Technical Services

We complement our clients' skills.

From design to start-up

Vogelbusch provides engineering documentation and various types of service packages to assist in project implementation. Coming up with the best possible solutions also includes scaling our services to your needs.

 

Your bioprocess engineering partner

We support you every step of the way

We transfer our technologies to clients and/or help them to improve their own processes. Our engineering capabilities cover the construction and upgrading of bioprocess plants, with services ranging from feasibility studies through to the launch of production.

Bespoke solutions - tailored to suit you

Rather than start out from standard solutions we focus on your special requirements from the outset — in terms of raw materials, product quality, plant configuration and the scope of service delivery. We concentrate on getting to know your problems and coming up with the best possible solutions.

  • icon conceptualdesign

    Conceptual Design

    As part of conceptual design the fundamentals of your project are developed.

    Project studies

    Starting from scratch, our feasibility studies give a basis to make an investment decision; examples are:

    • Determination of objectives and plant performance
    • Comparisons of options with regard to raw materials, final products and capacities
    • Detailed investigations of plant economics
    • Investigation of infrastructure requirements for site selection

    Pre-engineering studies

    Are more in-depth, to appropriately reflect the economic and technical framework of the project. In this preliminary stage of project realization we determine:

    • Raw material and product specification
    • Technical process description
    • Consumption figures
    • Site requirements
    • Capital cost assessment
    • Plant configuration and equipment
    • Project time schedule


    Project studies that go into sufficient depth can also be used in obtaining approvals. For instance, they can serve as technical documentation for submissions for building permission or environmental impact assessments.

    The actual scope of analysis, and thus the time taken to complete it, depends on the purpose and is evaluated in consultation with the client.

    References
    4 YeastConsulting
    Yeast plant in Tashkent
    CANDY GOLD - Tashkent, Uzbekistan

    Following a feasibility study on the production of baker's yeast, the pre-engineering for a yeast plant designed for a daily capacity of 10,000 kg based on molasses was carried out in 2015.

    4 ishim0
    Glucose plant for processing compex in Ishim
    AMINOSIB - Ishim, Tyumen Region, Russia

    ZAO Agroholding «Yubileinii» sets up a wheat processing complex -  AminoSib - in Ishim in the Tyumen Region. VOGELBUSCH has been assigned by the general contractor, Talmax Engineering s.r.o., with the supply of a glucose plant to produce a fermentation substrate. The order includes the process design as well as the supply of...

    4 promaiz
    Bioethanol Plant in Alejandro Roca
    PROMAÍZ - Alejandro Roca, Córdoba Province, Argentina

    With a nameplate capacity of 420,000 liters per day, Promaíz is the largest bioethanol production facility in Argentina. The plant processes bioethanol from corn which is used as fuel additive in the local markets. Besides the technology package for the complete plant and detailed planning of piping and vessels, Vogelbusch has...

    4-rosva
    Biotechnological Complex in Kaluga
    BIOTECH ROSVA - Kaluga, Russia

    The biotechnological complex put up by JSC «Biotech Rosva» uses wheat as a feedstock to produce speciality goods such as starch, gluten and various starch sugars, which are intended as ingredients for the food industry. A by-product will be used as animal feed. VOGELBUSCH is responsible for the planning and delivery...

    MES.jpg
    D|R Pilot Plant in Tennamaram
    SIME DARBY | MITSUI ENGINEERING - Tennamaram, Malaysia

    Local palm oil producer Sime Darby together with the Japanese company Mitsui Engineering & Shipbuilding Co. Ltd. (MES) installed a pilot plant for second generation (2G) bioethanol in Tennamaram, Malaysia. Based on technology licensed from the Danish company Inbicon the plant produces bioethanol from empty fruit bunches that are left...

  • icon basicengineering new

    Basic Engineering

    Our basic design package for technology transfer comprises the process engineering and documentation for the implementation of your plant.

    Based on the conceptual design and - if necessary - validation of design data in our in-house laboratories, the relevant documents for the realization of the plant are issued:

    • Flow sheets
    • Mass balances
    • Process description
    • Emission point list
    • Terminal point list
    • Operating manual
    • Methods of analysis
    • Equipment specifications and schedules
    • Specifications and execution standards for instrumentation, automation, electrical equipment and pipework
    • Layout and foundation plans
    • Installation and acceptance standards

     

    Basic design data establish the foundation for the following detail engineering of all components of the plant.

    In the interest of process assurance, the supervision of performance tests during plant erection and commissioning is part of our design package.

