2525

24 26
26

733
7

ALCOHOL TECHNOLOGY
The department provides guidance to alcohol
industry for achieving maximum productivity,
efficiency and yield from different feedstocks and
also to enhance the quality of finished products
viz. rectified spirit, extra neutral alcohol and
ethanol. The department is also engaged in research
in the areas of water conservation in distilleries for
achieving zero liquid discharge of effluent
generated. The consultancy and inspection of
ongoing projects, proposed molasses and nonmolasses based distilleries and distillery effluent
treatment projects are the integral assignments of
the department. Government agencies at the central
and state level department seek technical inputs
and advice from the department. A publication on
Technical Performance of Distilleries affiliated to
co-operative sugar mills of Maharashtra State is also
brought out annually.

A masters degree course in Wine Technology

(brewing, distilling & wine making) affiliated to
University of Pune was started during the current
year. In addition, post graduate diploma course in
Industrial Fermentation and Alcohol Technology,
short-term training programmes and courses are
conducted in the Institute. The department also
provides guidance to the PhD, M Tech, M Pharm
and MSc students from different universities for their
project work.

RESEARCH AND DEVELOPMENT

Studies on Improving Molasses Quality and Effect
of Sludge, Calcium, Total Organic Volatile Acids
(TOVA), Sulfur Dioxide Content and Microbial
Count on Fermentation Process

Improving Molasses Quality in Respect of

TOVA Content

In the year 2010-11, studies related to this aspect

were done at Shree Doodhganga Krishna SSKN.
The TOVA of molasses was found to be above
10,000 ppm, which affected the efficiency of
continuous fermentation process and continuity of
fermentation cycle. In association with the
department of sugar technology, the volatile acidity
levels at different stations in sugar manufacturing
process were measured. Steps were taken to reduce
the volatile acidity during sugar manufacturing
process, which resulted in improving the quality

74

of molasses to a certain extent. The volatile acidity

of various intermediates and products of sugarcane
processing including primary juice, mixed juice,
clear juice, sulfured and unsulfured syrup, oliver
combine filtrate, samples of A, B and C
massecuites, A-Heavy molasses, A-Light molasses,
B-Heavy molasses etc. was analyzed at this mill.
The precautions taken during this season helped
to reduce the TOVA content in final molasses from
10,000 ppm to 3,500 ppm.

Development of Method for Estimation of

Sulphur dioxide Content

It was observed that fresh molasses is difficult

to ferment due to higher concentration of dissolved
sulphur dioxide. Along with TOVA of molasses,
its sulphur dioxide content can also inhibit the
alcoholic fermentation by Saccharomyces
cerevisiae.
To evaluate this aspect, a method was
developed for estimation of free sulphur dioxide
content of molasses solutions by employing
modified Ripper titrimetric method using potassium
per-iodate.
Estimation of sulphur dioxide content and
TOVA content of molasses samples were carried
out simultaneously and the results are given in table
27. It was observed that the free sulphur dioxide
content increases with increasing TOVA of
molasses samples.

Table 27 : TOVA and free sulphur dioxide content in analyzed molasses samples
Name of mill

TOVA by Conventional
method (ppm)

Free Sulphur dioxide

(ppm)

3770
4113
4456
6513
8570
4713
5056
5142
5056
5142
5313
5741
5999
5999
6513
7884
6341
10541
4884
5056

420
690
450
790
774
490
700
660
620
610
680
670
720
680
700
720
780
940
650
510

Manganga SSK
Dnyaneshwar SSK
Ajinkyatara SSK
Ajinkyatara SSK
Ajinkyatara SSK
Kopargaon SSK
Bhaurao Chavan SSK
Bhaurao Chavan SSK
Majalgaon SSK
Siddheshwar SSK, Kumthe
Vitthalrao Shinde SSK
Sant Tukaram SSK
Nira-Bhima SSK
Satpuda Tapi SSK
Ashok SSK
Gangakhed Sugars & Energy Ltd
Doodhganga Krishna SSKN
Parry Sugars Ltd
Parry Sugars Ltd
Malprabha SSK
This method was tested repeatedly with different
molasses samples. The method gave consistent and
reproducible results. Further experiments will be
conducted to investigate the effect of individual
volatile acids (such as acetic, butyric, propionic
acids etc.) as well as free sulfur dioxide on the
activity of yeast and fermentation process. Further
studies are also planned in association with the
department of sugar technology to control the sulfur
dioxide content of final molasses to the minimum
possible level.

Improving Molasses Quality in Respect of

Sludge Content

The sludge content of molasses has shown an

increasing trend in the last few years. Higher sludge
content of molasses not only reduces the effective
volume of fermenter but can be detrimental to yeast
activity and fermentation process.
In association with the department of sugar
technology, a study was undertaken at Bhaurao
Chavan SSK Unit-II and III for the reduction in
sludge content of final molasses. The sludge
content in final molasses was found to be extremely
high at around 27%, which was seriously affecting

the operation of continuous fermentation process.

The sludge content was measured at different
stations in sugar manufacturing process. Based on
the analysis, following measures were taken to
reduce the sludge content in final molasses.

Stale cane percentage was reduced and fresh

cane was used for milling.
The quality of lime was found to be inferior
with calcium oxide content of 68-70%. This
was replaced with better quality lime.
The use of anti-scalant in the evaporators
was stopped.
The phosphoric acid dose was increased to
bring phosphorus pentoxide (P2O5) content
in mixed juice to 350 ppm.
These measures resulted in reducing the sludge
content of final molasses. The sludge content at
Unit-II was reduced to 17% and at Unit-III was
reduced to 21%.

Performance Evaluation of Bio-digesters and

Evaporation/Membrane Filtration (RO) System for
Distillery Effluent
The Central Pollution Control Board (CPCB),
New Delhi has sponsored this project for

75

undertaking performance evaluation of bio-digesters,

evaporation plants, reverse osmosis units and
Incineration systems for disposal of distillery
effluent.
The detailed studies and performance
evaluation work at remaining two units were
completed in the year 2011-12. Data collected

during the visit were studied and investigated in

depth. Performance evaluation work of all ten
distilleries as prescribed by the CPCB on different
technologies of effluent treatment was thus
completed. A presentation on this project was given
to the officials and expert committee of the CPCB.
Final report of this project was also prepared and
submitted to CPCB.

