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 biotechnological production systems, 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 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 issue the technical process description and determine:

    • Raw material and product specification
    • 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 El-Harrach
    CEGRO / AYS - El Harrach, Algeria

    SGP Cegro on behalf of AYS Algerian Yeast Society in 2014 ordered a feasibility study to investigate the production of 10,000 tons per year of baker's yeast to be made from imported molasses.

    4-Inbicon
    2G Demonstration Plant in Kalundborg
    ØRSTED (Inbicon) - Kalundborg, Denmark

    Inbicon has developed a proprietary process for the conversion of wheat straw. Complementing this biomass conversion process Inbicon has opted for sound and energy efficient technology from Vogelbusch for part of ethanol fermentation as well as the distillation, dehydration and stillage evaporation. The 17,000 liter per day demonstration plant served as...

    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 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,...

    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...

  • 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, all 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 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 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 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 YeastAerator
    Yeast fermenter in Hamburg
    OHLY (Deutsche Hefewerke) - Hamburg, Deutschland

    DHW of Hamburg decided to convert an existing fermenter to the Vogelbusch aeration system. The given situation required the redesign of the drive and included engineering and supply of the complete aerator system. The reconstructed fermenter has a capacity of 27,000 kg per day of baker’s yeast made from beet molasses....

    4 ineos
    D|D for Demonstration Plant in Vero Beach
    FRANKENS ENERGY (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 a feedstock-flexible biomass conversion technology. It's unique combination of gasification and fermentation technologies turns different types of waste materials, including...

  • 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 about  » 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 about  » Integration Engineering

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

    The plant of Kimia Gharb Gostar 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 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 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...

  • 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
    • Supervision of acceptance tests
    • Check of documentation

     

    Commercial assistance
    • Contract design
    • Purchasing terms
    • Offer comparison
    • Scheduling of procurement activities
    • Packing and marking instructions
    References
    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,...

    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-Inbicon
    2G Demonstration Plant in Kalundborg
    ØRSTED (Inbicon) - Kalundborg, Denmark

    Inbicon has developed a proprietary process for the conversion of wheat straw. Complementing this biomass conversion process Inbicon has opted for sound and energy efficient technology from Vogelbusch for part of ethanol fermentation as well as the distillation, dehydration and stillage evaporation. The 17,000 liter per day demonstration plant served as...

    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 agroetanol
    Distillation|Dehydration in Norrköping
    LANTMÄNNEN AGROETANOL - Norrköping, Sweden

    The bioethanol plant of Lantmännen Agroetanol AB utilises process technology licensed by Vogelbusch for distillation and dehydration. The proprietary Multipressure system considerably reduces the steam consumption compared to traditional distillation systems and optimum thermal integration further improves the energy-saving properties of the plant.   The facility, which is Agroetanol’s second production...

  • 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. 

    We also provide custom designed technical components for our plants.


    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. 

     

    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 gsonek0
    Vinegar fermenter in Austria
    MAUTNER MARKHOF (Gsonek) - Vienna, Austria

    Supply of a vinegar fermenter type 1200 including IP-8 self priming aeration with a daily capacity of 15,000 liter (10%) for processing pure ethanol and grape and apple wine. The unit, originally set up for Gsonek in 1998 in Laa an der Thaya (Lower Austria), was later acquired by Mautner Markhof and...

    4-Cosmo2011
    Ethanol dehydration in Osaka
    COSMO OIL - Sakai-City, Osaka, Japan

    Cosmo Oil produces 140,000 liters per day (12 MMGPY) of low moisture ethanol (300 ppm) utilizing process design by Vogelbusch USA. The skid-mounted unit was installed as part of a larger project to retrofit an existing MTBE production facility at their Sakai Refinery for ETBE production.

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

    The plant of Kimia Gharb Gostar 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...

  • 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
    4 borregaard
    Ethanol dehydration in Sarpsborg
    BORREGAARD - Sarpsborg, Norway

    Borregaard replaced a decades old ethanol dehydration system by a state-of-the-art molecular sieve unit from Vogelbusch. The limited space in the biorefinery recommended a skid construction with minimum footprint. A special feature of the installation is an unusually wide capacity span, which was realized in a fully automated process. The unit has...

    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 gsonek0
    Vinegar fermenter in Austria
    MAUTNER MARKHOF (Gsonek) - Vienna, Austria

    Supply of a vinegar fermenter type 1200 including IP-8 self priming aeration with a daily capacity of 15,000 liter (10%) for processing pure ethanol and grape and apple wine. The unit, originally set up for Gsonek in 1998 in Laa an der Thaya (Lower Austria), was later acquired by Mautner Markhof and...

    Cepsa2015
    Dehydration Unit for Gibraltar
    CEPSA - San Roque, Gibraltar

    CEPSA (Compañía Española de Petróleos, S.A.U.) ordered a molecular sieve dehydration unit from Vogelbusch to purify ethanol which subsequently is to be processed to ETBE. The 12,000 liter per day unit has been prefabricated and skid-mounted in Austria and transferred to Gibraltar by truck to be integrated in the San Roque...

    4 ineos
    D|D for Demonstration Plant in Vero Beach
    FRANKENS ENERGY (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 a feedstock-flexible biomass conversion technology. It's unique combination of gasification and fermentation technologies turns different types of waste materials, including...

  • 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 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,...

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

    The plant of Kimia Gharb Gostar 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-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-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...

  • 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 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-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-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-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...

    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.