Alcohol Textbook 4thEd

1 THEALCOHOLTEXTBOOK4 THEDITIONTHEALCOHOLTEXTBOOK4 THEDITIONA reference for the beverage, fuel and industrial Alcohol industriesA reference for the beverage, fuel and industrial Alcohol industriesEdited by KA Jacques, TP Lyons and DR KelsallForeword iiiThe Alcohol Textbook4th EditionA reference for the beverage, fuel and industrial Alcohol Jacques, Lyons, LyonsNottingham University PressManor Farm, Main Street, ThrumptonNottingham, NG11 0AX, United KingdomNOTTINGHAMP ublished by Nottingham University Press (2nd Edition) 1995 Third edition published 1999 Fourth edition published 2003 Alltech Inc 2003 All rights reserved. No part of this publicationmay be reproduced in any material form(including photocopying or storing in anymedium by electronic means and whether or nottransiently or incidentally to some other use ofthis publication) without the written permissionof the copyright holder except in accordance withthe provisions of the Copyright, Designs andPatents Act 1988.

2 applications for the copyrightholder s written permission to reproduce any partof this publication should be addressed to the 1-897676-13-1 Page layout and design by Nottingham University Press, NottinghamPrinted and bound by Bath Press, Bath, EnglandForeword vContentsForewordixT. Pearse LyonsPresient, Alltech Inc., Nicholasville, Kentucky, USAE thanol industry today1 Ethanol around the world: rapid growth in policies, technology and production1T. Pearse LyonsAlltech Inc., Nicholasville, Kentucky, USARaw material handling and processing2 Grain dry milling and cooking procedures: extracting sugars in preparation forfermentation9 Dave R. Kelsall and T. Pearse LyonsAlltech Inc., Nicholasville, Kentucky, USA3 Enzymatic conversion of starch to fermentable sugars23 Ronan F.

3 PowerNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA4 Grain handling: a critical aspect of distillery operation33 David J. RadzanowskiAlltech Inc., Nicholasville, Kentucky, USAS ubstrates for ethanol production5 Lignocellulosics to ethanol: meeting ethanol demand in the future41 Charles A. AbbasArcher Daniels Midland, Decatur, Illinois, USA6 Ethanol production from cassava59 Nguyen VinhThe Research Institute of Brewing, Hanoi, Vietnam7 Whey Alcohol - a viable outlet for whey?65 Jack O SheaAlltech Inc., Dunboyne, County Meath, Ireland8 Treatment and fermentation of molasses when making rum-type spirits75 Robert PiggotAlltech Inc., Nicholasville, Kentucky, LyonsYeast and management of fermentation9 Understanding yeast fundamentals85 Inge RussellInternational Centre for Brewing and Distilling, School of Life Sciences,Heriot-Watt University, Edinburgh, UK1 0 Practical management of yeast: conversion of sugars to ethanol121 Dave R.

4 Kelsall and T. Pearse LyonsAlltech Inc., Nicholasville, Kentucky, USA1 1 Continuous fermentation in the fuel Alcohol industry:How does the technology affect yeast?135W. M. IngledewUniversity of Saskatchewan, Saskatoon, Saskatchewan, Canada1 2 Understanding near infrared spectroscopy and its applications in the distillery145 Don Livermore1, Qian Wang2and Richard S. Jackson21 Hiram Walker & Sons Ltd., Walkerville, Ontario, Canada2 Bruker Optics Inc., Billerica, Massachusetts, USA1 3 Emerging biorefineries and biotechnological applications of nonconventionalyeast: now and in the future171 Charles A. AbbasArcher Daniels Midland, Decatur, Illinois, USAB everage Alcohol production1 4 Production of Scotch and Irish whiskies: their history and evolution193T.