Table 28 : Comparative performance evaluation of bio-methanation plants

Particulars
Type of digester
(D1, D2 etc)

A
Fixed
film

Designed and
actual capacity
for SW treatment,
m3/day

600
(360)

Design HRT,
Days (Actual
HRT, Days)

12.2
(20.3)

Design COD
loading rate,
kg/m3/day

9.8
(5.5)

COD reduction,
%

64.81

BOD reduction,
%

87.0

Gas generation,
m3/kg of COD
reduction

0.49

Gas generation
m3/m3 of raw
spent wash

*D1 not operational

76

35.11

B*
D2, D3Packed
media,
D4-UASB
D2-360
(243)
D3-360
(133)
D4-400
(424)

Name of Distillery

C
Down flow
followed by
up-flow
(Thermophilic)

D1-750
(512)

D2-390
(130)
D3-285
(206)

1000
(703)

D1- 18.0
(19.4)
D2- 18.0
(19.4)

D1- 12.0
(18)

D2- 14.0
(42.3)
D3- 26.0
(36)

21.0
(30)

D2- 10.8
(7.1)
D3- 11.3
(4.1)
D4- 5.0
(4.94)

D1- 5.62
(4.34)
D2- 5.62
(4.34)

D1- 7.0
(7.1)

D2-9.95
(2.68)
D3- 5.34
(3.10)

7.16
(4.94)

D2- 61.11
D3- 57.68
D4- 61.99

63.70

55.0

D2-89.41
D3- 85.88
D4- 88.82

90.0

72.21

D2- 0.50
D3- 0.50
D4- 0.53

D1- 0.59
D2- 0.59

0.47

D1- 37.25
D2- 37.25

33.20

D2- 9.0
(13.7)
D3- 8.8
(24)
D4- 21.0
(20)

D2- 29.88
D3- 28.30
D4- 31.74

D1-600
(550)
D2-600
(550)

D
E*
F
Down flow
D1-UASB CSTR
followed by
D2-Fixed
up-flow
film,
(Thermophilic) D3-CSTR

D2- 54.21 64.25

D3- 62.00
Facilities
were not
available
D2- 0.50
D3- 0.50

85.0

H*
UASB

D2-236
(175)
D3-226
(208)
D4-214
(226)

D2-8.0
(10.7)
D3-10.6
(11.5)
D4- 10.6
(11.2)
D2-10.0
(7.87)
D3-10.0
(7.3)
D4-10.0
(7.55)

D2- 66.0
D3- 66.0
D4- 64.0
90.0

0.55

0.60

D2- 30.87 52.33

D3- 35.41

32.82

The comparative performance evaluation,

conclusions and recommendations on different
technologies of effluent treatment studied under
this project are given in tables 28 to 32 respectively
i) A to J indicates the different distilleries in
the country where performance evaluation
studies were carried out.
ii) Figures in parenthesis ( ) are the actual
quantities.

Conclusions/Recommendations

It is possible to achieve COD reduction in

the range of 55-60 %, BOD reduction of 8590 % and gas generation of 0.50-0.60 m3/kg
COD consumed.
It is now well-established and results in
substantial reduction of COD and BOD and
brings the pH to near neutral.
Bio-methanation is not suitable for seasonal
distilleries.
Ideally, distilleries with bio-methanation
should run throughout the year. Therefore,

bio-methanation followed by incineration

can be an ideal system.
Digesters designed for COD loading rate of
5 Kg/M3/day has given best performance.
CSTR and UASB based digesters are more
suitable for molasses based distilleries.
Biogas based power generation or CNG
production can offer higher returns.
Gas zone region (particularly the mild steel
roof) of the digester is susceptible to heavy
corrosion and needs replacement every 8 to
10 years.

Further evelopments required in bio-methanation

Corrosion resistant roof for digesters made

of either SS 304 or polymeric membrane.
Biomethanation technology that can accept
high strength spent wash.
Wet-corona discharge oxidation of biomethanated spent wash to break down the
recalcitrant COD followed by secondary biomethanation.

Table 29 : Comparative performance evaluation of membrane filtration plants

Particulars
Type of technology

B
Disc &
tube

i) Number of stages

ii) Total number of

membranes

C
Disc & tube
followed by
NF followed
by UF
12

1,61,100

64,750

Design and actual quantity

of BMSW treatment,
M3/day (Actual feed,
M3/day)

800
(697)

1400
(950)

Design TSS, ppm

2000

4500

Actual TSS, ppm

Retention time before feed

Feed brix

Reject, M /day
3

Reject Brix

Permeate, M3/day

Design and actual

permeate recovery ( %)
Disposal of reject

1480

2100

Name of Distillery
E
Disc & tube

F
Disc & tube

2,208

16,110

RO1-Not in
RO1- 500
operation
(436)
RO2-260
RO2- 500
(190)
(Not in
RO3- Dismantled operation)

H
Membrane bioreactor
with NF and RO
membrane system
(Spirally wound type)
2

Nano- 45RO- 30
840 (614)

2000

3000

5000

2200

500

10 days

0.5 days

9 days

25 days

9 days

393

402.6

103

231

393

304

547.4

205

221

6.1

10.0
55.0
(43.61)

Bio-com
posting

6.3

6.0

5.5

11.3

11.0

10.5

55.0
(57.6)

55.0
(45.50)

55.0
(47.0)

Bio-com
posting

87

Feed to MEE

Bio-com
posting

2.1

5.1

60.0
(58.06)

Feed to MEE

77

Table 29 : Comparative performance evaluation of membrane filtration plants

Particulars

B
Disc &
tube

Type of technology

Disposal of permeate

Polishing unit to treat

permeate

C
Disc & tube
followed by
NF followed
by UF

For
process
& non
process

Degasser
followed
by ACF

E
Disc & tube

F
Disc & tube

H
Membrane bioreactor
with NF and RO
membrane system
(Spirally wound type)

For molasses
dilution

For cooling
tower make
up water

For cooling
tower make
up water

For molasses
dilution & floor
washing

Degasser
followed by
ACF

Degasser

Degasser

Degasser followed
by ACF

Conclusions/Recommendations

Name of Distillery

About 70-80 RO plants are now installed in

the Indian distillery industry.
RO plants are more useful for biomethanated spent wash treatment than raw
spent wash treatment.
Disc and tube configuration is well
established with 50% average recovery of
permeate from bio-methanated spent wash.
Maximum recovery reported is about 60 %.
Suspended solids are most critical factor and
suspended solids are required to be
maintained below 2,000 ppm.