    References
    4-ravenna2007
    Bioethanol Plant in Ravenna
    KAAPA ETHANOL (Abengoa) - Ravenna, Nebraska, USA

    Abengoa Bioenergy successfully started up their state-of-the-art fuel ethanol facility located in Ravenna, Nebraska in September 2007. The plant utilizes technology licensed by Vogelbusch USA, including the Vogelbusch Multicont continuous fermentation process, and has a nameplate capacity of 88 million gallon per year (950,000 lpd). The facility uses 32 million...

    4 YeastFermenter
    Yeast fermenter in Osaka
    ORIENTAL YEAST - Osaka, Japan

    To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering for an additional yeast fermenter and the supply of key equipment (aeration). The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up...

    4 lexington0
    Bioethanol Plant in Lexington
    CHIEF ETHANOL FUELS (Cornhusker) - Lexington, Nebraska, USA

    Vogelbusch USA Inc started up the ethanol plant of Cornhusker Energy in spring 2006, with a production capacity of 450,000 litres/day of bioethanol from corn. The plant employs a state of the art Vogelbusch continuous fermentation process. An energy integrated distillation, evaporation and dehydration system ensures maximum efficiency. In 2016, Chief Ethanol...

    4 GreenP2007
    Ethanol Dehydration in North Sitra
    GREEN POWER - North Sitra, Kingdom of Bahrain

    Some 400,000 lpd of crude industrial alcohol from a refinery in Saudi Arabia are processed in the Bahrain unit. After entering the plant, the feed is purified in a rectification column where low-boiling substances such as diethylether and acetaldehyde are separated before being dehydrated by molecular sieve technology to achieve...

    4 ineos
    D|D for Demonstration Plant in Vero Beach
    ALLIANCE BIO-PRODUCTS (Ineos Bio) - Vero Beach, Florida, USA

    Vogelbusch USA supplied the ethanol distillation and dehydration equipment for the 2G (second generation) demonstration plant of Ineos Bio’s , a first-of-its-kind waste-to-bioenergy facility near Vero Beach, Florida. The project uses Ineos Bio’s feedstock-flexible biomass conversion technology. It's unique combination of gasification and fermentation technologies turns different types of waste materials,...

  • icon detailengineering

    Detail Engineering

    We engineer the piping, vessels and equipment details, and the automation of the plant and integrate other systems.

    Piping design

    Detailed piping design is carried out in accordance with the relevant European or US standards and regulations:

    • Elaboration of complete piping engineering as 3D model
    • Isometric drawings
    • Support drawings
    • Stress calculation
    • Material take-off for procurement

     

    Vessels

    Detailed design of tanks and vessels whether shop-made or built at construction sites includes:

    • Stress calculations
    • Workshop drawings
    • Steel sheet drawings
    • List of materials for steel sheets, welding material, quality requirements
    • Welding layouts: welding joints preparation, processing and testing quidelines

     

    Automation

    Design of instrumentation, control and automation systems includes the detailed specification of:

    • Field instruments and control valves
    • Process control systems (PCS)
    • Control cabinets

    As well as:

    • Programming of application software

    More on Process Automation

     

    Cross integration

    Engineering services for the system integration of third party processes are carried out during the inquiry, procurement and execution phase of the project and cover for instance:

    • Preparation of equipment specifications
    • Document approval and inspections
    • Coordinate installation, commissioning and start-up

    More on Cross Integration

    References
    4-hugoton.jpg
    D|D for Cellulosic Ethanol Plant in Hugoton
    SYNATA BIO (Abengoa) - Hugoton, Kansas, USA

    The commercial-scale, cellulosic ethanol facility in Hugoton utilizes Abengoa’s own enzymatic hydrolysis technology to produce 25 million gallons of ethanol and 21 megawatts of electricity from 300,000 tons of biomass per year. Implemented in 2014, Vogelbusch USA provided process design for the distillation and molecular sieve dehydration areas and also supplied...

    4 KGG
    Citric Acid Plant in Kermanshah
    KIMIA GHARB GOSTAR - Kermanshah, Iran

    The plant of Kimia Gharb Gostar Industries Industries Co. has a capacity of 36 tons per day and is the first citric acid plant set up in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either...

    4 DHWN
    Yeast fermenter in Nuremberg
    DEUTSCHE HEFEWERKE - Nuremberg, Germany

    DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building. Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system including drive, mash pumps and heat exchangers). The fermenter is designed for 25,000 kg of baker's yeast per day made...

