Objective

To strengthen fermentation performance by reducing bacterial contamination, lowering Volatile Acidity (VA), maintaining stable fermentation conditions, and improving overall process hygiene through the implementation of BactoShield, a targeted microbial control solution from The Catalysts Group.

Plant Profile

Parameter Specification
Feedstock Rice + Maize (Approx. 80% Maize & 20% Rice)
Composite Starch ~62%
Fermentation Setup Volume ~1200 m³
Product Evaluated BactoShield
Application Dosage 5 ppm
Trial Duration 11 Commercial Fermentation Batches

The Challenge

  • Elevated Volatile Acidity (VA) across critical fermentation stages indicated   significant bacterial contamination, impacting fermentation hygiene
  • High bacterial load and sub-optimal process conditions affected yeast performance and overall fermentation stability
  • Inefficient cooling and inadequate aeration created conditions favorable for bacterial proliferation during fermentation
  • The plant required a robust microbial control solution to reduce contamination, improve fermentation hygiene, and ensure consistent commercial production

Catalysts Solution

The Catalysts Group implemented BactoShield at a dosage of 5 ppm to strengthen microbial control and reduce bacterial contamination during fermentation. Supported by continuous technical monitoring and process optimization, including improvements in yeast management, aeration, and fermentation practices, the solution created a cleaner fermentation environment, resulting in enhanced process stability and improved fermentation hygiene. 

Performance Highlights

  • Hot Water Volatile Acidity was reduced from 1100–1200 ppm to 500–700 ppm, representing a reduction of approximately 42–55%
  • FLT Volatile Acidity decreased from 1200–1400 ppm to 500–700 ppm, delivering an improvement of approximately 42–64%
  • Consistently achieved Final Gravity of 1.000 across all commercial batches, demonstrating complete fermentation
  • Maintained low residual sugar (0.13–0.20%), indicating efficient fermentable sugar utilization
  • Achieved alcohol concentrations of up to 12.08% v/v while maintaining stable fermentation performance under commercial operating conditions

Before vs After Performance

Parameter Before After Observed Change
Hot Water VA (ppm) 1100–1200 500–700 ↓ 42–55%
FLT VA (ppm) 1200–1400 500–700 ↓ 42–64%
Final Fermenter VA (ppm) 1200–1400 750–900 ↓ 25–46%
Yeast Dosage 50 kg 60 kg ↑ 20%
Final Gravity Process Dependent 1.000 Complete Fermentation
Residual Sugar (%) Higher contamination risk 0.13–0.20 Improved Sugar Utilization
Maximum Alcohol (% v/v) Existing Programme 12.08 Stable Alcohol Production

Key Outcomes

  • Successfully reduced bacterial contamination by significantly lowering Volatile Acidityacross the hot water system, FLT, and fermenters.
  • Achieved up to 64% reduction in VA, creating a healthier fermentation environment for improved yeast performance.
  • Maintained Final Gravity of 1.000 across all commercial trial batches, demonstrating complete and consistent fermentation.
  • Maintained low residual sugar, indicating efficient substrate utilization and stable fermentation performance.
  • Improved overall fermentation hygiene through targeted microbial control and process optimization.
  • Established an optimized biological treatment programme capable of supporting consistent commercial fermentation under challenging operating conditions.

Conclusion

The commercial evaluation demonstrated the effectiveness of BactoShield in strengthening microbial control and improving fermentation hygiene in a grain-based ethanol production process. By significantly reducing Volatile Acidity throughout critical stages of fermentation, the Catalysts biological programme created a cleaner and more stable fermentation environment, supporting consistent process performance and efficient sugar utilization.

Beyond product application, the integrated technical support provided by The Catalysts Group helped optimize key fermentation practices, further enhancing operational reliability. Based on the observed improvements in bacterial control and fermentation stability, BactoShield offers a dependable biological solution for distilleries seeking to improve process consistency, reduce contamination risk, and support long-term fermentation performance.