By K .P. SINGH

• Established in 1943.

• Among one of the oldest distilleries of the country.

• Renovation, Expansion and Modernization converted Radico into the Most Modern and Largest Potable Distillery of India.

• Replaced all the old plants by new most modern, DCS controlled Wash to ENA plants.

• Radico is an ISO 9000 (Since 2001 ) & 22000 (Since 2012).

• Obtained Koscher Quality Certificate for our Grain and Molasses during 2013 for ENA exports out of India.

• We are the First Having Biogas Plant Established in 1986-87.

• Radico is having SAP System for Integration of all the function of Organization as System Control.

• Up-Gradation & Modernization of Boilers

• Self reliance in power generation

• Modernization of distillation

• Modernization of fermentation

• Modernization of Bottling

• Up-gradation of ETP

• Backward integration ( Pet bottle plant & bottle Printing Plant)

• We had natural draft boilers till 1984. These

boilers were very inefficient.

• Since 1984 we started up-grading our boilers

and installed forced draft boiler with Turbo-

grate.

• 1988 we started feeding Bio-Gas in our boilers

which made us self sufficient in fuel and

increased consistency in steam pressure .

• We had natural draft boilers till 1984. These

boilers were very inefficient.

• Since 1984 we started up-grading our boilers

and installed forced draft boiler with Turbo-

grate.

• 1988 we started feeding Bio-Gas in our boilers

which made us self sufficient in fuel and

increased consistency in steam pressure .

• We modernized our batch fermentation By

installing PHE for Fermenter cooling in place

of surface cooling .

• Installed temperature indicators in each

fermenter for better temp. control of

fermenters.

• Installed series of Sludge settlers in order to

have clearer wash for distillation.

• We have installed improved batch

fermentation in our Molasses

Fermentation.

• Fermentation tanks are MS epoxy coated

and covered at the top for CO2 recovery.

• With High Brix Fermentation we are able to

maintain 9.5–10.0% Alcohol in Wash in a

Molasses having only 42-43% TRS.

• Fermentation Efficiency is maintained between 91.5-92.0% with efficient process controls during fermentation.

• Fresh yeast is used for every fermentation tank.

• Cell concentration in pre-fermenters is maintained at 4 X108 .

• With the recycling of Spent Lees and condensate water as dilution water, fresh water consumption in fermentation is reduced by about 80% and water born contamination is almost Zero.

YV.No Yeast Vessels Microbiology

Initial Sp.

Gr

Final

Sp. Gr Temp

Aeration

hrs

Yeast Cell

Concentration

Alc

% TBC WY MOLD

YV-1

1.044-

1.046

1.024-

1.026 35.0 10.0 hrs 1.50 - 1.60 x 108 < 1.0 NIL NIL NIL

YV-2

1.044-

1.046

1.024-

1.026 35.0 10.0 hrs 1.90-2.0 x108 < 1.0 NIL NIL NIL

YV-3

1.044-

1.046 1.024 35.0 10.0 hrs 2.20-2.40 x 108 < 1.0 5 / ML NIL NIL

PF.

No Prefermenter Microbiology

Initial

sp.gr

Final

sp.gr Temp.

Aeration

hrs

Yeast Cell

Concentration Alc % TBC WY

PF-1

1.046-

1.048

1.022

-

1.024 35.0 10.0 hrs

3.30 – 3.40 x 108

1.00-1.20 1 - 2*102 1--2 x 102

ParticularsNorm without jet

cooker

Fermenter no-1

(Culture Yeast)

Fermenter no-2

(Culture Yeast)

Fermenter no-3

(Culture Yeast)

Fermenter no-2

(Culture Yeast)

Fermenter no-3

(Culture Yeast)

Fermenter no-4 (DRY

Yeast)

Fermenter no-5

(Culture Yeast)