    MES.jpg
    D|R Pilot Plant in Tennamaram
    SIME DARBY | MITSUI ENGINEERING - Tennamaram, Malaysia

    Local palm oil producer Sime Darby together with the Japanese company Mitsui Engineering & Shipbuilding Co. Ltd. (MES) installed a pilot plant for second generation (2G) bioethanol in Tennamaram, Malaysia. Based on technology licensed from the Danish company Inbicon the plant produces bioethanol from empty fruit bunches that are left...

    4 YeastFermenter
    Yeast fermenter in Osaka
    ORIENTAL YEAST - Osaka, Japan

    To raise the production capacity of Oriental Yeast in Osaka, Komatsugawa Chemical Engineering Co. assigned Vogelbusch with the engineering for an additional yeast fermenter and the supply of key equipment (aeration). The unit is designed for the production of 20,000 kg per day of baker's yeast made from cane molasses. Start-up...

  • icon procurementassistance

    Procurement Assistance

    In the course of procurement we assist you both commercially and technically.

    Our services are designed to facilitate your own procurement, including local supplies. We can coordinate the purchasing process and support you with:

    Technical assistance
    • List of suppliers
    • Offer comparison and purchase recommendation
    • Review and approval of key supplier specifications and detailed designs
    • Manufacturing supervision
    • Acceptance tests
    • Check of documentation

     

    Commercial assistance
    • Contract design
    • Purchasing terms
    • Offer comparison
    • Scheduling of procurement activities
    • Packing and marking instructions
    References
    4 YeastFermenter
    Yeast fermenter in Malmö
    SPECIAL YEAST - Malmö, Sweden

    The utilization of a hydrolysate made from bakery waste was the object of the order by Special Yeast. The process for this novel feedstock was developed and implemented, including supply of the aeration system. The unit has a capacity of 9,000 kg/d and was started up in 2006.

    4-citrom0
    Citric Acid Plant near Cairo
    CITRO MISR - 10th of Ramadan City, Egypt

    Raw sugar from local production was the substrate of choice for Citro Misr Co. of Egypt. This raw material required a new approach in the fermentation process to assure the economic feasibility of the plant. The spore cultivation was adapted and the fructose utilization was optimized for the substrate. Products include...

    4 leopoldov
    Extra Neutral Alcohol D|R in Leopoldov
    SLOVENSKE LIEHOVARY À LIKÉRKY - Leopoldov, Slovakia

    The plant in Leopoldov produces extra neutral alcohol for the company's well established range of beverage brands. 30,000 liters of high quality alcohol are distilled per day from alcoholic mashes from molasses and grain. Vogelbusch designed the distillation and rectification unit and supplied key equipment for the plant, which was commissioned in...

    4 SCY
    Yeast plant in Ahvaz
    RAZI YEAST & ALCOHOL COMPANY - Ahvaz, Iran

    Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from cane molasses. Production in the yeast plant started in 2009, since manufacturing 32,000 kg per day of high quality instant active dry...

    4 cropernergies
    Bioethanol plant in Zeitz
    CROPENERGIES - Zeitz, Germany

    The 800,000 litre/day plant of CropEnergies,  a unit of German Südzucker group,  is designed for multiple grain sources together with by-products of beet sugar processing. The plant and is highly advanced in terms of energy saving and environmental protection. Vogelbusch contributed process design for the raw material processing, continuous fermentation,...

  • icon supply

    Supply

    Our scope of supply services is customized, ranging from critical equipment components to full EPC contracts.

    Key equipment

    In the interest of process assurance, we assume responsibility for supplying key equipment. This is the equipment that is critical to fulfilment of the process guarantee, and includes for instance:

    • Column trays for distillation plants
    • Mole sieve material for dehydration plants
    • Aeration systems for yeast, vinegar and citric acid plants


    Optionally we can supply all major parts of equipment. 


    EPC: Engineering-Procurement-Construction 

    Depending on the project scale we can also offer turnkey installation of complete process units, such as:

    • Distillation
    • Rectification
    • Dehydration
    • Evaporation


    Where appropriate, units are skid-mounted to accelerate the installation process. 

    We also provide custom designed technical components for our plants.

    References
    4-citrom0
    Citric Acid Plant near Cairo
    CITRO MISR - 10th of Ramadan City, Egypt

    Raw sugar from local production was the substrate of choice for Citro Misr Co. of Egypt. This raw material required a new approach in the fermentation process to assure the economic feasibility of the plant. The spore cultivation was adapted and the fructose utilization was optimized for the substrate. Products include...