Permeate can be recycled after proper

treatment as make-up water in cooling
towers or for molasses dilution.
Operational cost is slightly less than MEE
plants for about 50% reduction in effluent
volume.
Major recurring cost in this option is the
membrane replacement cost.
Most of the membranes are imported.
Proper pre-treatment to bring down the
suspended solids would increase the life of
membranes.
This is a promising technology, which
would bring further improvements in future.

Table 30 : Comparative performance evaluation of multiple effect evaporation plants

Particulars
Type of
Technology

With or
Without TVR

A
D
Falling film Falling film

E
Falling film

Name of Distillery
G
Falling film

H
Falling film

With TVR

With TVR

With TVR

Without TVR

With TVR

Type of
effluent used
as feed

BMSW

BMSW

RO reject

Raw spent
wash

Nano reject

No. of effects

Designed &
5.0 40.0 5.0 30.0 10.0 35.0
actual solids (6.540.0) (6.5 10.9) (20.1-53.5)
concentration,
%

78

10.0 60.
(12.0 62.0)

I
J
Falling film
Forced
& forced
circulation
circulation
(Fluebex)
Without TVR TVR was
not in use
Raw spent
/concentrated
spent wash

Raw
spent
wash

3+4

02.0 40.0 IE-(14.024.0) 14.5 65.0

(5.552.5)
(15.924.2) (17.061.0)
SE(24.0 55.0
(24.2-56.5)
5

Table 30 : Comparative performance evaluation of multiple effect evaporation plants

Particulars
Type of
Technology
Design &
actual Steam
requirement,
MT/hr

A
D
Falling film Falling film

E
Falling film

Name of Distillery
G
Falling film

H
Falling film

I
J
Falling film
Forced
& forced
circulation
circulation
(Fluebex)

4.5
(4.5)

5.9
(4.5)

P1 2.
(P22.16)

114
(6.16.3)

2.5
(2.39)

IE- Alcohol
Vapour
SE 7.3 (5.4)

9.0
(9.0)

3.5
(3.2)

1.5
(1.2)

7.5
(7.5)

4.5
(4.5)

7.5
(7.5)

1.5
(1.2)

2.4
(2.4)

Design &
actual feed
M3/hr

30.00
(17.00)

40.40
(30.60)

15.90 Each
(P1-14.70)
(P2-14.74)

67.70
(15.00)

15.00
(12.88)

45.37
(37.50)

Design &
actualproduct
output, M3/hr

3.00
(2.24)

6.73
(18.60)

4.99
(9.50)

11.54
(Not in
operation)

0.75
(1.60)

IE- 26.00
(21.70) SE
-20.00
(14.40)

Design &
actual Water
evaporation
rate, M3/hr

25.00
(15.00)

33.66
(12.00)

10.90
(P1- 9.53)
(P2 9.58)

56.16
(12.10)

13.00
(11.52)

5.50
(3.30)

5.70
(2.70)

NP
(P1 4.54)
(P2 4.44)

4.01
(1.97)

5.20
(4.82)

20

20

20

24

170

207

185

NP

Design &
actual Steam
pressure,
kg/cm2

Steam
economy,
Kg of water
evaporated/
Kg of steam
used
Operation
hours/ day

Power
consumption,
Kw/hr
Treatment for
process
condensate

Degasser
followed
by ACF

Disposal of
condensate
water

Fertiirrigation

Disposal of
concentrate
product

No treatment Air sparger

is given
provided in
RCC aeration
tank

Spent wash
dilution,
floor
washing &
pump sealing

Spray dryer
Biofollowed by composting
Incineration

IE- 19.50
(14.50)
SE - 8.00
(4.80)

10.24
(12.77)

IE -6.00
(7.10)
SE -11.50
(9.50)

35.69
(25.00)

1.57
(1.76)

3.96
(2.77)

20

24

24

74

IE- 226
SE 339

501

Reverse
osmosis
Plant

No
treatment
is given

No treatment
Degasser
is given
followed by
ACF

Cooling
tower
make up

Molasses
dilution

Cooling
tower
make up

Biocomposting

Incineration

Spray
dryer
followed by
Incineration

Molasses
Irrigation
dilution,
floor
washing &
pump sealing

Incineration Incineration

TVR- Thermal Vapor Re-compressor, IE- Integrated Evaporator, SE- Standalone Evaporator, ACF- Activated Carbon Filter,
NP-Not provided.

79

Conclusions/Recommendations

Process condensate requires polishing

treatment before reuse in process and nonprocess applications. Therefore, additional
treatment cost.
Integrated raw spent wash evaporation can
result in reduction of final spent wash
volume to between 3.5 to 6.5 lit./lit. of
alcohol produced without additional steam
requirement, depending on fermentation
technology employed.
Scaling is severe when the product is
concentrated above 50% solids and it is
extremely difficult to remove the scaling.

Well-established
technology
for
concentration up to 30% solids, which can
help in substantial reduction of spent wash
quantity.
Susceptible to scaling above 2,000 ppm
suspended solids in feed. Concentration
above 40% solids is yet not well established.
Proper de-gassing of bio-methanted spent
wash is required before concentration
through multiple effect evaporation plant.
Substantial quantity of steam is required for
evaporation of spent wash and therefore,
there will be additional recurring cost.

