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Extra neutral Alcohol is produced by fermenting sugar and is used in industry as industrial alcohol or for drinking purposes as potable alcohol. The basic raw material used is molasses or grain. Potable alcohol produced from grain has better quality, smoother taste and better flavour. The potable alcohol segment is growing by almost 15% per year. Grain alcohol is much preferred base material for potable liquor than molasses alcohol because of silent & smoother flavour & taste. Most of the IMFL brands in the prestige segment are now made from grain spirit. This grain spirit is the prime raw material for sophisticated liquor like whisky, vodka, gin etc. In UK, USA & European countries, the liquor industry use grain spirit for all brands, except Rum as per their manufacturing codes. Foreign brands are also being manufactured in India and therefore have boosted the demand of grain alcohol. Foreign brands are now being bottled in ASEAN, SAARC & African countries and Indian made grain alcohol is getting acceptance, export potential is growing.
PROCESS DESCRIPTION
The basic process involves milling of grain and its liquefaction to produce starch. Starch is converted to sugar and fermented with yeast to convert sugar to alcohol. The fermented wash is distilled to recover alcohol and the same is concentrated.
Grain from Grain silo is fed to Grain Handling & Milling section. After milling; flour is mixed homogenously in blunging tank with recycled thin stillage, process condensate & some make up water.
The slurry is pumped to jet cooker, where it cooked at high temperature. The slurry is cooked for specific period by allowing specific retention in holding coil. This cooked slurry is passed through liquefaction section followed by Sacchrification process. From this process the starch is converted in to sucrose & fructose. The Alfa amylase & gluco amylase enzymes added in the process. The slurry is cooled & sent to fermentation process.
In Fermentation the glucose & fructose (Invert sugar) in the slurry get converted to ethanol. CO2 is liberated during Fermentation process. The fermented wash containing 8%-9% v/v alcohol, after fermentation is feed to Distillation to separate & purify the alcohol up to 96 % v/v.
The spent raw stillage from bottom of first column passes through decanter, where wet cake and the thin stillage are separated.
Part of thin stillage is recycling to process. Balance thin stillage is fed to integrated evaporator; alcohol Vapours from distillation is used to concentrated the stillage up to 40% solids contain. The process condensate after evaporator is recycling back to process for dilution. The conc. Stillage is mixed with the wet cake recovered from decanter. The mixture is then sent to the dryer for making of DDGS. The DDGS (Distillers Dry Grain Soluble) contained of 10% - 12% moisture & 30% protein, is produced; which is then used as cattle feed & sale in market directly.