    4 goncalves
    Vinegar fermenter in Golegã
    MENDES GONÇALVES - Golegã, Portugal

    Mendes Gonçalves, a well known Portuguese producer of vinegar and condiments ordered a vinegar fermenter from Vogelbusch. The new fermenter raised production capacity in Golegã, north of Lisbon by 15,000 litres to some 27,000 litres per day. We supplied the fermenter including IP-8 self priming aeration and process equipment such as...

    4-almagest
    Neutral Alcohol Plant in Verinsko
    ALMAGEST - Verinsko, Ihtiman, Bulgaria

    Almagest opted for Vogelbusch in 2009 to produce top quality extra neutral alcohol with the highest purity and organoleptic demands, to be used in the production of alcoholic beverages. The excellent alcohol quality convinced Almagest to commission Vogelbusch again in 2011 to expand the plant capacity to 80,000 liters per...

    Tharaldson distillation dehydration
    Bioethanol Plant in Casselton
    THARALDSON ETHANOL - Casselton, North Dakota, USA

    Tharaldson Ethanol started up their state-of-the-art fuel ethanol facility located in Casselton, North Dakota in 2009. The plant utilizes technology licensed by VOGELBUSCH USA, including the VOGELBUSCH Multicont continuous fermentation process, and is currently operating at a capacity of 1,300,000 liters per day, making it one of the largest dry corn...

    4 KGG
    Citric Acid Plant in Kermanshah
    KIMIA GHARB GOSTAR - Kermanshah, Iran

    The plant of Kimia Gharb Gostar Industries Industries Co. has a capacity of 36 tons per day and is the first citric acid plant set up in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either...

  • icon supervision

    Supervision

    On site, we go along with you throughout project execution and oversee the plant start-up.

    Erection supervision

    During erection of the plant our activities focus on:

    • Supervision of the plant erection from the technology perspective and compliance with the provided designs
    • Pre-commissioning including supervision of dry and hydraulic testing of equipment, adjustment of installations, etc.
    • Site acceptance test of the process control system

    Start-up supervision

    After certification of completion by the client, start-up supervision and acceptance testing include:

    • Supervision of commissioning, e.g operation with product, ramping up capacity, optimizing process and control parameters
    • Operator training for the plant, controls and system
    • Supervision of performance guarantee run
    References
    4roquette2008
    Bioethanol Plant in Beinheim
    ROQUETTE - Beinheim, France

    As part of a wet milling complex, this plant is designed to utilize wheat starch and optionally milled grain. It has a daily capacity of 400,000 liter ethanol and was put into operation in 2008. Vogelbusch provided the know-how and technology package for the process plant and supplied key equipment for distillation...

    4 DHWN
    Yeast fermenter in Nuremberg
    DEUTSCHE HEFEWERKE - Nuremberg, Germany

    DHW Nuremberg enhanced their manufacturing capacity by adding a fermenter which had to be placed outside the production building. Vogelbusch engineered the expansion and supplied the key equipment (EB4 aerator system including drive, mash pumps and heat exchangers). The fermenter is designed for 25,000 kg of baker's yeast per day made...

    4-ethylchem1
    Dehydration Unit in Pointe-a-Pierre
    ETHYLCHEM - Pointe-a-Pierre, Trinidad, West Indies

    Hydrous ethanol imported from Brazil is the feedstock for a molecular sieve dehydration facility set up by EthylChem at the Pointe-a-Pierre refinery in Trinidad. It has a production capacity of 1,082,000 litres per day (100 MMGY) of fuel ethanol with a purity of over 99.9 per cent that is intended...

    4 KGG
    Citric Acid Plant in Kermanshah
    KIMIA GHARB GOSTAR - Kermanshah, Iran

    The plant of Kimia Gharb Gostar Industries Industries Co. has a capacity of 36 tons per day and is the first citric acid plant set up in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either...

    4 goncalves
    Vinegar fermenter in Golegã
    MENDES GONÇALVES - Golegã, Portugal

    Mendes Gonçalves, a well known Portuguese producer of vinegar and condiments ordered a vinegar fermenter from Vogelbusch. The new fermenter raised production capacity in Golegã, north of Lisbon by 15,000 litres to some 27,000 litres per day. We supplied the fermenter including IP-8 self priming aeration and process equipment such as...

  • icon technicalsupport

    Technical Support

    We continue to work for you after plant handover.

    To round off our customer service beyond initial start-up, we assist with extended supervision and personal support in order to 

    • Ensure optimal operation and practical experience in routine work
    • Recognize potential for enhancement

     

    References
    4 SCY
    Yeast plant in Ahvaz
    RAZI YEAST & ALCOHOL COMPANY - Ahvaz, Iran

    Razi Yeast & Alcohol Company, formerly Sugar Cane By-Products Corporation, assigned Vogelbusch with the process design, engineering and supply of a complete plant for the production of baker's yeast from cane molasses. Production in the yeast plant started in 2009, since manufacturing 32,000 kg per day of high quality instant active dry...

