Objective

To evaluate the impact of EnzyPro MV-6 as the primary fermentation-support solution, supported by Bactoshield for contamination and foam/scum control, with the aim of improving fermentation efficiency, alcohol production, sugar utilization, and recovery without major changes to the existing fed-batch process. The case study focused on achieving higher alcohol production, better sugar utilization with lower residual sugar, improved fermentation efficiency and recovery, and greater control over contamination, foaming, and scum formation during fermentation.

Plant Profile

Region North India
Plant Capacity 130 KLPD Ethanol
Fermentation Mode Fed-batch
Pre-Fermenters 1
Fermenters 3
Fermenter Working Volume 880–920 m³
Application EnzyPro MV-6 + Bactoshield

The Challenge

  • Maximizing alcohol yield: The process needed to extract higher alcohol yield from molasses while maintaining stable fermentation conditions
  • High residual sugar: Residual sugar averaged 2.66%, indicating scope for better sugar utilization
  • Lower fermentation efficiency: Control batches averaged 79.33% fermentation efficiency, leaving room for improvement
  • Contamination and process instability: Foaming, scum formation, and contamination were observed in the pre-fermenter and fermenters, creating additional operational challenges

Catalysts Solution

The process was evaluated using a combination of EnzyPro MV-6 and Bactoshield serving as the primary fermentation-performance solution and Bactoshield providing secondary support for process hygiene and contamination/foam control

  • EnzyPro MV-6 – EnzyPro MV-6 was applied at 5 ppm in the fermenter system to support improved conversion of available fermentable sugars and enhance fermentation performance
  • Bactoshield- Bactoshield was applied at 5 ppm alongside EnzyPro MV-6 to support control of bacterial contamination, foaming and scum formation observed during fermentation

Performance Highlights

The combination demonstrated a clear improvement across the key fermentation-performance indicators

  • Average alcohol increased from 8.48% to 9.02%, indicating improved conversion of available sugars into alcohol
  • Residual sugar reduced from 2.66% to 2.08%, showing better utilization of available fermentable material
  • Fermentation efficiency improved from 79.33% to 88.20%, representing a substantial improvement in conversion performance
  • Alcohol recovery increased from 20.16 BL/Qtl to 22.19 BL/Qtl, demonstrating improved overall process yield
  • The trial also reported improved control of foaming, scum formation and contamination in the pre-fermenter and fermenters following application of the product combination

Before vs After Performance

Parameter Before / Control After MV-6 + Bactoshield Improvement
Alcohol 8.48% 9.02% +0.54
Residual Sugar 2.66% 2.08% −0.58
Fermentation Efficiency 79.33% 88.20% +8.87
Recovery 20.16 BL/Qt1 22.19 BL/Qt1 +2.03 BL/Qt1

Key Outcomes

  • Average alcohol increased from 8.48% to 9.02%, with the trial achieving alcohol levels as high as 9.40% during the observed batches
  • Residual sugar reduced from an average of 2.66% to 2.08%, indicating more effective utilization of the available sugar during fermentation
  • Fermentation efficiency improved significantly from 79.33% to 88.20%, demonstrating stronger conversion performance under the trial conditions
  • Average recovery increased from 20.16 BL/Qtl to 22.19 BL/Qtl, with the highest observed recovery reaching 22.53 BL/Qtl

Conclusion

The trial demonstrated that the application of EnzyPro MV-6 and Bactoshield supported a measurable improvement in overall fermentation performance. Alcohol production increased from 8.48% to 9.02%, while fermentation efficiency improved significantly from 79.33% to 88.20%. At the same time, residual sugar was reduced from 2.66% to 2.08%, indicating better utilization of available sugars, and alcohol recovery improved from 20.16 to 22.19 L/Qtl.

The trial also reported better control of contamination, foaming, and scum formation, contributing to improved process stability. Overall, the results demonstrate the potential of the combined solution to deliver higher alcohol yield, improved fermentation efficiency, better sugar utilization, and stronger process stability without major changes to the existing fed-batch fermentation process.