, I place my kettle in cold water in one side of my 2-basin sink. I then stick my handheld faucet in the water pointed on the kettle and run the cold water full blast. The excess water runs over the divider between the two basins and drains out the other side. It's not as efficient as an immersion chiller, but it works well enough with the smaller batch sizes.
5. Do you have a favorite piece of equipment that you like to use especially for small batches?
I use 5 gallon kegs as my fermenters. It has just about all the advantages of a conical, at a fraction of the price. Plus, they double as a keg.
6. If you've brewed larger batches how would you comapre the two in terms of effort? Time? Equipment needs? Recipe consistency?
I've only brewed larger batches for a couple of extract kit beers that were among my first few batches. Since those were partial boil and topped off with cold water in the fermenter, I don't think that makes a good apples-to-apples comparison to the all-grain batches I'm doing now. I couldn't brew a 5-gallon all-grain batch using my current setup unless I had a double brewday.
7. What am I missing that should be known about small batch brewing?
The differences on the cold side are often overlooked. Yeast pitches are different - for most ales I don't need a starter if I have a reasonably fresh pack of liquid yeast. For some (low-to-moderate gravity English ales and hefeweizens), I don't even pitch a full pack. Temperature swings happen more easily in fermentation if ambient temperature varies.