Are you interested in the fascinating world of ethanol production? Look no further! KATZEN International, Inc. is at the forefront of innovative technologies and processes that are revolutionizing the industry. With a commitment to excellence and a track record of success, KATZEN is setting new standards in ethanol production efficiency and sustainability.
Coarse Grind Milling: The Power of Particle Size
Did you know that the size of grain fragments can have a significant impact on ethanol yield? KATZEN’s coarse grind milling system allows for the processing of grains with fragments as large as ¼ of a kernel. Not only does this reduce power and maintenance on the milling equipment, but it also improves the efficiency of other crucial processes such as decanter centrifuges and DDGS dryers.
Flexible Feedstocks: Endless Possibilities
At KATZEN, versatility is the name of the game. Their facilities are designed to process a wide range of cereal grains without major modifications. From corn and wheat to sugar beets and molasses, KATZEN can handle it all. This flexibility ensures that their ethanol production remains efficient and cost-effective, without compromising on quality.
Vacuum Liquefaction: Simplicity and Efficiency Combined
KATZEN’s liquefaction process is a marvel of engineering. By combining auto-refrigeration mash cooling with enzymatic hydrolysis, they have created a process that requires minimal equipment and reduces both installation and operating costs. Say goodbye to unnecessary complexities and hello to a streamlined and efficient ethanol production process.
Simultaneous Saccharification and Fermentation (SSF): The Gold Standard
Since 1981, KATZEN has been a pioneer in the commercial implementation of SSF. This fermentation process, used in 90% of grain-based ethanol plants, ensures maximum efficiency and ethanol yield. By optimizing the hydrolysis of the starch fraction of the grain kernel, KATZEN guarantees industry-leading results.
High Yield Fermentation: Excellence in Every Drop
KATZEN’s commitment to high yield fermentation is unmatched in the industry. Their process technology package maximizes the recovery of non-starch carbohydrates, optimizes starch hydrolysis, and ensures sanitary operations. Thanks to their expertise, KATZEN plants consistently achieve sustainable high ethanol yields while keeping enzyme and nutrient costs significantly lower than the industry average.
Disc and Donut Beerstill: Uninterrupted Operations
Maintenance downtime is a thing of the past with KATZEN’s disc and donut beerstill. Their design allows for extended operations without the need for cleaning column internals, resulting in uninterrupted production periods of over four years. When it comes to efficiency and reliability, KATZEN is the undisputed champion.
Pressure Cascade Distillation: Efficiency in Every Drop
KATZEN’s distillation system is a game-changer for ethanol production. Designed for pressure cascade operations, it ensures high efficiency, minimal downtime, and reduced capital equipment costs. With KATZEN, every drop counts.
Direct Coupled Molecular Sieve Dehydration: Reducing Energy Demand
Thanks to their rectifying column operating at elevated pressures, KATZEN eliminates the need to revaporize the molecular sieve feed. This innovative approach significantly reduces energy demand and equipment costs, making ethanol production more sustainable and cost-effective.
High Solids Evaporation: Concentrated Excellence
KATZEN’s high solids evaporation system allows for extended operations at product solids concentrations of up to 40 wt.%. This means higher efficiency and productivity, resulting in exceptional ethanol production.
High Quality DDGS: Raising the Bar
With KATZEN, even the byproducts of ethanol production are exceptional. Their overall process design, coupled with high yield fermentation, ensures the production of high-quality Distillers Dried Grains with Solubles (DDGS). These DDGS have higher protein content and reduced concentrations of unconverted starches and bacterial byproducts, making them the perfect choice for animal feed.
Zero Discharge Process: Sustainability at its Core
KATZEN’s commitment to sustainability is evident in their zero discharge process. They recycle or recover all process fluids, leaving no waste behind. Evaporator condensate, thin stillage, CIP rinses, and process spills are all reused or recovered, minimizing environmental impact and maximizing resource efficiency.
Future Applications: Innovating for the Future
KATZEN is not one to rest on its laurels. Their major processes and equipment items are designed with future applications in mind. Whether it’s handling high non-Newtonian fluids or saturated calcium salt solutions, KATZEN is prepared for the evolving landscape of ethanol production.
High-Moisture Corn Processing: Efficiency and Cost Savings
KATZEN-designed plants have the capability to process high-moisture corn, eliminating the need for drying. This not only reduces feedstock costs but also allows for direct delivery of the corn, eliminating storage costs. With KATZEN, efficiency and cost savings go hand in hand.
Integrated Feedlot Operations: A Perfect Match
KATZEN’s integrated feedlot plants take efficiency to the next level. By directly feeding wet cake to livestock, the need for a drying process is eliminated, reducing capital investment and operating costs. The shared overhead between the feedlot and ethanol production facilities further enhances cost-effectiveness.
With KATZEN International, Inc., the future of ethanol production has never looked brighter. Their innovative processes, advanced technologies, and commitment to excellence make them a true industry leader. Join the ethanol revolution today and experience the KATZEN difference!
