Liquefaction and Saccharification

After a laboratory control the grain is taken into the milling unit, where is the first cleaning stage, and then is being stored in silo cells. Before milling the grain passes through a second cleaning stage. The produced grist is transported into the installation via pneumatic transport and a control scale.
The first phase of the technological process is “Liquefaction and Saccharification”. At this phase the grist is mixed with process water, decanted stillage, a few chemical compounds and enzymes. The necessary biochemical conditions are being maintained in special tanks and in there proceeds enzymatic process of liquefaction and saccharification, wherein the starch in the grist is being converted into glucose, maltose and dextrins.


Saccharified pulp enters the next phase “Fermentation”. Fermentation is performed in a continuous mode under a cascade Vogelbusch MULTICONT process in which fermentable sugars are converted into alcohol. The slurry passes through a cascade of fermenter tanks, in which the yeast is maintained in optimal process conditions. The density and vitality of the yeast are controlled through a specialized tank called “inoculator”.

Distillation and Rectification

The next phase in the process is “Distillation and Rectification”. The installation provides complex and highly efficient five-stage process of distillation, rectification and sequentially purification of the fermented pulp. The produced neutral ethanol is of the highest quality and covers all of the world standards.


Process “Vacuum-evaporation”. In this phase the stillage (pulp with ethanol taken out) from the distillation unit goes to two decanter centrifuges to be separated into water fraction (decanted stillage) and dry fraction (cake). The decanted stillage in turn is divided into two streams. One is taken back for recirculation in previous phases of the process and the other continues to the vacuum-evaporation installation. In there a multistage evaporation and concentration of the decanted stillage is performed under conditions of vacuum using waste heat. The result is producing of concentrated stillage which is mixed with the cake from the decanters and the mixture is then fed to the dryer for final drying.


The last phase in the process is “Drying”. In this phase the mixture of cake and concentrated stillage is fed to a specialized bundle dryer, where is being dried in a low oxygen environment and at a controlled temperature. The result is producing bulky DDGS with humidity of about 10%. The product is cooled, granulated and stored in specialized cells in the milling block.

And more

An integral part of the described process is the specialized installation for storage, preparation, dosing and transport of chemical materials. All processes are controlled and operated with its help. Through this installation is also performing periodical chemical cleaning of the main vessels and pipelines in the plant.

The entire process is monitored, controlled and managed through a computer control system, designed and implemented by VOGELBUSCH. The system collects real-time information from multiple sensors and recording devices, organizes this information and submits it in graphic trends on the screens of operator stations in a control room. With its help the technologists can operate and maintain the basic chemical and engineering processes in the plant. нейна помощ технолозите могат да управляват и обслужват основните химични и инженерни процеси в завода.

Certificate as meeting the requirements of ISO 9001:2015 (PDF)
Certificate as meeting the requirements of HACCP Codex Alimentarius (PDF)
Kosher Certificate (PDF)
Certificate as meeting the requirements of Renewable Energy Directive (RED) and the certification system ISCC EU (PDF)
Good Manufacturing Practice Guide For Active Pharmaceutical Ingredients (PDF)