Overview

To assess the effectiveness of Alcozyme G Pro in enhancing key fermentation performance parameters, with a focus on alcohol production, fermentation cycle time, residual sugar conversion, and fermenter-wise yield

Plant Profile

Parameter Details
Industry Distillery
Process Area Fermentation
Application Ethanol Production
Fermentation System Fermenters & Pre-Fermenter

The Challenges

The fermentation process was evaluated to improve alcohol yield and reduce fermentation time while maintaining consistent raw material input and process conditions. Key focus areas included:

  • Improving alcohol production
  • Reducing fermentation cycle time
  • Achieving better residual sugar conversion
  • Optimizing the fermentation process
  • Maintaining controlled TVA and other fermentation parameters

Catalyst Solution- Alcozyme G Pro

Alcozyme G Pro was introduced as an efficiency booster blended with a micronutrient formulation for yeast and incorporated into the proposed fermentation SOP.

The application was evaluated under comparable operating conditions to assess its impact on fermentation performance and process efficiency.

Application

Alcozyme G Pro:

  • 0.5 kg in Pre-Fermenter
  • 2.5 kg in Fermenter

The report identifies Alcozyme G Pro as a newly added component under the proposed SOP.

Performance Highlights

Parameter Performance Achieved
Plant Capacity 120 KLPD
Trial Duration 30 Days
Average Alcohol (Last 10 Fermenters) 13.71% v/v
Peak Alcohol Achieved 13.79% v/v
Residual Sugar 0.21–0.27%
Residual Starch 1.71–1.85%
Fermentation Consistency Improved
Process Stability Maintained Throughout the Trial

Performance Highlights

Parameter Control Trial
Alcohol 14.11% 14.47% ↑
Residual Sugars 0.20% 0.11% ↓
Fermentation Cycle 54 hrs 51 hrs ↓
Fermenter-wise Yield 460 BL/MT 467 BL/MT ↑
TVA 460 ppm 390 ppm

Overall Impact

Higher Alcohol Yield • Faster Fermentation • Better RS Conversion • Improved Fermenter-wise Yield • Controlled TVA

Key Outcomes

Outcome Result
Alcohol Yield 14.11% → 14.47%
Fermentation Cycle 54 hrs → 51 hrs
Residual Sugars 0.20% → 0.10%
Fermenter-wise Yield 460 → 467 BL/MT
TVA Control 460 → 390 ppm

Conclusion

The trial demonstrated improved fermentation performance, with alcohol increasing from 14.11% to 14.47%, an improvement of 0.36 percentage points over the control. The fermentation cycle reduced from 54 hours to 51 hours, while residual sugars decreased from 0.10% to 0.08%, indicating better conversion

Fermenter-wise yield improved from 460 BL/MT to 467 BL/MT, while TVA remained well controlled at 390 ppm compared with 460 ppm in the control

Overall, the trial delivered better alcohol yield, reduced fermentation time, improved residual sugar conversion, and higher fermenter-wise yield with comparable TVA levels. The report recommends maintaining the same dosing pattern for a longer run to understand process dynamics and further improve fermentation efficiency