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The Alcohol Textbook 4Th Edition

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The Alcohol Textbook 4Th Edition TTHEHE AALCOHOLLCOHOL TEXTBOOKEXTBOOK T TH 44TH EEDITIONDITION A reference for the beverage, fuel and industrial alcohol industries Edited by KA Jacques, TP Lyons and DR Kelsall Foreword iii The Alcohol Textbook 4th Edition A reference for the beverage, fuel and industrial alcohol industries K.A. Jacques, PhD T.P. Lyons, PhD D.R. Kelsall iv T.P. Lyons Nottingham University Press Manor Farm, Main Street, Thrumpton Nottingham, NG11 0AX, United Kingdom NOTTINGHAM Published 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 publication may be reproduced in any material form (including photocopying or storing in any medium by electronic means and whether or not transiently or incidentally to some other use of this publication) without the written permission of the copyright holder except in accordance with the provisions of the Copyright, Designs and Patents Act 1988. Applications for the copyright holder’s written permission to reproduce any part of this publication should be addressed to the publishers. ISBN 1-897676-13-1 Page layout and design by Nottingham University Press, Nottingham Printed and bound by Bath Press, Bath, England Foreword v Contents Foreword ix T. Pearse Lyons Presient, Alltech Inc., Nicholasville, Kentucky, USA Ethanol industry today 1 Ethanol around the world: rapid growth in policies, technology and production 1 T. Pearse Lyons Alltech Inc., Nicholasville, Kentucky, USA Raw material handling and processing 2 Grain dry milling and cooking procedures: extracting sugars in preparation for fermentation 9 Dave R. Kelsall and T. Pearse Lyons Alltech Inc., Nicholasville, Kentucky, USA 3 Enzymatic conversion of starch to fermentable sugars 23 Ronan F. Power North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA 4 Grain handling: a critical aspect of distillery operation 33 David J. Radzanowski Alltech Inc., Nicholasville, Kentucky, USA Substrates for ethanol production 5 Lignocellulosics to ethanol: meeting ethanol demand in the future 41 Charles A. Abbas Archer Daniels Midland, Decatur, Illinois, USA 6 Ethanol production from cassava 59 Nguyen T.T. Vinh The Research Institute of Brewing, Hanoi, Vietnam 7 Whey alcohol - a viable outlet for whey? 65 Jack O’Shea Alltech Inc., Dunboyne, County Meath, Ireland 8 Treatment and fermentation of molasses when making rum-type spirits 75 Robert Piggot Alltech Inc., Nicholasville, Kentucky, USA vi T.P. Lyons Yeast and management of fermentation 9 Understanding yeast fundamentals 85 Inge Russell International Centre for Brewing and Distilling, School of Life Sciences, Heriot-Watt University, Edinburgh, UK 10 Practical management of yeast: conversion of sugars to ethanol 121 Dave R. Kelsall and T. Pearse Lyons Alltech Inc., Nicholasville, Kentucky, USA 11 Continuous fermentation in the fuel alcohol industry: How does the technology affect yeast? 135 W. M. Ingledew University of Saskatchewan, Saskatoon, Saskatchewan, Canada 12 Understanding near infrared spectroscopy and its applications in the distillery 145 Don Livermore1, Qian Wang2 and Richard S. Jackson2 1Hiram Walker & Sons Ltd., Walkerville, Ontario, Canada 2Bruker Optics Inc., Billerica, Massachusetts, USA 13 Emerging biorefineries and biotechnological applications of nonconventional yeast: now and in the future 171 Charles A. Abbas Archer Daniels Midland, Decatur, Illinois, USA Beverage alcohol production 14 Production of Scotch and Irish whiskies: their history and evolution 193 T. Pearse Lyons Alltech Inc., Nicholasville, Kentucky, USA 15 Tequila production from agave: historical influences and contemporary processes 223 Miguel Cedeño Cruz Tequila Herradura, S.A. de C.V. Ex-Hda San Jose del Refugio Amatitán, Jalisco, México 16 Production of heavy and light rums: fermentation and maturation 247 Robert Piggot Alltech Inc., Nicholasville, Kentucky, USA 17 From pot stills to continuous stills: flavor modification by distillation 255 Robert Piggot Alltech Inc., Nicholasville, Kentucky, USA 18 From liqueurs to ‘malternatives’: the art of flavoring and compounding alcohol 265 Andy Head and Becky Timmons North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA Foreword vii 19 Production of American whiskies: bourbon, corn, rye and Tennessee 275 Ron Ralph Ron Ralph & Associates Inc., Louisville, Kentucky, USA Contamination and hygiene 20 Bacterial contamination and control in ethanol production 287 N.V. Narendranath North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA 21 Managing the four Ts of cleaning and sanitizing: time, temperature, titration and turbulence 299 Jim Larson and Joe Power North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA Recovery 22 Ethanol distillation: the fundamentals 319 P. W. Madson KATZEN International, Inc., Cincinnati, Ohio, USA 23 Development and operation of the molecular sieve: an industry standard 337 R. L. Bibb Swain Delta-T Corporation, Williamsburg, Virginia, USA Engineering ethanol fermentations 24 Water reuse in fuel alcohol plants: effect on fermentation Is a ‘zero discharge’ concept attainable? 