Table 31 : Comparative performance evaluation data/findings of spray dryers

Particulars

Feed
Feed, M3/day
Drying hot air inlet temperature, 0 C
Drying air outlet temperature, 0 C
Powder production, MT/day
Moisture % in powder
Calorific value of dry powder, Kcal/Kg

Particulars

Plant supplier

Capital investment
( ` crore)

Controlling system
used for plant
monitoring/operation
Design basis

Steam generation
capacity, (TPH)

Steam temperature,
( OC)
Boiler efficiency, (%)

80

MEE concentrate
60
400
125
20
4-5
2600

MEE concentrate
23.20
400
120
3.49
4-5
2200

Table 32 : Comparative performance evaluation of incineration boilers

Year or installation

Steam pressure,
Kg/cm2 (g)

2008-09

Name of Distillery
I

2009-10

2008-09

2009-10

Guangxi Luzhou
Thermal Power
Equipment Co., China

Thermax Ltd., Pune

Cheema Boilers Ltd.,

Chandigarh

Industrial Boiler
Ltd.,
Vapi

40.0-45.0 (Including
civil and structure
works, MEE plant, slop
fired boiler and stack
control equipment)

36.0 (Including
MEE plant, boiler
and accessories)

24.6(Including MEE
plant, boiler
and accessories)

0.80 (Only boiler)

Semi-automatic

DCS

PLC

Semi-automatic

D: 25.0
A: 6.7

D: 22.0
A: 19.0-20.0

D:30.0
A:22.0-23.0

A: 2.0-2.5

D: 400.0 +/- 20
A: 400.0

D: 380.0 +/- 5
A: 380.0

D: 425.0 +/-10
A: 425.0

D:192.0+/- 5
A: 170.0

70.0

60.0

60.0-62.0

80.8-82.0

D: 32.0
A: 26.0-29.0

D: 44.0
A: 43.0-44.0

D: 45.0
A: 44.0

D:10.5
A:7.0-9.0

Particulars

Table 32 : Comparative performance evaluation of incineration boilers

Name of Distillery
I

Fluidized bed

Fluidized bed

Fire tube

D: 950
A:938 -950

D: 980 -1020
A: 960 -1000

Two furnaces:
Traveling grate with
pulsating grate &
superheater furnace

Coal

Coal

Bagasse (or coal)

Calorific value,
Kcal/Kg

3,000 -3,500

3,800

2,000

i) Wooden chips
ii) Dried spent
wash powder

Fuel consumption,
Kg/hr.

30

D: 2,000
A:500 - 600

25-30

D: 2,250
A:2,100 -3600

20 (Bagasse)

D: 5,000
A:7,000 8,000

Less than 2%

3.0

NA

D: 11.2
A:

D: 7.8
A: 6.5 - 6.7

D: 10.5
A: 4.5

1,700 -1,800
@ 60O Bx

1,705

1,865
@65O Bx

Furnace details
Type

Temperature, OC
Fuel type

Ash, %

Bagasse/Coal
feeding point
height, meter

Slop feed
characteristics

Slop feed, Ton/hr.

Calorific value,
Kcal/Kg

Slop feed
temperature, OC

60 -70

1.5

D:81-88
A: 60-76

Conclusions/Recommendations

Technology is not matured and not yet well

established.
Various bottle-necks need to be overcome.
May not be economical for distilleries below
60 KLPD capacities.
Very high capital & operating cost.
Emission norms will have to be checked and
revised.
Due to high ash content in the spent wash
and supplementary fuel, fouling in flue gas
passage is severe and plant has to be
stopped for cleaning of ash deposition.
Due to frequent stoppages for cleaning
refractories of furnace are displaced, falls in
the furnace & disturbs fluidization.

D: Not provided
A: 600 -800
Superheater: 502 -680

D:
A: 60 - 65

D :
A : 300

i) 2,200
ii) 2,200

D: 1,850
A: 2,200

150 -160 Kg/hr.

spent wash
powder
NA

NA

Development of Standards and Guidelines for

Grain Based Distillery Waste in India
The CPCB, Delhi has entrusted this project to
VSI. The proposed study will help CPCB to evolve
new standards and guidelines for disposal of solid,
liquid effluents and gaseous emissions from grain
based distilleries in the country.

Under the project, ten different distilleries

across the country are to be studied for the systems
they have implemented for disposal of waste of
solid, liquid and gaseous emissions. Out of the ten
proposed distilleries, detailed studies in three
distilleries have been completed. Collection of
design data, operating conditions/parameters and
performance evaluation of grain handling, milling,
saccharification and liquefaction, fermentation,
distillation, decantation, multi effect evaporation

81

(MEE) plants, DWGS, DDGS, biogas plants and

extended aeration system were completed.
Occurrence of stoppages, reasons for stoppages
and other problems faced by units were discussed
in detail with the distillery staff during visits.
Various bottle necks in the process operations of
different effluent treatment plants were identified
and data was compiled. The configuration of the
distilleries studied has been given in table 33.

The molasses sample from Kumbhi Kasari SSK was

used for the experiments. Starting with 31.10C the
maximum temperature reached was 36.4C during
one of the experiments.

Screening and Development of Thermotolerant

Yeast for Alcoholic Fermentation

Fig. 19 : Temperature and pH profiles during the

fermentation process
The effect of increasing temperature on yeast
cell growth, sugar consumption rate and ethanol
production rate were also checked (Fig. 19).
The sugar was almost completely consumed
under uncontrolled fermentation temperature. The
fermentation was completed in 30 hr with ethanol
volumetric yield of 9.53 % (v/v).

Research work of the remaining seven

distilleries will be completed in the following year.
Compilation and evaluation of data collected was
under progress.

Experiments were carried out using the selected

strain of yeast TSC-20073 on 100 litres pilot scale
to test its performance at higher temperature. The
fermentation experiments were carried out at
uncontrolled temperature i.e. cooling water for
controlling fermentation temperature was not used.
Particulars

Table 33 : Configuration of grain based distilleries

Capacity

Grain feed stocks used

Fermentation technology

65 KLPD

Maize/Sorghum
Batch

Name of Distillery
B
30 KLPD

Sorghum/Broken rice
Batch

80 KLPD

Sorghum/Broken rice
/Millet
Batch

Distillation technology

Multi-pressure

Multi-pressure

Multi-pressure

Alcohol % in Wash

10.0 11.0

9.0 11.0

13.0 14.0

Decantation
Evaporation
DWGS & DDGS
manufacture

Decantation
Bio-methanation
Reverse Osmosis
Bio-composting

Bio-methanation
Aerobic treatment
clarifier
Ferti-irrigation

Bio-methanation
Aerobic treatment
Ferti-irrigation

21.66

24.83

Neutralization & recycle

for liquefaction.
Fermenter washing
added into beer-well.

