Abstract: Methods of and system for growing and maintaining an optimized/ideal active yeast solution in the yeast tank and fermenter tank during the fermentation filling cycle are provided. A new yeast stage tank is used between the yeast tank and the fermenter tank allowing yeast to rapidly produce a huge amount of active young yeast cells for a fermenter during the filling period. A measurable and useful controlling factor, % DT/% Yeast by weight ratio (or “food” to yeast ratio), is used (e.g., % DT=glucose), which offers information on the health status of the yeast. The controlling factor is used to control the status of the yeast throughout the entire process.

Abstract: A novel dry mill process for producing pure starch, which can be used as a feed stock for bio tech processes. Corn feedstock is sent through a particle size reduction device, such as a hammer mill, to produce corn flour. The corn flour is screened into a small particle portion (which mainly contains “free” starch from the floury endosperm) and a larger particle portion (which mainly comprises the horny endosperm, germ pericarp and tip cap). The small particle potion is sent to a liquefication and a saccharification process to produce high Be corn syrup. A mud phase (mixture of oil, germ, and any light solid) is centrifuged. The light phase is sent to precoat drum filtration to produce clean corn syrup. Further, a novel wet mill process to produce starch and alcohol is disclosed. A three-section paddle screen can be used to separate starch from grit and fiber.

Abstract: Methods of and system for growing and maintaining an optimized/ideal active yeast solution in the yeast tank and fermenter tank during the fermentation filling cycle are provided. A new yeast stage tank is used between the yeast tank and the fermenter tank allowing yeast to rapidly produce a huge amount of active young yeast cells for a fermenter during the filling period. A measurable and useful controlling factor, % DT/% Yeast by weight ratio (or “food” to yeast ratio), is used (e.g., % DT=glucose), which offers information on the health status of the yeast. The controlling factor is used to control the status of the yeast throughout the entire process.

Abstract: A method of and system for making at least four types of animal feed products for various types of animals to maximize and use all of the components found in the whole stillage in an alcohol producing plant. The method includes liquefying, fermenting, distilling, performing a selective particle size separating into three streams, wherein the three streams contain a first stream of a large particle stream that is used to form a first animal feed suitable for ruminant animals, a second stream of a coarse protein stream that is used to form a second animal feed suitable for chicken and pigs, and a third stream of a fine particle stream that is used to form a third animal feed suitable for fish and pet. The third stream is further concentrated and enriched to have a syrup with 35%-80% of dry solid.

Abstract: A multi-zoned screening apparatus is disclosed for separating fiber from a liquid medium during, for example, a grain wet mill or dry grind process. The apparatus can include a housing having a first and second zone and situated adjacent one another along a length of the housing. A cylindrical screen having a plurality of openings is situated lengthwise within the housing to correspond with the first and second zones. A conveyor is situated lengthwise within the screen and includes an elongated shaft having a first and second conveyor section and along a length of the conveyor that corresponds with the first and second zones, respectively. Each conveyor section is configured to move material in a direction along a length of the screen. In one example, the first conveyor section includes vanes and a ribbon flight helically winding about the vanes, and the second conveyor section includes a plurality of paddles.

Abstract: Methods of and devices for recovering oil and protein and increasing production yields using two centrifuges in series or a centrifuge with dual oil and protein separating functions in a dry mill are provided.

Abstract: A dry grind ethanol production process and system with front end milling method is provided for improving alcohol and/or by-product yields, such as oil and/or protein yields. In one example, the process includes grinding corn kernels into particles then mixing the corn particles with a liquid to produce a slurry including oil, protein, starch, fiber, germ, and grit. Thereafter, the slurry is subjected to a front end milling method, which includes separating the slurry into a solids portion, including fiber, grit, and germ, and a liquid portion, including oil, protein, and starch, then milling the separated solids portion to reduce the size of the germ and grit and release bound starch, oil, and protein from the solids portion. The starch is converted to sugar, and alcohol is produced therefrom then recovered. Also, the fiber can be separated and recovered. Oil and protein may be separated and recovered as well.

Abstract: A method of and system for producing oil and valuable byproducts from grains, such as corn, in dry mills are disclosed. The method and system include dewater milling process after fermenting. Further, the method and system are able to produce oil without evaporating. Moreover, the method and system include one or more of the germ processing units, emulsion processing units, fiber processing units, high value protein producing units, and glycerol and inorganic salt producing units, such that high value byproducts are able to be generated.

Abstract: A disc mill includes an inlet configured to provide solid material for grinding to the grind plates in a smooth and constant manner. A solid ring is added around an outer circumference of the grind plates to control the grinded solid discharge rate. In some embodiments, the grind plates are configured with constant solid path way open area from row to row. The grind surface and solid pass way open area are maximized by increasing the relative tooth height compared to the tooth width. The teeth can be positioned according to a block channel configurations so as to force the solid material to pass along the grind surface of each row. A grind plate design program is used to enable conjunction of the design parameters with application variation, thereby enabling the optimum grind plate design to meeting various applications needed.

Abstract: Methods of and devices for extracting nutrients (such as, proteins, oils, hydrocarbons, antioxidants, organic antibiotics, minerals, and vitamins) from discarded plant wastes (roots, skins, seeds, stalks, leaves, and stems) using grinding and separation processes are provided.

Abstract: A dry grind ethanol production process and system with front end milling method is provided for improving alcohol and/or by-product yields, such as oil and/or protein yields. In one example, the process includes grinding corn kernels into particles then mixing the corn particles with a liquid to produce a slurry including oil, protein, starch, fiber, germ, and grit. Thereafter, the slurry is subjected to a front end milling method, which includes separating the slurry into a solids portion, including fiber, grit, and germ, and a liquid portion, including oil, protein, and starch, then milling the separated solids portion to reduce the size of the germ and grit and release bound starch, oil, and protein from the solids portion. The starch is converted to sugar, and alcohol is produced therefrom then recovered. Also, the fiber can be separated and recovered. Oil and protein may be separated and recovered as well.

Abstract: A dry grind ethanol production process and system with front end milling method is provided for improving alcohol and/or by-product yields, such as oil and/or protein yields. In one example, the process includes grinding corn kernels into particles then mixing the corn particles with a liquid to produce a slurry including oil, protein, starch, fiber, germ, and grit. Thereafter, the slurry is subjected to a front end milling method, which includes separating the slurry into a solids portion, including fiber, grit, and germ, and a liquid portion, including oil, protein, and starch, then milling the separated solids portion to reduce the size of the germ and grit and release bound starch, oil, and protein from the solids portion. The starch is converted to sugar, and alcohol is produced therefrom then recovered. Also, the fiber can be separated and recovered. Oil and protein may be separated and recovered as well.