Commercial Evaluation of EnzyTreat Adv, DSPN-M & Catalysts-ADY at a Molasses-Based
Distillery, North India

Objective

To evaluate the effectiveness of an integrated fermentation optimization program comprising EnzyTreat Adv, DSPN-M, and Catalysts-ADY in improving fermentation efficiency, reducing microbial losses, increasing alcohol recovery, and lowering overall fermentation cost in a commercial molasses-based distillery.

Plant Profile

Location North India
Feedstock Molasses
Fermentation System Continuous Molasses Fermentation
Fermenters 6
Pre-Fermenters 2

Process Challenge

  • Prior to implementation, the distillery was experiencing several process limitations affecting fermentation efficiency and operating economics:
  • Fermentation performance was constrained by limited availability of fermentable nutrients, restricting complete sugar conversion
  • Microbial activity and volatile acid generation were reducing yeast efficiency and fermentation stability
  • Higher residual sugars indicated loss of potential alcohol recovery from available molasses
  • Variability in fermentation conditions resulted in inconsistent alcohol yield across operating cycles
  • Dependence on conventional fresh yeast contributed to higher recurring operating costs

Catalysts Solution

  • A comprehensive fermentation optimization program was implemented using EnzyTreat Adv, DSPN-M, and Catalysts-ADY, with each product targeting a specific process bottleneck
  • EnzyTreat improved fermentable sugar availability and enhanced yeast nutrition by increasing Free Alpha Amino Nitrogen (FAAN), resulting in improved sugar conversion and alcohol recovery
  • DSPN controlled microbial contamination and significantly reduced volatile acid formation, creating a healthier and more stable fermentation environment
  • The combined action of EnzyTreat-Adv and DSPN-M improved fermentation consistency, minimized microbial losses, and enhanced overall process stability
  • Catalysts-ADY replaced conventional fresh yeast, delivering reliable fermentation performance while reducing yeast cost by approximately 20%, providing an additional commercial advantage

Performance Highlights

The integrated program delivered measurable improvements across key fermentation parameters:

  • Alcohol concentration increased to 11.25%
  • Residual sugar was reduced to 1.97%
  • Volatile acidity reduced to 514 ppm
  • Stable final gravity achieved at 1.038
  • Improved fermentation consistency across multiple fermenters

Before vs After Performance

Parameter Before After Improvement
Alcohol (%) 10.02 11.25 +12.3%
Residual Sugar (%) 2.46 1.97 ↓20%
Volatile Acidity (ppm) 942 514 ↓45.4%
Final Gravity 1.051 1.038 Improved Fermentation Completion

Key Outcomes

  • Alcohol concentration increased by 12.3%, improving ethanol recovery and overall fermentation performance
  • Residual sugar was reduced by 20.0%, demonstrating more efficient utilization of available fermentable sugars
  • Volatile acidity decreased by 45.4%, indicating significantly improved microbial control and a healthier fermentation environment
  • Final gravity improved from 1.051 to 1.038, confirming more complete fermentation and improved substrate conversion

Conclusion

  • The commercial evaluation demonstrated that the integrated application of EnzyTreat and DSPN effectively addressed the primary limitations affecting molasses fermentation by improving sugar utilization, reducing microbial interference, and enhancing overall fermentation stability
  • The trial achieved higher alcohol recovery, lower residual sugar, and a substantial reduction in volatile acidity, confirming improved process efficiency
  • The combined Catalysts program successfully demonstrated that integrated enzyme, antimicrobial, and yeast technologies can simultaneously improve fermentation performance while reducing operating costs, making it a commercially viable solution for large-scale molasses distilleries