From Grain to Gallon: Total Process Visibility for Ethanol Producers
Ethanol production runs on tight margins. When feedstock quality varies, fermentation underperforms, or DDGS leaves the dryer at the wrong moisture level, the financial impact is immediate.
Process NIR solutions give operators real-time visibility across every stage of production, turning process data into decisions that drive yield, efficiency, and co-product value.
Measuring moisture, starch, sugars, protein, ethanol, and solids in seconds, Perten's diode array NIR systems integrate seamlessly with plant control systems to keep every control point optimized, from grain intake through to DDG/DDGS production.
The numbers show what that control is worth:
- Generate $800K in additional annual revenue from a 0.5% ethanol yield improvement at a 100 MMgy plant
- Save $150K–$200K annually through real-time moisture control reducing over-drying by just 1%
- Recover $500K in co-product revenue from 0.75% additional sellable DDGS mass at a 300,000-ton plant
This flyer details how our DA 7250 at-line, DA 7350 in-line, and DA 7440 on-line NIR solutions deliver the process intelligence ethanol producers need to protect margins and maximize output at every shift, across every site.
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