Commercial Evaluation at a Large-Scale Molasses-Based Ethanol Distillery, Uttar Pradesh, Northern India

Objective

To improve fermentation performance by reducing bacterial contamination, enhancing alcohol generation, maintaining stable fermentation conditions, and improving overall process efficiency through the application of Catalysts' biological fermentation optimization program.

Plant Profile

Parameter Specification
Feedstock C-Heavy Molasses
Fermentation Mode Fed-Batch
Plant Capacity 65 KLPD Ethanol
Fermenter Capacity 800 m³
Fermenter Working Volume 630 m³
P.F Working Volume 100 m³

Process Challenges

Prior to implementation, the fermentation process exhibited several operational challenges that affected overall productivity:

  • Elevated bacterial contamination resulting in high Volatile Acidity (VFA)
  • Lower alcohol generation during fermentation
  • Higher residual sugar indicates incomplete substrate utilization
  • Reduced fermentation efficiency
  • Process instability under commercial operating conditions

Catalyst Solution

To address the identified process challenges, Catalysts implemented a customized biological fermentation optimization program comprising:

  • Bactoferm-M – A broad-spectrum antimicrobial formulation designed to suppress undesirable bacteria, protect yeast viability, and stabilize fermentation performance
  • Bactosafe DF – A synergistic antimicrobial formulation that effectively controls bacterial contamination, reduces by-product formation, and maintains a healthy fermentation environment

The products were strategically applied in both pre-fermenters and fermenters using an optimized dosing schedule to suppress bacterial contamination, improve yeast performance, and stabilize the fermentation process.

Performance Highlights

  • Average alcohol concentration increased from 9.35% under the existing fermentation programme to 10.31% following implementation of the CATALYSTS fermentation optimisation programme
  • Average Volatile Acidity (VFA) reduced from 1208 ppm to 875 ppm, demonstrating effective bacterial contamination control throughout the fermentation cycle
  • Average residual sugar reduced from 2.60 to 2.56, indicating improved fermentable sugar utilisation and more efficient substrate conversion
  • Fermentation efficiency improved from 90.34% to 90.72%, reflecting enhanced fermentation performance and process consistency

Before vs After Performance

Parameter Before After Observed Change %
Alcohol (%) 9.35 10.31 +10.27%
Residual Sugar (%) 2.60 2.56 −1.54%
Volatile Acidity (ppm) 1208 875 −27.57%
Fermentation Efficiency (%) 90.34 90.72 +0.42%

Cost–Benefit Summary

Parameter Specification
Additional Ethanol Production 6,048 L/day
Additional Revenue ₹3,50,784/day
Catalysts Cost ₹25,450/day
Net Daily Benefit ₹3,25,334/day
Net Annual Benefit (300 days) ₹9.76 Cr/year (US $1,024,461.01/year)

Key Outcomes

  • Achieved 10.27% improvement in alcohol concentration, reflecting enhanced sugar conversion efficiency
  • Reduced bacterial contamination by 27.57%, leading to improved fermentation health and process stability
  • Lower residual sugar indicated more efficient substrate utilization
  • Improved fermentation efficiency while maintaining stable operating conditions
  • Successfully established an optimized biological treatment program suitable for routine commercial operation
  • Demonstrated improved process consistency with enhanced overall fermentation performance

Conclusion

  • The trial successfully demonstrated the effectiveness of the integrated application of Bactoferm-M & Bactosafe DF in optimizing fermentation performance under commercial operating conditions
  • The biological fermentation program delivered a stable, reliable, and sustainable solution for improving process efficiency while effectively managing bacterial contamination
  • Based on the observed performance, the Catalyst solution is recommended for long-term implementation to support consistent ethanol production and overall plant productivity

Cost–Benefit Summary

Parameter Specification
Additional Ethanol Production 6,048 L/day
Additional Revenue ₹3,50,784/day
Catalysts Cost ₹25,450/day
Net Daily Benefit ₹3,25,334/day
Net Annual Benefit (300 days) ₹9.76 Cr/year (US $1,024,461.01/year)