Objective

To optimize the application of Catalysts Bactoferm in the fermentation process and evaluate its impact on fermentation efficiency, residual sugars, alcohol formation and bacterial contamination. The trial was conducted using experimental fermenters operated in parallel with control fermenters under comparable molasses conditions.

Plant Profile

  • Plant capacity: 85 KLPD ethanol
  • Location: Uttar Pradesh, North India
  • Fermentation mode: Fed-batch
  • Fermentation system: 2 pre-fermenters and 8 fermenters
  • Fermenter working volumes: 200–400 m³ and 750 m³
  • Pre-fermenter working volume: 40–80 m³

Process Challenges

The fermentation process faced several challenges in maintaining efficient sugar conversion and stable alcohol production while dealing with bacterial contamination and residual sugars. The key challenges were:

  • Maintaining efficient sugar conversion: Ensuring maximum utilization of fermentable sugars without excessive residual sugar at the end of fermentation
  • Controlling bacterial contamination: Managing bacterial activity that could interfere with yeast performance and negatively affect fermentation
  • Maintaining consistent alcohol production: Achieving stable alcohol levels despite variations in fermentation conditions and molasses quality
  • Improving fermentation efficiency: Enhancing overall process performance without significantly altering the plant’s existing fermentation and feeding practices

Plant Profile

  • Plant capacity: 85 KLPD ethanol
  • Location: Uttar Pradesh, North India
  • Fermentation mode: Fed-batch
  • Fermentation system: 2 pre-fermenters and 8 fermenters
  • Fermenter working volumes: 200–400 m³ and 750 m³
  • Pre-fermenter working volume: 40–80 m³

Catalyst Solution - Bactoferm

  • Catalysts Bactoferm was introduced into the existing fermentation process as part of the optimization trial
  • The product was applied at 0.8–1 ppm, with the documented trial results including applications at both levels
  • The existing feeding pattern was maintained, allowing the performance of Bactoferm® to be evaluated within the plant’s regular fermentation operation

Performance Highlights

  • The trial demonstrated a positive impact on key fermentation performance indicators:
  • Alcohol production increased from 8.60% to 9.41%, indicating stronger conversion of sugars into alcohol
  • Fermentation efficiency improved from 86.78% to 90.21%, reflecting better overall fermentation performance
  • Lactic acid decreased from 7,175 ppm to 5,650 ppm, indicating improved control of bacterial/acid-related fermentation stress
  • Fermentable sugar decreased from 38.70% to 37.23%, indicating effective utilization of available fermentable sugars during fermentation

Before vs After Performance

Parameter Before After Change
FS 38.70% 37.23% ↓ 1.47
Lactic Acid 7,175 ppm 5,650 ppm ↓ 1,525 ppm
Alcohol % 8.60% 9.41% −27.57%
Residual Sugar 1.94% 2.04% ↑ 0.10
Fermentation Efficiency 86.78% 90.21% ↑ 3.43

Key Outcomes

  • Alcohol production improved by 0.81 percentage points, reaching 9.41%
  • Fermentation efficiency increased by 3.43 percentage points, reaching 90.21%
  • Lactic acid reduced by 1,525 ppm, representing approximately a 21% reduction from the baseline
  • Fermentable sugar reduced by 1.47 percentage points, indicating effective sugar utilization
  • Overall, the trial demonstrated stronger fermentation performance and improved process stability with Bactoferm application

Conclusion

The trial demonstrated that the fermentation process achieved stronger overall performance following Bactoferm application. Alcohol production increased from 8.60% to 9.41%, while fermentation efficiency improved from 86.78% to 90.21%. Lactic acid also reduced significantly from 7,175 ppm to 5,650 ppm, indicating improved control of fermentation-related bacterial activity. The reduction in fermentable sugars from 38.70% to 37.23% further indicates effective utilization of available fermentable sugars during fermentation. Overall, the results demonstrate that Bactoferm® supported improved fermentation efficiency, higher alcohol production, better sugar utilization and improved process stability under the evaluated operating conditions