    4 SCA
    Neutral Alcohol Plant in Ahwaz
    RAZI YEAST & ALCOHOL COMPANY - Ahwaz, Iran

    The plant now operated by Razi (formerly Sugar Cane By-Products Corporation) was designed for a daily capacity of 110,000 litres of high quality pharmaceutical alcohol from cane molasses complying with EU standards. A special challenge was designing the plant for the extreme climatic conditions (0°C to 50°C) and the highest...

    4 goncalves
    Vinegar fermenter in Golegã
    MENDES GONÇALVES - Golegã, Portugal

    Mendes Gonçalves, a well known Portuguese producer of vinegar and condiments ordered a vinegar fermenter from Vogelbusch. The new fermenter raised production capacity in Golegã, north of Lisbon by 15,000 litres to some 27,000 litres per day. We supplied the fermenter including IP-8 self priming aeration and process equipment such as...

    4 pekin
    Bioethanol Plant in Pekin
    PACIFIC ETHANOL (Aventine) - Pekin, Illinois, USA

    In March 2004 the molecular sieve unit at the Aventine Renewable Energy plant was brought on stream. With a rated capacity of 1.2 million liters per day (110 mm gallons/year) anhydrous alcohol, at that time the largest capacity molecular sieve alcohol dehydration unit in the world. The molecular sieve unit replaced...

    4 KGG
    Citric Acid Plant in Kermanshah
    KIMIA GHARB GOSTAR - Kermanshah, Iran

    The plant of Kimia Gharb Gostar Industries Industries Co. has a capacity of 36 tons per day and is the first citric acid plant set up in Iran. It is suitable for processing of raw sugar and sugar beet molasses. The process concept allows for a choice between production of either...

  • icon consulting

    Consulting

    Take the benefit from our technical expertise for queries with your existing equipment.

    We provide technical advisory services relating to the upgrade or revamp of existings plants for improvement of productivity and process economics. Let us help you to make the most of your resources, for instance:

    • Changes of raw material quality and product quality requirements
    • Enhancing yield and/or plant capacity
    • Adding economic value by product diversification

    As well as process improvements for operational cost reductions such as:

    • Increasing heat recovery within and across process units
    • Boosting energy efficiency
    • Optimizing water recovery within the plant


    We analyze your process data and come up with adequate solutions that align with your manufacturing goals.

    References
    4-almagest
    Neutral Alcohol Plant in Verinsko
    ALMAGEST - Verinsko, Ihtiman, Bulgaria

    Almagest opted for Vogelbusch in 2009 to produce top quality extra neutral alcohol with the highest purity and organoleptic demands, to be used in the production of alcoholic beverages. The excellent alcohol quality convinced Almagest to commission Vogelbusch again in 2011 to expand the plant capacity to 80,000 liters per...

    4-Jilin2003
    Bioethanol Plant in Jilin
    JILIN FUEL ALCOHOL COMPANY - Jilin Province, PR China

    Located in Jilin City in Northeast China, this production line for bioethanol was officially commissioned in November 2003 after an implementation period of 22 months. The plant produces 300,000 tonnes of fuel alcohol annually from maize. The product is used as a 10% petrol additive.  Process design by Vogelbusch provided for...

    4 lactomisr
    Plant for Baby Milk Powder near Cairo
    LACTO-MISR - 10th of Ramadan City, Egypt

    This plant for baby milk powder and protein drink concentrates was realised by Vogelbusch in 2002 with a process licensed from a German producer of infant formula.  The enterprise is the first manufacturer of infant formula in the Middle East. The production capacity is 32 tons per day. The plant location,...

    4 YeastFermenter
    Yeast fermenter in Malmö
    SPECIAL YEAST - Malmö, Sweden

    The utilization of a hydrolysate made from bakery waste was the object of the order by Special Yeast. The process for this novel feedstock was developed and implemented, including supply of the aeration system. The unit has a capacity of 9,000 kg/d and was started up in 2006.

    4-rosva
    Biotechnological Complex in Kaluga
    BIOTECH ROSVA - Kaluga, Russia

    The biotechnological complex put up by JSC «Biotech Rosva» uses wheat as a feedstock to produce speciality goods such as starch, gluten and various starch sugars, which are intended as ingredients for the food industry. A by-product will be used as animal feed. VOGELBUSCH is responsible for the planning and delivery...