Block diagram<\/p>\n
\n Vogelbusch process for neutral alcohol production\n <\/h3>\n \n Yeast is used to ferment sugars into ethanol which is refined and concentrated in further process steps.<\/p>\n
![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-blockdia-bioethanol.gif\"\/)
<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
\n \n \n Adjusted to feedstock<\/p>\n
\n RAW MATERIAL PREPARATION\n <\/h3>\n \n STARCH:<\/strong> Grains and tubers are milled before they are used in the process. Starch or by-products from wet milling plants do not require any special treatment and are fed directly to liquefaction.<\/p>\nSUGAR:<\/strong> Molasses and sugar syrups seldom require special treatment; they are diluted, acidified and fed straight to the fermentation unit. For substrates containing large amounts of inhibiting substances (affecting fermentation), pasteurization and\/or stripping may be necessary. Occasionally, a sludge removal process may be required.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n ![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-fermentation-375.jpg\")
\n \n Transformation into alcohol<\/p>\n
\n BIOREACTION\n <\/h3>\n \n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> to obtain glucose as a fermentable sugar. The partly saccharified substance is cooled down and fed directly to the fermentation unit. Final conversion of the starch into glucose takes place simultaneously during fermentation. To reuse water and latent heat, the Vogelbusch HotMash\u00a9 process recycles a decanted stillage stream to liquefaction \/ saccharification.<\/p>\nAt the fermentation stage, yeast is employed to convert monosaccharides into alcohol. <\/p>\n
Fermentation units<\/a> can be implemented as batch, fed batch or continuous processes. Continuous systems are generally cheaper and easier to operate. Batch systems are often preferred for highly inhibiting substrates (e.g. low-grade molasses) or situations in which feedstocks must be frequently switched (e.g. molasses vs. grain). <\/p>\nThe Vogelbusch standard fermentation process in alcohol production is our advanced MultiCont\u00a9<\/a> continuous fermentation. <\/p>\nFermentation of the substrate starts in a pre-fermenter under adjusted conditions that promote yeast growth. The fermenting mash flows steadily through a series of main fermenters, while the alcohol concentration increases to a range of 12 – 14 % vol, (depending on the raw material). From the last fermenter the alcohol mash is fed to an intermediate tank for distillation.<\/p>\n
The heat generated during fermentation is removed via external heat exchangers, exhaust air from the fermenters is led through a scrubber for recuperation of alcohol.<\/p>\n
With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n Final product<\/p>\n
\n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n \n The alcoholic mash is preheated and fed to the distillation<\/a><\/strong>section where the crude alcohol is stripped from the mash, leaving behind an alcohol-free liquid, the stillage. The crude alcohol vapors are purified and concentrated in several process columns and fed to rectification<\/a> for further refining and concentration to at least 96 % vol,.<\/p>\nVogelbusch column systems are individually tailored to the desired quality specifications and analytical and organoleptic characteristics. Process schemes are optimized for separation of impurities and avoidance of undesired chemical reactions and the temperature range of the columns is selected for superior product quality. <\/p>\n
Recovery rates from fermented mash to final product of 97.5 % are typical.<\/p>\n
Energy saving features include the Vogelbusch MultiPressure<\/a> column system and advanced thermal integration techniques, bringing the steam demand for distillation and rectification down to 1,950 kg per 1,000 liters of neutral alcohol.<\/p>\nA dehydration<\/a><\/strong>process is used to obtain super dry ethanol for pharmaceutical or industrial applications. Standard Vogelbusch technology employs a Pressure Swing Adsorption (PSA) process using molecular sieves. The final water content can be reduced to 0.01 % wt.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n Adding value to production<\/p>\n
\n CO-PRODUCTS\n <\/h3>\n \n As only the sugar respectively starch is needed for the process, the remaining ingredients of the raw material in turn can provide valuable co-products. <\/p>\n
Yeast is used to ferment sugars into ethanol which is refined and concentrated in further process steps.<\/p>\n
<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n
Adjusted to feedstock<\/p>\n
\n RAW MATERIAL PREPARATION\n <\/h3>\n \n STARCH:<\/strong> Grains and tubers are milled before they are used in the process. Starch or by-products from wet milling plants do not require any special treatment and are fed directly to liquefaction.<\/p>\nSUGAR:<\/strong> Molasses and sugar syrups seldom require special treatment; they are diluted, acidified and fed straight to the fermentation unit. For substrates containing large amounts of inhibiting substances (affecting fermentation), pasteurization and\/or stripping may be necessary. Occasionally, a sludge removal process may be required.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n \n Transformation into alcohol<\/p>\n
\n BIOREACTION\n <\/h3>\n \n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> to obtain glucose as a fermentable sugar. The partly saccharified substance is cooled down and fed directly to the fermentation unit. Final conversion of the starch into glucose takes place simultaneously during fermentation. To reuse water and latent heat, the Vogelbusch HotMash\u00a9 process recycles a decanted stillage stream to liquefaction \/ saccharification.<\/p>\nAt the fermentation stage, yeast is employed to convert monosaccharides into alcohol. <\/p>\n
Fermentation units<\/a> can be implemented as batch, fed batch or continuous processes. Continuous systems are generally cheaper and easier to operate. Batch systems are often preferred for highly inhibiting substrates (e.g. low-grade molasses) or situations in which feedstocks must be frequently switched (e.g. molasses vs. grain). <\/p>\nThe Vogelbusch standard fermentation process in alcohol production is our advanced MultiCont\u00a9<\/a> continuous fermentation. <\/p>\nFermentation of the substrate starts in a pre-fermenter under adjusted conditions that promote yeast growth. The fermenting mash flows steadily through a series of main fermenters, while the alcohol concentration increases to a range of 12 – 14 % vol, (depending on the raw material). From the last fermenter the alcohol mash is fed to an intermediate tank for distillation.<\/p>\n