12.16

11.97

Main Product

Whole stillage generated,

lit/lit of alcohol

EQRS/ENA
7.75

Technology adopted for

disposal of whole stillage

Decantation
Evaporation DWGS
manufacture

Quantity of secondary
effluent generated, lit/lit of
alcohol

5.46

Effluent treatment system for

disposal of low strength
waste (Secondary effluent)
Fresh water consumption
without recycle, M3/KL
Fresh water consumption
with recycle, M3/KL

82

EQRS/ENA
8.00

2.70

EQRS/ENA
4.00

1.02

15.14
6.93

The results indicate that the thermophilic yeast

strain developed gives the same performance as
that obtained with normal yeast strain requiring
proper temperature control. Further trails on plant
scale are proposed in the coming year.
Use of such thermophilic yeast will help the
distilleries to reduce the cost of production by saving
in the energy required for cooling fermenting broth.

EXTENSION AND ADVISORY SERVICES

Detailed Project Reports (DPRs) on new

distilleries, modernization of existing units and
ETPs completed during the year

Technical Meetings and Evaluation of Technical

Offers (SLMPC)
The staff of the department attended the prebid, technical sub-committee and State level
machinery purchase committee (SLMPC) meetings
at MRSSK Sangh Ltd. for the following distilleries
as detailed in table 36. Technical offers received
for different technologies were critically evaluated
and comparative technical statements were
prepared.

The following DPRs were prepared by the

department. (Table 34)
Tender Documents

The department provided guidance to mills in

preparation of comprehensive tender documents
required for erection of various plants by member
distilleries as listed in table 35.
Discussion with Mr. Ashok Pawar, Chairman, Ghodganga SSK
during a visit to the distillery
Name of Distillery

Table 34 : Detailed Project Reports prepared

Plant Configuration

Dnyaneshwar SSK

Rectified Spirit and Extra Neutral

Alcohol (MPR distillation).

Majalgaon SSK

Biogas based power generation

Tridhara Sugars

Anhydrous Alcohol (MPR

distillation and MSDH Technology)

Rameshwar SSK

Makai SSK
Mula SSK
Lok. B. Patil SSK

Rectified Spirit, Extra Neutral Alcohol

(MPR distillation) and Anhydrous
Alcohol (MSDH Technology)

1.4 MW power generation from biogas

New 30 KLPD distillery

New 30 KLPD distillery

New 30 KLPD distillery

Biogas based power generation

1.22 MW power generation from biogas

Export Quality Rectified Spirit

Modernization of existing 30 KLPD

distillery plant

Anhydrous Alcohol (MSDH

Technology)

Extra Neutral Alcohol

Kumbhi Kasari SSK

Rectified spirit and Extra Neutral

Alcohol (MPR distillation)

NSL Sugars, Ghana

Expansion of 45 KLPD distillery to 75

KLPD and up-gradation of effluent
treatment system

Anhydrous Alcohol (MPR distillation

and MSDH Technology)

Pad.Dr.VV Patil SSK

Datta Shetkari SSK

Assignment details

Rectified spirit, Extra Neutral

Alcohol and Anhydrous Alcohol

New 30 KLPD MSDH plant

New 20 KLPD - RS to ENA plant.

Modernization of existing 30 KLPD

distillation plant
New 50 KLPD distillery plant

83

Name of Distillery

Table 35 : Tender documents prepared

Plant Configuration

Dnyaneshwar SSK

RS and ENA (MPR distillation)

Vikas SSK

RS / ENA / AA

Vikas SSK

Biomethanated spent wash

evaporation plant

Vikas SSK

Plant Capacity

Expansion of 45 KLPD to 75
KLPD and up-gradation of effluent

30 KLPD

Biogas plant

630 M3/day spent wash feed

SMSM Patil SSK

RS / ENA / AA

60 KLPD

Datta Shetkari SSK Ltd

Export Quality RS

30 KLPD

Kumbhi Kasari SSK

Datta Shetkari SSK Ltd

Datta Shetkari SSK Ltd

Sanjivani (Takli) SSK Ltd.

Sahyadri SSK

630 M3/day biomethanated spent

wash feed

RS / ENA

30 KLPD

Biogas plant

600M3/day spent wash feed

Biomethanated spent wash

evaporation plant

600M3/day biomethanated spent wash

feed

Compost yard as per CREP norms

45 KLPD

Export quality RS

60 KLPD

Table 36 : Technical Meetings (SLMPC) and evaluation of technical offers

Name of Distillery

Vikas SSK
(Pre-bid, Technical subcommittee
and SLMPC meetings)
SMSM Patil SSK (Pre-bid, Technical subcommittee
and SLMPC meetings)
Kumbhi Kasari SSK (Pre-bid, Technical
subcommittee and SLMPC meetings)
Datta Shetkari SSK (Pre-bid, Technical
subcommittee and BoDs meetings)

Plant Configuration

30 KLPD distillery plant 630 M3/day spent wash

feed biogas plant 630 M3/day to 189 M3/day
(9% Total solids to 30% Total solids) spent wash
evaporation plant
60 KLPD distillery plant with integrated spentwash
evaporation plant

30 KLPD distillery modernization

30 KLPD distillery modernization

Visits

The staff of department visited member and nonmember distilleries in Maharashtra and other states,
government offices, institutions etc. for different
assignments. The details of these 172 visits are
given in Annexure XIII
Recommendation of Proposals

VSIs technical recommendations are required

for installation of new as well as for modernization
and modification of distilleries and ETP plants.
Details of recommendations given to distilleries
are detailed in table 37.
Visit of Dr. KC Mohite, Dean Faculty of Science,
University of Pune

84

Inspection of Plant and Machinery /Consultancy

services
Distilleries request VSI to inspect the plant and
machinery during the plant erection period and
Name of Distillery

Table 37 : Recommendations

Recommendation

Dharani Sugars and Chemicals Ltd

PRC, Rectifier cum exhaust and methanol column

specifications.P & I diagram for pipeline modification
of fermentation section

Dnyaneshwar SSK

Installation of new molasses weighing system.