5 Pearse LyonsAlltech Inc., Nicholasville, Kentucky, USA1 5 Tequila production from agave: historical influences and contemporary processes223 Miguel Cede o CruzTequila Herradura, de Ex-Hda San Jose del Refugio Amatit n, Jalisco, M xico1 6 Production of heavy and light rums: fermentation and maturation247 Robert PiggotAlltech Inc., Nicholasville, Kentucky, USA1 7 From pot stills to continuous stills: flavor modification by distillation255 Robert PiggotAlltech Inc., Nicholasville, Kentucky, USA1 8 From liqueurs to malternatives : the art of flavoring and compounding alcohol265 Andy Head and Becky TimmonsNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USAF oreword vii1 9 Production of American whiskies: bourbon, corn, rye and Tennessee275 Ron RalphRon Ralph & Associates Inc.

6 , Louisville, Kentucky, USAC ontamination and hygiene2 0 Bacterial contamination and control in ethanol NarendranathNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA2 1 Managing the four Ts of cleaning and sanitizing: time, temperature, titration andturbulence299 Jim Larson and Joe PowerNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USAR ecovery2 2 Ethanol distillation: the fundamentals319P. W. MadsonKATZEN International, Inc., Cincinnati, Ohio, USA2 3 Development and operation of the molecular sieve: an industry standard337R. L. Bibb SwainDelta-T Corporation, Williamsburg, Virginia, USAE ngineering ethanol fermentations2 4 Water reuse in fuel Alcohol plants: effect on fermentationIs a zero discharge concept attainable?

7 343W. M. IngledewUniversity of Saskatchewan, Saskatoon, Saskatchewan, Canada2 5 Understanding energy use and energy users in contemporary ethanol plants355 John MeredithRo-Tech, Inc., Louisville, Kentucky, USAThe dryhouse, co-products and the future2 6 Dryhouse design: focusing on reliability and return on investment363 John MeredithRo-Tech, Inc., Louisville, Kentucky, USA2 7 Ethanol production and the modern livestock feed industry: a relationshipcontinuing to grow377 Kate A. JacquesNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, Lyons2 8 Biorefineries: the versatile fermentation plants of the future387 Karl A. DawsonNorth American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USAThe Alcohol Alphabet399A glossary of terms used in the ethanol-producing industriesIndex441 Foreword ixForewordAlcohol production: a traditional process changing rapidlyT.

8 PEARSE LYONSP resident, Alltech Inc., Nicholasville, Kentucky, USAIn its simplest form, Alcohol production is theprocess of preparing starch- or sugar-containingraw materials for fermentation by yeast, whichis currently the only microorganism used forconverting sugar into Alcohol . The ethanol isthen concentrated and recovered in a processcalled distillation. Though essentially a simpleprocess, making it happen with maximumefficiency on a very large scale is a remarkablecombination of microbiology and the past 25 years progress has been madein virtually all aspects of the process, but whatare the challenges facing Alcohol in the future?Beginning with raw material processing, hereare the areas that we feel need to be addressed:Raw material reception and processingDespite many declarations to the contrary, it isvirtually impossible for a distillery to accuratelycalculate true yields.

9 A sampling of grains iseither done in very cursory fashion or not at distiller must see himself first as a processorof grain rather than a producer of Alcohol . Hemust know accurately how much starch ispresent in his raw material and he must be ableto measure that immediately. NIR spectroscopyhas much to offer in terms of raw materialapplications; and this topic is detailed in thisvolume. However, if we control the process anduse the appropriate enzymes from solid statefermentation, such as Rhizozyme andAllzyme SSF, which are capable of releasingnot just bound starch but also hemicellulose andcellulose, we can and indeed some plants do,get + gallons per bushel (116 gallons or 420liters/tonne. In fact, we predict yields of in the near future.)

10 For molasses, theadvent of detranases can ensure maximumyields. Every aspect of cooking and fermentationmust be controlled, cooking processMuch debate exists at the moment regarding thecooking process. It is a sad reflection perhapson our industry that since the pioneering PhDwork by Dr. John Murtagh in 1972 no furtherscientific thesis has been published on grain be finely ground? Should cookinginvolve high temperature -amylase or shouldan entirely different type of enzyme be used?Often the enzyme selected is one developedbased on experience in the corn wet millingsector, which may be far from ideal for dry millalcohol industry needs a new enzyme, one tailoredto our specific needs: converting grain tofermentable sugar. Raw materials contain notonly starch, but also hemicellulose (a polymerof 5-carbon sugars) and cellulose.