There’s protein and profits in fermented corn stillage…but they’re not easy to get to. Proteins are delicate and maintaining quality specs is tough. Bepex equipment protects protein quality while dramatically reducing utility requirements and emissions from processing.
Ethanol plants have become biorefineries, capable of producing value-added products from the stillage left after fermentation. One product – proteins for shelf-stable, high-protein animal feed – can be especially profitable. But traditional drying technologies struggle to handle highly cohesive, high-protein feeds. The Bepex PCX Dispersion Dryer delivers better control over product quality while utilizing far less utilities and floor space.
Innovative Equipment. Better Product.
High-protein feeds are easily damaged in the drying process. Traditional dryers are prone to build-up and burning, which degrades protein. Our proprietary PCX dispersion drying technology dries non-pumpable, water-laden solids without build-up or excessive heat input. Pair it with upstream mechanical separation and filtration equipment to reduce the thermal energy required and drastically lower emissions.
Less Space. Better Cap Ex.
Space is at premium in many fermentation processing plants. But traditional dryers take up massive amounts of floor space – especially compared to the production capacity actually needed. The PCX takes up far less space, and operates with far lower expenses, to produce the same or more product than old-school technologies. And that means a better cap ex return.
Improved Sustainability and Carbon Intensity Score
The Bepex process uses less space, less utilities and has the potential to lower the overall carbon intensity of the production processes. This is cutting edge protein processing technology. That’s why major producers work with our Process Development Center to create continuous production systems to improve production and processing sustainability.
Better Protein Processing from Bepex
Drying proteins without damage is a challenge in producing corn-derived protein ingredients. Led by the innovative PCX flash dispersion dryer, Bepex offers the industry’s broadest range of drying technologies. Bepex focuses on providing superior control over drying, lower operating costs, and high capacity in a compact footprint. The result is a better product, improved sustainability and better cap ex return than spray, rotary, ring, or other traditional drying technologies.
As the protein content increases, so do the cohesive tendencies in the resulting solids. Traditional dryers often leave clumps in solids after extraction. Our RP Disintegrator delumps high-protein solids prior to product collection and transportation. It eliminates lumps of product without further reducing the actual particle size, protecting your already on-size material.
Drying under a vacuum lowers the evaporation temperature of fluids. That allows dying at lower temperatures, protecting protein quality during processing. It’s an innovative drying technology, especially suitable where there is a volatile organic compound in the material.
All new inquiries begin with a feasibility study. These studies aim to provide preliminary insights into the viability of a commercial process. Using as little as 100 grams of material, we can begin early process design, develop plans for pilot-testing and/or confirmation, and begin providing early economic estimates. Our experience across our wide range of technologies gives us a unique ability to provide quick feedback on the feasibility of your process.
From our learnings, we’ll begin the process development work. The primary work in this phase takes place in the form of pilot-scale testing in our Process Development Center. Our pilot tests look a bit different than what you may have experienced in the past. Each test is designed to measure the system performance and feasibility rather than that of any single machine.
Each system is custom assembled for each test. Our goal is to provide as much of a pilot-scale simulation as possible while gathering scale-up data to deliver on commercial capacities. When a certain technology proves ineffective, we’ll draw from our range of options to determine if there is a better fit. The Process Development Center is our sandbox to build, test, and revise to ensure we get every detail right.
With a successful pilot simulation completed, we now have everything we need to scale up and provide proposals for capital equipment with included performance guarantees.
System Design And Build
After receipt of the purchase order, we begin with both equipment and system engineering. Each proprietary technology we sell is custom-designed and built per application. We do not have any off-the-shelf units. At this stage, your exact system begins to take shape, including auxiliary equipment, process flow diagrams, process and instrumentation diagrams, safety provisions, and more.
After delivery and installation of your new system, Bepex will provide a mechanical check to ensure everything is placed according to plan. This is followed shortly thereafter by system commissioning. This is where our pilot-scale simulations become invaluable, as our team of application engineers, controls technicians, and sales engineers begin working with your team to successfully bring your system online.
At this point, you’re up and running at rate, producing a quality product, but our work doesn’t stop there.
Following commissioning, Bepex remains a reliable partner, providing quality OEM parts, immediate field service, process optimization, training, system troubleshooting, and more. We have consistently had high customer retention rates, and we believe it is due in large part to our comprehensive approach to serving our customers long after the original sale.