Manganga SSK

Installation of pre-fermenters.

Sonhira SSK

Installation of integrated evaporation plant.

Datta Shetkari SSK

Installation of integrated evaporation plant.

Kumbhi Kasari SSK

Modernization of existing 30 KLPD atmospheric

distillation in to MPR distillation.

Sahyadri SSK

Construction of impervious compost yard as per

CREP norms.

Datta Shetkari SSK

30 KLPD MPR distillation with Integrated evaporation

plant.

Dnyaneshwar SSK

Installation of Molasses automatic weighing system.

Kopargaon SSK

Thermal gasification project on BOOT basis.

Molasses storage tank.

Ganesh SSK
Name of Distillery

supervise the commissioning and performance trial

run. The department carried out the inspection/
consultancy services are mentioned in table 38.

Repairs/replacement of distillery equipment.

Table 38 : Consultancy services

Details of consultancy services

Bhima SSK, Patas

500 M /day spent wash feed biogas plant.

Vitthalrao Shinde SSK

30 KLPD distillery to produce RS, ENA & AA.

750 M3/day spent wash feed Biogas plant
750 M3/day to 125 M3/day Spent wash evaporation plant

Makai SSK

Pandurang SSK

Rena SSK

Kumbhi Kasari SSK

Dnyaneshwar SSK
Kopargaon SSK

30 KLPD distillery to produce RS, ENA & AA.

350 M3/day spent wash feed biogas plant.
Spent wash storage tanks and biocompost yard.

45 KLPD distillery to produce RS, ENA & AA.

500 M3/day spent wash feed Biogas plant.
500 M3/day to 167 M3/day spent wash evaporation plant
Spent wash storage tanks and biocompost yard.
30 KLPD distillery to produce RS, ENA & AA.
350 M3/day spent wash feed biogas plant.
Spent wash evaporation plant.
Spent wash storage tanks and biocompost yard.
30 KLPD MPR distillation plant.

45 KLPD MPR distillation plant.

Thermal gasification plant.

85

Checking and Approval of Drawings

Drawings such as Lay out, GA, Civil and

structural, P & I diagrams and invoices were
checked and approved for distilleries as detailed
in table 39.
Design and Costing of Plant and Machinery

Design and costing of plant and machinery was

carried out for member and non-member
distilleries as given in table 40.
Name of Distillery

Chem-cad Simulations

The department has prepared Chem-cad

simulation of 30 KLPD Multi-pressure distillation
plant having four columns for Datta SSK Ltd for
improving the quality of spirit. Simulation study
was also carried out for operation of old forced
circulation spent wash concentration reboilers to
work under vacuum mode of operation. It was
observed that the same reboiler can be also
operated under vacuum for better performance.

Table 39 : Checking and approval of drawings

Makai SSK

Vitthalrao Shinde SSK

Dharani Sugars and Chemicals

Type of Project

30 KLPD Distillery for RS and ENA.

350 M3/day spent wash feed biogas plant.
Spent wash storage tanks and biocompost yard.

30 KLPD Distillery for RS, ENA and AA.

750 M3/day spent wash feed Biogas plant.
750 M3/day to 125 M3/day Spent wash evaporation plant.
110 KLPD distillery for RS, ENA and AA.

Kumbhi Kasari SSK

30 KLPD MPR distillation for RS and ENA.

Kopargaon SSK

Thermal gasification Plant for disposal of spent wash.

Flowchart of RO, MEE, Dryer, CBT etc.

Dnyaneshwar SSK

45 KLPD MPR distillation plant for EQRS.

Datta Shetkari SSK

Cheyyar Cooperative Sugar Mills

30 KLPD MPR distillation with integrated evaporation for RS.

45 KLPD MPR distillation plant for RS.

Table 40 : Design and costing of plant and machinery

Name of Distillery

Kumbhi Kasari SSK

Datta Shetkari SSK

Manganga SSK

Datta Shetakari SSK

Dnyaneshwar SSK
Someshwar SSK

Kisanveer Satara SSK

Type of Equipment

New 30 KLPD distillery foundations and structure

Total cost estimation of modernization for 30 KLPD distillery

Total cost estimation for modernization of 30 KLPD distillery

600 M3/day spent wash feed biogas plant
Modernization 30 KLPD distillery with MPR distillation and
integrated evaporation plant
Cost estimation of new fermenter and pre-fermenter

Valuation of existing old batch fermentation and atmospheric

distillation plant
New 45 KLPD MPR distillation plant

Cost estimation for additional pipeline for new fermenter

Cost estimation for 6000 toones of molasses storage tank

Nira-Bhima SSK

Cost estimation for new 210 M3 fermenter

Cheyyar Co-op. Sugar mills

Cost estimation for 45 KLPD distillery and biocompost yard

Ganesh SSK

86

Verification of estimated cost of repairs/replacement/modification

of 30 KLPD distillery

Yeast Culture Bank

The department has established a yeast culture

bank, wherein different cultures of yeast with
various specific characters such as, osmotolerance, thermo-tolerance, high alcohol tolerance
etc. are preserved. These strains are either isolated
in the laboratory or collected from various sources.
The department provides these strains in the form
of slants to distilleries across the country.

The feedback from these distilleries reveals that

the performance of cultures supplied by VSI was
encouraging. Satisfied with the performance of the
yeast culture, Bannari Amman Sugars Ltd., NSL
sugars Ltd., Kothari Sugars Ltd, Saswad Mali Sugars
Ltd, Shrigonda SSK, Ashok SSK have purchased
yeast slant in current year too. Yeast culture slants
were provided to the following distilleries.
Bannari Amman Sugars Ltd.
Loknete B. Patil SSK
Vitthal SSK
KBK-Chem Pvt. Ltd.
EI D Parry Ltd.
RP Ghodganga SSK
Ajinkyatara SSK
India Brewery & Distillery Pvt. Ltd.
Rena SSK
Baramati Agro Industries Ltd.
Sanjivani (Takli) SSK
GMR Industries Ltd.
Vijaynagar Sugar Pvt. Ltd.

