Commercial Evaluation at an Integrated C-Heavy Molasses Distillery, Maharashtra, India

Objective

To evaluate the effectiveness of the CATALYSTS biological fermentation programme (ADY, Bactoshield and MV6) in improving ethanol production, reducing bacterial contamination, lowering residual sugar, minimizing spent wash generation, and enhancing overall fermentation performance under commercial C-heavy molasses fermentation conditions.

Plant Profile

Parameter Specification
Feedstock C-Heavy Molasses
Production Capacity 60 KLPD
Fermentation Mode Fed-Batch
Pre-Fermenters 1 Unit
Fermenters 4 Units
Working Fermenter Volume 370 m3
Pre-Fermenter Volume 55 m3

Process Challenges

The distillery was processing C-heavy molasses, where maintaining consistent fermentation performance under commercial operating conditions remained a significant operational challenge. The plant experienced:

  • Difficulty in achieving higher alcohol recovery due to suboptimal fermentation performance
  • Increased bacterial contamination leading to elevated volatile acidity and fermentation stress
  • Incomplete conversion of fermentable sugars, resulting in higher residual sugar losses
  • Excessive spent wash generation, increasing downstream handling and treatment requirements
  • Limited utilization of treated RO permeate water while maintaining stable fermentation performance
  • The need for a more robust biological programme capable of improving productivity without disrupting existing plant operations

Catalyst Solution

To overcome microbial contamination, improve fermentation robustness, and maximize ethanol recovery, a three-product biological fermentation optimization programme was implemented:

  • BactoShield – An advanced membrane-active antimicrobial formulation that effectively suppresses bacterial contamination, reduces volatile acid formation, minimizes sugar losses,
    and maintains hygienic fermentation conditions at low application dosage
  • Enzypro MV-6 – A specialty enzyme blend that enhances fermentable sugar availability, improves yeast nutrition through increased FAAN release, revitalizes yeast metabolism, and
    supports stable, high-efficiency fermentation while reducing process interruptions and spent wash generation
  • CATALYSTS ADY – A high-performance Active Dry Yeast providing rapid fermentation initiation, superior yeast vitality, high ethanol tolerance, and consistent alcohol production without dependence on conventional culture propagation

Performance Highlights

The commercial trial delivered measurable improvements across multiple fermentation parameters:

  • Alcohol concentration increased from 9.30% to 10.43%
  • Residual sugar reduced from 1.94% to 1.48%
  • Volatile acidity reduced from 1866 ppm to 1155 ppm
  • Daily ethanol production increased from 61,000 L/day to 64,000 L/day
  • Spent wash generation was reduced by 28,000 L/day
  • Successfully recycled 55% of treated RO permeate water while maintaining stable fermentation performance

Before vs After Performance

Parameter Before After Observed Change %
Alcohol (%) 9.30 10.43 ↑ 12.15%
Residual Sugar (%) 1.94 1.48 ↓23.7%
Volatile Acidity (ppm) 1866 1155 ↓38.1%
Daily Ethanol Production 61,000 L 64,000 L +3,000 L/day
Spent Wash Generation 470,000 L/day 442,000 L/day ↓28,000 L/day

Key Outcomes

  • 12.15% increase in alcohol concentration, resulting in higher ethanol recovery
  • 23.7% reduction in residual sugar, indicating more efficient fermentation
  • 38.1% reduction in volatile acidity, demonstrating effective bacterial control
  • 3,000 liters/day increase in ethanol production without additional fermentation capacity
  • 28,000 liters/day reduction in spent wash, lowering environmental load
  • Successful reuse of 55% treated RO permeate water, reducing fresh water consumption

Conclusion

  • The commercial evaluation demonstrated that the Bactoshield+
    EnzyPro-MV6+CATALYSTS ADY programme significantly enhanced C-heavy molasses fermentation performance under industrial operating conditions
  • The biological programme improved ethanol yield, reduced bacterial contamination, enhanced sugar utilization, lowered spent wash generation, and enabled higher treated water recycling without compromising fermentation stability
  • The trial confirms that the CATALYSTS fermentation programme provides a reliable solution for improving productivity, process stability, and operational sustainability in commercial molasses-based ethanol distilleries