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Advanced Process Analytics for Better Process Control
Fermentation is the most critical stage in ethanol production, yet it is often monitored using manual methods that provide limited process visibility. Delayed or inaccurate measurements make it difficult to identify contamination, sugar losses, and process deviations before they impact plant performance.
The Catalysts Group offers on-site implementation of advanced HPLC and NIR analytical services, enabling distilleries to access accurate process insights directly at their plant. Our technical experts support the complete implementation-from sample collection and analysis to result interpretation and process recommendations-helping plants optimize fermentation performance, improve process control, and make faster, data-driven decisions.
Why Conventional Fermentation Monitoring Falls Short
Many distilleries still rely on manual titration and hydrometer readings. While these methods provide basic process information, they cannot measure several critical parameters that directly influence ethanol yield and fermentation performance.
Common Challenges
- Operator-dependent measurements
- No continuous process visibility
- Delayed identification of contamination
- Limited trend analysis
- Manual documentation
- Corrective action after losses have already occurred
Without instrument-generated analytical data, production teams often make decisions based on incomplete information.
NIR + HPLC: Complementary Technologies for Complete Process Control
Both technologies play important but different roles.
NIR (Near Infrared)
Best suited for
- Rapid screening
- Raw material analysis
- Real-time operational checks
Rapid screening
Raw material analysis
Real-time operational checks
Typical Parameters
- Moisture
- Starch
- Protein
- Oil Content
Moisture
Starch
Protein
Oil Content
Advantages
Fast results
Minimal sample preparation
Operator friendly
Low operating cost
HPLC
Best suited for
- Detailed fermentation diagnostics
- Sugar profiling
- Contamination monitoring
- Process optimization
Detailed fermentation diagnostics
Sugar profiling
Contamination monitoring
Process optimization
Measures
- Sugars
- Ethanol
- Organic Acids
- Lactic Acid
- Acetic Acid
- Glycerol
Sugars
Ethanol
Organic Acids
Lactic Acid
Acetic Acid
Glycerol
Advantages
High analytical accuracy
Reliable quantification
Excellent sensitivity
Supports informed process decisions
High Performance Liquid Chromatography
- Detailed fermentation profiling
- Sugar and organic acid analysis
- Ethanol, glycerol, lactic & acetic acid measurement
- High-precision laboratory analysis
Parameters Monitored
Sugars (DP Profile)
Residual Sugars
Ethanol %
Lactic Acid
Glycerol
Organic Acids
Total Volatile Acids
Why Choose The Catalysts Group
HPLC-Led Fermentation Optimizations: Closing the Loop from Data to Yield Improvement
Objective
- Turning Fermentation Data into Process Improvement
- Routine fermentation monitoring can confirm ethanol performance without revealing the underlying causes of process losses. In this case study, HPLC monitoring provided deeper visibility into bacterial contamination, yeast stress and residual sugar conversion, enabling targeted corrective action and improved fermentation control
- Explore how analytical insights were translated into measurable process improvement and greater ethanol recovery
End-to-End HPLC Implementation
Unlike conventional equipment supply, The Catalysts Group delivers a fully managed analytical implementation.
Included in the Service
- HPLC system installation
- Application-specific column selection
- Complete AMC and preventive maintenance
- Calibration and validation
- Analytical consumables management
- Trained on-site HPLC analyst
- Standard Operating Procedures (SOPs)
- Trend reporting and alerts
- Technical interpretation
- Process improvement recommendations
- Audit-ready analytical documentation
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