Analytical Services

In all 340 samples of different products were

analyzed. The details of samples received and
tested during the year are as under.
Molasses samples - 174 nos.
RS & ENA samples - 60 nos.
Anhydrous alcohol - 10 nos.
IMFL samples - 64 nos.
Wine samples - 28 nos.
Others (Ayurvedic formulations, etc.) - 4 nos.

Calibration Work

The department calibrated 47 hydrometers

(Sykes), 5 alcohol meters and 27 thermometers.
Gas Chromatographic (GC) analysis of total 335
spirit samples from different sources were
performed during the year 2011-12. The details of
samples tested by GC analysis are as under.
ENA samples - 93
Rectified spirit samples -53
Impure spirit samples -14
Grape spirit - 6
Indian Made Foreign Liquor - 56
Anhydrous alcohol - 41
Ultraviolet test - 26
Potassium permanganate time test - 46

Microbial analysis of 19 samples which

includes 16 molasses samples, 2 water samples
and aurvedic formulation were carried out.

Analysis and Processing of Sweet Sorghum Stalks

from CF Biotech, Belgaum
CF Biotech is planning to set-up a distillery
based on sweet sorghum in the state of Karnataka.
Various sweet sorghum varieties were planted in
and around Dharwad district of Karnataka. The
work of analysis and processing of six different
varieties (namely S1, S2, S3, S4, S5 and S6) of sweet
sorghum was assigned to VSI .

These varieties were processed to extract juice

and manufacture of alcohol on bench scale in VSI
laboratories. Analysis of intermediates and
products was carried out and a final report on
possible yields and efficiencies of operations was
submitted to CF Biotech.
Improving Performance of Distillery Units

The department staff helped distilleries in

improving performance and solving process
problems faced by distilleries. Some examples are
given in table 41.

The Gas Chromatography-Mass Spectrometry

(with EI, CI, SPME, DEAN SWITCH etc) was installed
in the department. With the help of this instrument,
analysis of volatile compounds at ppm and ppb levels
from samples of various feed stocks, molasses, spirits,
liquors, wines, process intermediates, liquid and solid
effluents will be possible.
87

Name of distillery
Ajinkyatara SSK

Table 41: Problems and remedial measures

Nature of problem

Suggestions/Remedial measures and results

Low yield of alcohol in 1) Microscopic examination of the fermented wash and

their continuous
analysis of molasses and fermented wash samples for its
fermentation process.
TOVA content was carried out. 2) Care to be taken for
reducing TOVA content of final molasses. 3) Antibiotic doses
to control the contamination were suggested.
4) TOVA content of molasses was reduced from 8,000
ppm to 4,000 ppm. 5) Alcohol concentration in the
fermentation was increased from 5.5 to 7.5 % v/v.

Tulja Bhavani SSK Low yield of alcohol

and instability in
continuous
fermentation process.

1) Temperature of the fermentation process was in the

range of 36-390C. 2) TOVA content of molasses was
20,000 ppm. 3) Antibiotic doses were suggested to
control the contamination. 4) Some operating parameters
of the fermentation process were modified. 5) Measures to
be taken for storage of molasses and to maintain hygienic
condition in the fermentation house were suggested.

Madhukar SSK

Low yield of alcohol in

continuous
fermentation process.

Renuka Sugars
Pvt. Ltd.

Methanol content in
the ENA was on
higher side.

Kumbhi Kasari
SSK

Foaming and low

1) Proper feeding to the fermenters and maintaining
production rate
fermentation parameters properly, increased the alcohol
problem in continuous concentration and production rate to 8.5 - 9.0 % v/v and
fermentation process.
30,000 to 35,000 lits. per day respectively. 2) Frequency
of pre-fermenter addition to fermenters was extended from
3-4 days to 14 to 15 days.

Ashok SSK

1) Due to high ambient temperature of 40-420C, it was not

possible to bring the fermentation temperature below 360C.
2) VSI thermotolerant yeast (TSC-20073) was used.
3) 8 % v/v alcohol in fermenter at 360C and improvment in
fermentation process was achieved

1) Spirit samples were analyzed by gas chromatography.

2) Adjustment of reflux ratio of simmering column, vapour
load to simmering column re-boiler and impure cut was
done. 3) Methanol content was reduced from 30 to 40 ppm
to 12 ppm.

Disturbed fermentation
process after weak beer
recycle of more than
10%.

1) Yeast propagation was optimized by using VSI yeast

culture. 2) Weak beer recycle was gradually increased from
10 % to 25 %. 3) Spentwash generation and fresh water
requirement for molasses dilution was substantially reduced.

Incidence of
spontaneous
combustion of
molasses in steel tank.

1) Installation of external pipe in pipe molasses cooler to

keep the molasses temperature within permissible range
was suggested. 2) C - massccuite was not getting cooled
to the desired extent due to blockage of passages in monovertical crystallizer. 3) Molasses cooling system was put in
to operation and the molasses temperature came down by
2 to 30C. 4) Immediate use of mixture of the burnt and good
quality molasses was advised before it became unfit for
fermentation.

Rajarambapu Patil Alcohol losses through 1) There was a difference in scanner temperature of 230C
SSK
spent lees from existing as compared to the caliberated thermometer. 2) Advice
20 KLPD ENA plant.
was given to calibrate all temperature sensors, to supply
sufficient flow of cooling water to the condensers and to
optimize the RS feed to the column. 3) After taking necessary
precautions the performance of ENA plant improved.

Gangakhed Sugar
and Energy Ltd

88

Name of distillery

Table 41: Problems and remedial measures

Nature of problem

Siddheshwar SSK, Low yield (5 to 6 %)

Kumthe
of alcohol in batch
fermentation process.
Majalgaon SSK

Dharani Sugars
and Chemicals
Ltd.
Ganesh SSK

Sanjivani (Takli)
SSK

Malegaon SSK

Manjara Shetkari
SSK

Fermentation process
problems and low
alcohol yield per ton
of molasses.

Low alcohol percentage

in fermented wash and
alcohol losses in spent
wash and spent lees.
Severe problem of
digester disturbance.

