Rahul - Industrial Visit Report

REPORT ON INDUSTRIAL VISIT TO
MODI DISTILLERY, MODINAGAR

(UP)
SUBMITTED BY:-
RAHUL AGARWAL
10/PBT/015
M.TECH BIOTECHNOLOGY
REPORT ON INDUSTRIAL VISIT TO
MODI DISTILLERY, MODINAGAR (UP)
(I YEAR M.Tech II Sem).
The School of Biotechnology Gautam Buddha University has organized an

Industrial Visit to MODI DISTILLERY, MODINAGAR (UP) for the I YEAR
M.Tech. II semester students on 21.04.2011. A total of 23 students along with 1
faculty members (Dr. Barkha Singhal) The Salient features of the plant
observed by the students are as follows:-
MANUFACTURE PROCESS
SUBSTRATE: MOLASSES
Sugarcane molassess, a by- product of MODI SUGAR MILL is used

as a substrate. Molasses contains high percentage of sucrose and fructose sugars
and a good substrate for ethanl production.
STAGE 1: STRAIN DEVLOPMENT
The strain of Saccharomyces cervisiae is developed and maintained by

using slant. This strain is used as a inoculum for further process.
STAGE 2: LABORATORY INOCULUM PREPRATION
To initiate the fermentation, a substantial number of yeast cells called

inoculum is built up by transferring the fresh biomass from a slant culture into
the liquid inoculum medium, which is more like the production medium except
that the sugar content has been reduced to 4-6 % . The culture is grown at 25-
30oC with aeration, to allow a faster multiplication of cells.
STAGE 3: INDUSTRIAL INOCULUM
After 12 h from stage 2, the contents are transferred to another flask

containing the same inoculum medium which is larger in size by 4-5 volumes.
After a 12 h growth further transfers are made into the inoculum medium with
increasing size in the same fashion. The culture thus obtained is called the
industrial inoculum.
STAGE 4: PREFERMENTER
The 1200 l culture was used to inoculate a 6m3 open vessel in which
aeration was not possible and molasses medium was at ambient temperature
(<30°C) steadily increasing during the fermentation to <40°C. Molasses were
used in The pre-fermenter (commonly known in distilleries as the bub-stage)
and had a specific gravity <1.090 (corresponding to <16% (w/v) total sugar
concentration). The prefermenter stage continued for 8h during which vigorous
Fermentation occurred with occasional excessive foaming.
STAGE 5: INDUSTRIAL FULL-SCALE PRODUCTION
Full scale production was carried out by transferring the 6m3 bub-stage
fermentation broth into a 60m3 working capacity vessel (cylindrical shaped,
diameter <3.2m and height <10m) containing molasses (spec. gravity <1.090,
corresponding to <16% (w/v) total sugar). No aeration or temperature control
facilities were available. Initial ambient growth temperature varied between 28–
32°C steadily increasing during the fermentation run up to <42°C. The
fermentation run was allowed to continue until near consumption of all
available sugar as observed by diminished gas production and static specific
gravity. This usually took about 24h Distillation of the fermentation wort was
then carried out for ethanol extraction.
STAGE 6: RECOVERY OF ALCOHOL
The fermented wash besides some by-products such as fusels and aldehydes
contains only 6-8% ethanol by volume. The ethanol at this concentration can
not be put to use for any useful purpose. It, therefore, must be concentrated for
various end uses. This is usually achieved by the process of distillation. Further,
alcohol distillation separates the alcohol, (BP. 78.3oC) from water (BP. 100oC),
from a water-alcohol solution, by heating the solution and collecting the alcohol
rich vapours. The process basically is based on the fact that the vapour of a
boiling mixture will be richer in the component that has a lower boiling point or
in other words is relatively more volatile. When this vapour is cooled and
condensed the condensate will contain more concentration of alcohol. Repeated
batch distillations of the condensate called refluxing, will thus produce a
condensate which will every time be enriched more and more with ethanol until
a concentration of 96% (v/v) ethanol is achieved.
Distillation Unit
DREAM PROJECT OF MODI DISTILLERY CHAIRMAN: ARTIC

VODKA
Modi Illva India, a 50:50 joint venture between India’s Umesh Modi
Group and Italian spirits maker Illva Saronno. Neutral alcohol (flavourless) is
the base for producing these flavored beverages, which are colourless in
appearance. They are generally produced by alcoholic fermentation of extracts
from cereals (maize etc.) or potatoes, with emphasis on efficiency and economy
of production. The final distillate (base) contains greater than 96% (v/v) of
ethanol with very little flavour contribution from congeners. Various flavours
are added to this alcohol-base to produce quite distinct products. The flavours
may be directly added as essences or the product may be redistilled from a
mixture of the base and flavour contributing plant and diluted to give an
appropriate strength of alcohol. Gin derives its flavour from addition of juniper
berries etc. called botanicals. Vodka is pure, unaged spirit that has been filtered
through charcoal. It may be flavored with a variety of materials such as orange
and lemon peels, ginger, cloves and sugar. They also start to produce scotch
whisky.
USES OF EFFLUENTS: BIOGAS AND ELECTRICITY PRODUCTION
Bagasse, a major residue of sugarcane juice extraction can be utilised

as fuel for biogas, ethanol and electricity production. The use of bagasse and, if
economically viable, cane trash as a fuel for high efficiency electric power
production is the most important diversification option for sugar industry.
Anaerobic digestion processes take place in a closed tank, generally called a
digester or reactor .The reactor is equipped with an inlet and an outlet port, and
a mixing device. Mixing can be done by mechanical means or by gas
recirculation. A gas outlet at the top of the reactor removes gas, produced
during the digestion process. Often a reactor of this type is heated (e.g. by
combustion of the produced biogas or via cogeneration to produce electricity
and heat), for which heat exchangers are used in the reactor and heat insulation
to prevent heat losses.
BIODIGESTER GAS HOLDER
GROUP PHOTO

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REPORT ON INDUSTRIAL VISIT TO

MODI DISTILLERY, MODINAGAR

The School of Biotechnology Gautam Buddha University has organized an

Sugarcane molassess, a by- product of MODI SUGAR MILL is used

STAGE 1: STRAIN DEVLOPMENT

The strain of Saccharomyces cervisiae is developed and maintained by

STAGE 2: LABORATORY INOCULUM PREPRATION

To initiate the fermentation, a substantial number of yeast cells called

STAGE 3: INDUSTRIAL INOCULUM

After 12 h from stage 2, the contents are transferred to another flask

STAGE 5: INDUSTRIAL FULL-SCALE PRODUCTION

STAGE 6: RECOVERY OF ALCOHOL

DREAM PROJECT OF MODI DISTILLERY CHAIRMAN: ARTIC

Bagasse, a major residue of sugarcane juice extraction can be utilised

BIODIGESTER GAS HOLDER

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