343 W. M. Ingledew University of Saskatchewan, Saskatoon, Saskatchewan, Canada 25 Understanding energy use and energy users in contemporary ethanol plants 355 John Meredith Ro-Tech, Inc., Louisville, Kentucky, USA The dryhouse, co-products and the future 26 Dryhouse design: focusing on reliability and return on investment 363 John Meredith Ro-Tech, Inc., Louisville, Kentucky, USA 27 Ethanol production and the modern livestock feed industry: a relationship continuing to grow 377 Kate A. Jacques North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA viii T.P. Lyons 28 Biorefineries: the versatile fermentation plants of the future 387 Karl A. Dawson North American Biosciences Center, Alltech Inc., Nicholasville, Kentucky, USA The Alcohol Alphabet 399 A glossary of terms used in the ethanol-producing industries Index 441 Foreword ix Foreword Alcohol production: a traditional process changing rapidly T. PEARSE LYONS President, Alltech Inc., Nicholasville, Kentucky, USA In its simplest form, alcohol production is the liters/tonne. In fact, we predict yields of 3.2 process of preparing starch- or sugar-containing gallons in the near future. For molasses, the raw materials for fermentation by yeast, which advent of detranases can ensure maximum is currently the only microorganism used for yields. Every aspect of cooking and fermentation converting sugar into alcohol. The ethanol is must be controlled, however. then concentrated and recovered in a process called distillation. Though essentially a simple process, making it happen with maximum The cooking process efficiency on a very large scale is a remarkable combination of microbiology and engineering. Much debate exists at the moment regarding the Over the past 25 years progress has been made cooking process. It is a sad reflection perhaps in virtually all aspects of the process, but what on our industry that since the pioneering PhD are the challenges facing alcohol in the future? work by Dr. John Murtagh in 1972 no further Beginning with raw material processing, here scientific thesis has been published on cooking. are the areas that we feel need to be addressed: Should grain be finely ground? Should cooking involve high temperature α-amylase or should an entirely different type of enzyme be used? Raw material reception and processing Often the enzyme selected is one developed based on experience in the corn wet milling Despite many declarations to the contrary, it is sector, which may be far from ideal for dry mill virtually impossible for a distillery to accurately alcohol production. calculate true yields. A sampling of grains is Our industry needs a new enzyme, one tailored either done in very cursory fashion or not at all. to our specific needs: converting grain to The distiller must see himself first as a processor fermentable sugar. Raw materials contain not of grain rather than a producer of alcohol. He only starch, but also hemicellulose (a polymer must know accurately how much starch is of 5-carbon sugars) and cellulose. The cooking present in his raw material and he must be able process must be designed to loosen these to measure that immediately. NIR spectroscopy materials such that they release bound starch and has much to offer in terms of raw material also become available in turn for fermentation. applications; and this topic is detailed in this volume. However, if we control the process and use the appropriate enzymes from solid state Yeast and fermentation fermentation, such as Rhizozyme™ and Allzyme™ SSF, which are capable of releasing Despite all we know about it, yeast remains not just bound starch but also hemicellulose and underrated and misunderstood. It is the cellulose, we can and indeed some plants do, workhorse of the distillery, yet ‘economies’ on get 2.9+ gallons per bushel (116 gallons or 420 quality and quantity of yeast are made; and we x T.P. Lyons Corn Rye STARCH Wheat LIQUIFACTION Potatoes Barley Milo (sorghum) Enzymes DEXTRINS Cellulose Molasses Agave Sugarcane SUGAR Sugarbeets Whey CO-PRODUCTS Yeast CO2 DDGS BIOREFINERY Wet cake Value-added Solubles PRIMARY ALCOHOL co-products POT STILL CONTINUOUS STILL Irish Rum Grain Grain Fuel Whiskey Whisky Alcohol Alcohol Malt Tequila Whisky Bourbon Gin Vodka Blended Whisky Scotch Whisky WHITE SPIRITS MATURATION SPIRITS often force it to grow
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