The heat generated during fermentation is removed via external heat exchangers, exhaust air from the fermenters is led through a scrubber for recuperation of alcohol.<\/p>\n
With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n Final product<\/p>\n
\n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n \n The alcoholic mash is preheated and fed to the distillation<\/a><\/strong>section where the crude alcohol is stripped from the mash, leaving behind an alcohol-free liquid, the stillage. The crude alcohol vapors are purified and concentrated in several process columns and fed to rectification<\/a> for further refining and concentration to at least 96 % vol,.<\/p>\nVogelbusch column systems are individually tailored to the desired quality specifications and analytical and organoleptic characteristics. Process schemes are optimized for separation of impurities and avoidance of undesired chemical reactions and the temperature range of the columns is selected for superior product quality. <\/p>\n
Recovery rates from fermented mash to final product of 97.5 % are typical.<\/p>\n
Energy saving features include the Vogelbusch MultiPressure<\/a> column system and advanced thermal integration techniques, bringing the steam demand for distillation and rectification down to 1,950 kg per 1,000 liters of neutral alcohol.<\/p>\nA dehydration<\/a><\/strong>process is used to obtain super dry ethanol for pharmaceutical or industrial applications. Standard Vogelbusch technology employs a Pressure Swing Adsorption (PSA) process using molecular sieves. The final water content can be reduced to 0.01 % wt.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n \n \n \n Adding value to production<\/p>\n
\n CO-PRODUCTS\n <\/h3>\n \n As only the sugar respectively starch is needed for the process, the remaining ingredients of the raw material in turn can provide valuable co-products. <\/p>\n
STARCH:<\/strong> Grains and tubers are milled before they are used in the process. Starch or by-products from wet milling plants do not require any special treatment and are fed directly to liquefaction.<\/p>\n SUGAR:<\/strong> Molasses and sugar syrups seldom require special treatment; they are diluted, acidified and fed straight to the fermentation unit. For substrates containing large amounts of inhibiting substances (affecting fermentation), pasteurization and\/or stripping may be necessary. Occasionally, a sludge removal process may be required.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n Transformation into alcohol<\/p>\n Starch is treated by liquefaction<\/strong> and saccharification<\/strong> to obtain glucose as a fermentable sugar. The partly saccharified substance is cooled down and fed directly to the fermentation unit. Final conversion of the starch into glucose takes place simultaneously during fermentation. To reuse water and latent heat, the Vogelbusch HotMash\u00a9 process recycles a decanted stillage stream to liquefaction \/ saccharification.<\/p>\n At the fermentation stage, yeast is employed to convert monosaccharides into alcohol. <\/p>\n Fermentation units<\/a> can be implemented as batch, fed batch or continuous processes. Continuous systems are generally cheaper and easier to operate. Batch systems are often preferred for highly inhibiting substrates (e.g. low-grade molasses) or situations in which feedstocks must be frequently switched (e.g. molasses vs. grain). <\/p>\n The Vogelbusch standard fermentation process in alcohol production is our advanced MultiCont\u00a9<\/a> continuous fermentation. <\/p>\n Fermentation of the substrate starts in a pre-fermenter under adjusted conditions that promote yeast growth. The fermenting mash flows steadily through a series of main fermenters, while the alcohol concentration increases to a range of 12 – 14 % vol, (depending on the raw material). From the last fermenter the alcohol mash is fed to an intermediate tank for distillation.<\/p>\n The heat generated during fermentation is removed via external heat exchangers, exhaust air from the fermenters is led through a scrubber for recuperation of alcohol.<\/p>\n With some non-fibrous substrates such as molasses or starch milk, yeast recycling<\/strong> can be used to improve yield and accelerate fermentation.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n Final product<\/p>\n The alcoholic mash is preheated and fed to the distillation<\/a><\/strong>section where the crude alcohol is stripped from the mash, leaving behind an alcohol-free liquid, the stillage. The crude alcohol vapors are purified and concentrated in several process columns and fed to rectification<\/a> for further refining and concentration to at least 96 % vol,.<\/p>\n Vogelbusch column systems are individually tailored to the desired quality specifications and analytical and organoleptic characteristics. Process schemes are optimized for separation of impurities and avoidance of undesired chemical reactions and the temperature range of the columns is selected for superior product quality. <\/p>\n Recovery rates from fermented mash to final product of 97.5 % are typical.<\/p>\n Energy saving features include the Vogelbusch MultiPressure<\/a> column system and advanced thermal integration techniques, bringing the steam demand for distillation and rectification down to 1,950 kg per 1,000 liters of neutral alcohol.<\/p>\n A dehydration<\/a><\/strong>process is used to obtain super dry ethanol for pharmaceutical or industrial applications. Standard Vogelbusch technology employs a Pressure Swing Adsorption (PSA) process using molecular sieves. The final water content can be reduced to 0.01 % wt.<\/p>\n\n <\/div>\n <\/div>\n <\/div>\n <\/div>\n \n Adding value to production<\/p>\n As only the sugar respectively starch is needed for the process, the remaining ingredients of the raw material in turn can provide valuable co-products. <\/p>\n\n \n BIOREACTION\n <\/h3>\n
\n PRODUCT ISOLATION AND CONCENTRATION\n <\/h3>\n
\n CO-PRODUCTS\n <\/h3>\n
![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-neutral-alcohol-distillery.jpg\")
\n ![\"\"](\"https:\/\/www.vogelbusch-biocommodities.com\/wp-content\/uploads\/2026\/06\/1-neutral-alcohol-taste.jpg\")
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