Abstract: System for and method of producing a pure starch slurry and alcohol by using combined corn wet and dry milling processes. A simple and lower cost process to obtain starch inside floury endosperm is provided. The starch can be highly purified to meet green technology process needs. The remaining starch inside the corn kernels can be used as feedstock for alcohol production and to produce valuable co-products such as oil and various animal feeds.

Abstract: This novel corn milling process includes a continuous steeping step, early separation of easy-to-access starch (e.g., starch in the floury endosperm part of a corn kernel), fine milling to secure germ protein without the use of solvents or heat, and performing a phase separation to collect the product of fermentation. The continuous steeping process uses a continuous steeping tank. The steeping liquid, which includes probiotics, flows in from the bottom of the tank in a countercurrent flow. Other features include efficiently producing high purity starch or sugar using the starch in the floury endosperm of the corn kernel, producing alcohols such as ethanol and butanol that can be used as sustainable aviation fuel or feedstock for sustainable aviation fuel, and producing a high protein animal feed product that includes yeast and germ protein without using toxic solvents.

Abstract: The present disclosure provides a two-step liquefication (e.g., using a high (>23 Be) and a low Be (<5 Be) liquid media) process in a dry milling process/plant. The dry milling process comprises liquifying starch from milled corns making a liquefied starch slurry in a first liquefication tank having a slurry >23 Be, performing a first solid/liquid separation using a first paddle screen after the liquifying starch, soaking, cooking, or degrading protein in a second liquefication tank with a slurry <5 Be, and performing a second solid/liquid separation using a second paddle screen after the soaking, cooking, or degrading protein in a second liquefication tank.

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: 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: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

Abstract: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

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: 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: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

Abstract: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

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: 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 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 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: 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: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

Abstract: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.

Abstract: The present invention relates generally to corn dry-milling, and more specifically, to methods for producing a high protein corn meal from a whole stillage byproduct produced in a corn dry-milling process for making ethanol and a system therefore. In one embodiment, a method for producing a high protein corn meal from a whole stillage byproduct includes, in a corn dry-milling process for making ethanol, separating the whole stillage byproduct into an insoluble solids portion and a thin stillage portion. The thin stillage portion is separated into a protein portion and a water soluble solids portion. Next, the protein portion is dewatered then dried to define a high protein corn meal that includes at least 40 wt % protein on a dry basis.