Ferm Solutions can help identify if the proper equipment, design and proposed plant changes works together in an optimal efficient fermentation system for maximum ethanol yield.  Our engineering teams do not offer design to build services and only support additional expertise to problem solving fermentation related problems.  The microbiolgical evaluation step is critical to yeast production and contamination prevention for any changes to your plant process or equipment in which our engineers, microbiologist and bio-chemist teams can review.

Engineering Services

Following high purity recommendations or food grade operation specifications can provide virtually contamination-free fermentation processes from a high purity methodology. Standards are created from various regulated and related industries for proven results in controlling bacteria contamination and should be considered in all ethanol plant construction.  Economics of equipment play a role in determining the equipment and even without high purity food grade options available there are still options for minimizing potential contamination. 

Related references can be found under;

ASME BPE (bio-processing equipment)                                                                                                               FDA (solutions from regulations for safety)                                                                                                          ANSI (proven related industry std.)                                                                                                                     ISO (economy in standardization)                                                                                                                       P3-A ( pharmaceutical seals standards)                                                                                                                USP class 6 ( pharmaceutical polymer std.)

Coupling the right system of valves, pumps,  and seals with effective plant training will ensure successful opera-
tion for applications that demand the highest levels of reduced contamination fermentation.  Ferm Solutions can help you with plant expansions or start ups  as it relates to fermentation for long lasting successful operations.

Design Engineering - Understanding correct decisions up front matter

Understanding Design Engineering ethanol plants must understand equipment choices are important contamination variables -

Metallurgy is a critical factor in proper valve selection for any process involving fermentation that could be effected by contamination.   316L - Stainless steel valves are essential for begining to address contamination free designs.  Cast valves are more economical but their porus nature of exposed pits are hiding grounds for microorganisms are more inferior to forged steel valves needed for tighter surface areas.   Electro-polishing is also recommended for valves to continue to refine the surface as smooth as possible to avoid trapping unwanted contamination as well as routine passivation (chemical cleaning processes).

Pumps that are selected with PFA or PTFE polymers have a higher resistance to corrosion, lower pH reactivity and better surface finish properties than pumps designed with metal alloys or glass.  Studies show that accumulated normal bio-film buildup is easier to remove from these pumps than other materials.  Polymers do not rust, offer high temperature, high pH resistance and offer very low particle generation than other materials.

The next main consideration would be the valve type between diaphragm and ball valve.  While the diaphragm would be the most common used valve for high purity applications due to their low contamination trapping properties, the ball valve is the prefered design for fermentation due to the use of the SIP & CIP processes.   A much longer life expectancy, higher temperature tolerance and lower pH tolerance would allow more intense cleaning operations with the ball valve.

Seal intergity is something that must also be considered and inferior seals will allow leakage or even failure, which results in contamination or even plant shut downs.   Proper selected seals that allow for high temperature, high pressure and multiple chemical resistance will allow for smoother operation along with proper preventative maintenance programs.

Engineering Solutions

Our fermentation problem solving approach involves the Microbiological, Bio-Chemistry and Engineering discliplines to assure the root cause is indentified and resolved.   Contamination can be found in various parts of an ethanol plant which lead to ehtanol yield loss.

             ~ dead cavities                         ~ Obstructions                                  ~ Poor surface finish 

             ~ sharp corners                        ~ Corrosion                                      ~ Particle generation

             ~ seams                                    ~ Oil & Grease contamination            ~ Bio-film build up

             ~ Heat exchangers                    ~ Incorrect waste returns                 ~ Plant modifications