Souring of digesters,
poor generation of
biogas and increase in
content of hydrogen
sulphide

Suggestions/Remedial measures and results

1) The use of chlorinated water for the molasses dilution

was suggested. 2) Use Strepto- penicillin from pre-fermenter
stage was suggested. 3) The alcohol % was increased
to 7.5- 8 % v/v.
1) Samples from pre-fermenter were found severely
contaminated. 2) Recommended the use of selected
antibiotics. 3) Yield of alcohol per ton of molasses was
improved.

1) The technical staff were trained to operate the plant as

per standard norms and monitoring the fermentation
parameters. 2) Lectures for the technical staff of plant were
conducted.
1) Dead sludge was replaced partly by fresh active sludge.
2) Feeding of hot spent wash, addition of fresh cow-dung,
lime & nutrients etc. were suggested to maintain the
parameters in the normal range, 3) The digester was
stabilized and operational parameters and biogas
generation was restored.

1) Advised to water wash the digester, load fresh cow-dung

& nutrients to the digesters. 2) The performance of digesters
was brought under control and all digesters started running
smoothly.

Digesters were unable 1) Suggested addition of fresh cow-dung, lime, nutrients.

to accept the designed 2) The digesters were stabilized and biogas production
spent wash load.
was also restored to normal. 3) The temperature of digesters
was maintained by maintaining the temperature of feed,.
Digester of Manjara
SSK was under
stabilization but facing
the problem of increase
in TOVA.

1) The suction of feed pump was surrounded by sludge

resulting in carryover of sludge in to the digester leading to
increase in TOVA. 2) Errors in estimation of TOVA were
corrected. 3) After changing the location of feed pump
suction & taking proper care during analysis, the TOVA
of the digester improved.

Compilation of Technical Performance Data of

Cooperative Distilleries
The department compiled information on
performance of distilleries in Maharashtra State,
which was published in a booklet entitled
Performance of Distilleries affiliated to Cooperative
Sugar Mills in Maharashtra for the financial Year
2009-10 and 2010-11. There are 68 operating
distilleries affiliated to cooperative sugar mills in
Maharashtra. The data on technical performance of
these distilleries were compiled for the previous five
years and presented in table 42.

CPCB Sponsored Training Programme on

Compliance of Zero Discharge Norms in
DistilleriesTechnical Challenges and solutions
The Department of Alcohol Technology
conducted a five days training programme on
Compliance of Zero Discharge Norms in
Distilleries Technical Challenges and solutions
in collaboration with HRD programme of CPCB,
Delhi at VSI, Pune. Around 20 officers from Central
and State Pollution Control Boards from various
parts of the country (i.e. Bihar, Chhattisgarh, Delhi,
Haryana, Karnataka, Maharashtra, Orissa, Uttar
Pradesh and West Bengal) participated in this
training programme which covered all the subjects

89

related to technologies of manufacture of alcohol

and effluent treatment systems.

Workshop on Zero Liquid Discharge in Distilleries

with Emerging Technologies

A one day workshop was organized jointly with

the Central Pollution Control Board on Zero Liquid
Discharge in Distilleries with Emerging Technologies
on August 21, 2011 at VSI. The workshop aimed to
bring members of the Distillery Industry from across
the state of Maharashtra to a common platform for
debating various aspects of environmental
management with a techno economic perspective.
The policy makers and technologists from all the
distilleries in the state actively participated in the
workshop which was inaugurated by Shri.
Sharadchandra Pawar, Honble Minister, Agriculture
and Food Processing Industry, Government of India.
He emphasized the need of adoption of emerging
technologies for achieving ZLD from distilleries.
Consensus Resolution adopted during the
Workshop
(i) There is a need to switch over to cleaner and
advance technologies from the existing practices
of CREP guidelines, in a time bound manner, for
achieving Zero Liquid Discharge in Distilleries.
(ii) As the co operative sector has significant role in
socio economic welfare of rural population and
farmers, distilleries attached with smaller co
operative sugar mills may be considered for a while
to continue with unleachable bio composting
practices with revised guidelines, considering the
capital intensive greener technologies.

(iii) The practices of ferti irrigation and one time

land application are not implementable, and
pose potential threat to environmental pollution
and therefore shall be abandoned by the
distilleries at the earliest.
(iv) VSI shall draft proposal for fiscal and financial
assistance from Central and State Government
Departments seeking soft loans, tax holidays and
grants to make the adoption of greener
technologies economically viable for distilleries.
(v) CPCB shall also extend their technical and
logistic support to VSI and distilleries in
preparation of action plan and proposals.

Technical Guidance to Government and NonGovernment Organizations

The member distilleries need administrative as

well as financial clearance from the State
Government when they intend to replace their old
machinery by new one or venture into new projects.
To arrive at a decision in this regard, the
Commissioner of Sugar seeks technical guidance
from VSI, which is provided by the department.
Similar support was also provided to SLMPC,
Purchase Committees of the mills, Distillers
Association of Maharashtra, MPCB, Geographical
Indications Registry (Intellectual Property Office) etc.

MoU with National Research Centre for Grapes

MoU was signed by VSI and NRC for Grapes,
regarding collaboration in academic activities of
MSc (Brewing, Distilling & Wine making).

Table 42 : Technical performance of distilleries affiliated to co-operative sugar mills in Maharashtra

Parameter

2006-07
Production Capacity (million lit./300days) 618.00
considering all distilleries.
Production Capacity (million lit./300days) 489.48
based on received information
Number of distilleries whose
49
information was compiled
Average net working days
195.65
Molasses consumed (million tonnes)
1.363
Alcohol produced (million lit.)
347.54
Average Fermentation Efficiency (%)
89.17
Average Distillation Efficiency (%)
98.41
Recovery of Alcohol (lit./tonnes of molasses) 266.08
Capacity utilization (%)

90

63.31

Year

2007-08
654.00

2008-09
663.00

2009-10
723.00

2010-11
745.50

618.00

604.50

604.50

640.50

53

51

51

53

216.85
1.754
446.07
89.44
98.31
270.19

180.66
1.468
364.24
89.44
98.43
271.12

148.80
1.125
309.33
89.78
98.45
270.28

178.84
1.344
363.68
89.70
98.40
270.51

76.69

66.85

47.34

52.25