Date 04.02.16 05.02.16 06.02.16 06.02.16 07.02.16 07.02.16 08.02.16

DS % in fermenter 30-33 33 33 33 33 33 33 33

Flour ( Ton) 115-118 118 118 118 117 117 117 118

Starch % 60--62 % 66.0 66.0 66.0 66.0 66.0 66.0 66.0

YCC in Bub /ml 3.20- 3.30 *108

3.45*108

3.35*108

3.35*108

3.35*108

3.35*108

3.40*108

3.35*108

Alcohol % 12.0 - 13.0 13.95 14.02 14.02 14.08 13.96 14.01 13.92

Residual Sugar 0.20-0.25 0.28 0.29 0.29 0.29 0.25 0.26 0.26

Residual Starch 0.80-0.90 0.78 0.85 0.85 0.85 0.88 0.78 0.76

Final Gravity 1.000--1.005 1.005 1.006 1.006 1.002 1.002 1.003 1.002

Fermentation Time 38--42 42.0 42.0 42.0 42.0 42.0 42.0 42.0

FE% 91.8 -92.0 % 92.19 92.23 92.29 92.23 92.26 92.19 92.26

Alcohol % after 10 hrs

• Cooling of Fermenting Wort through Heat

Exchangers for optimizing fermentation efficiency .

• Cleaning of Fermentation Tanks through Spray Balls

Water Jet to save Water.

• Use of cleaning agents for maintaining aseptic

conditions after washing of Fermentation Tanks

through CIP System.

• Adequate nutrient dosing for facilitating quick

fermentation.

We have installed covered fermentation tank in order to

recover CO2.

CO2 is recovered and sold in Liquid and Dry Ice form.

We are using our own CO2 for captive usage for RTD

Bottling.

• Till 2001 we had atmospheric Distillation plants of RS and RS to ENA.

• In 2001 we installed our First 55 KL multi-pressure Wash to ENA plant with PLC based control system. Plant capacity increased from 46000KL/ Annum to 60,000 KL/ annum.

• In 2006 we installed 80 KLPD Grain Spirit plant with further improved DCS control system.

• In 2012 we improved Molasses Distillation plant by installing new multi-pressure with integrated evaporation system ( replacing old RS and RS to ENA plants) in order to reduce effluent volume.

• Till 1987 we had lagoons for effluent

treatment .

• In 1987 we were amongst the first few

installing Thermo-philic Bio-digesters on AQUA

TECHNOS technology

• In 1991 we installed Extended Aeration

system.

• In 2005 we installed our First RO Plant.

Our focus has been mainly on following...

A> Effluent Volume Reduction and Controls:

Reduced Effluent Generation through Multi Effect Evaporators and RO Plant.

Improved efficiency of RO Plant by improved TSS reduction system through installations of series of Degasser, Settlers, Lamella Clarifier and Diffused Floating Aeration (DAF) Mechanism with the help of Special Polyelectrolyte.

B> Water Usage Reduction:

Recycling of Lees, Process Condensate and Permeate.

Treatment of Recycling Stream based on it’s Characteristics.

C> Energy Sustainability:

Self sufficient on Captive Power generation.

Periodic Energy Audits

Implementation of Encon Proposals

S.NO. GURANTEED PARAMETERS UNIT VALUES

1 Feed to Evaporator TPD 1690

2Alcohol to Spent wash Ratio

(Before Evaporation)Ratio 1 : 9

3 Initial Solid in Concentration %W/W 12

4 Final Solid in Concentration %W/W 22

5 Spent wash Volume Reduced to TPD 930

6Alcohol to Spent wash Ratio

(After Evaporation)Ratio 1 : 5

7

Total Process condensate

generated from Evaporation

Plant

TPD 760

8Thick Sludge separation at

Filter Press M3/day 90

9 Volume Redcution at RO % 58 ~60 %

10Final Spent wash Volume for

Bio-compost M3/day 390

11Alcohol to Spent wash Ratio

(After RO)Ratio 1 : 2

Note : Till Now we have achieved >60% ( 1: 4 Ratio ) reduction in overall effluent volume

and targeted to have 80% reduction after stabilization of currently installed systems.

THERE ARE TWO OPTIONS OF EVAPORATION

1. EVAPORATION OF SPENT WASH THROUGH INTEGRATED / STAND ALONE

EVAPORATORS.

2. EVAPORATION OF BIO-METHANATED SPENT WASH THROUGH

INTEGRATED / STAND ALONE EVAPORATORS

RADICO HAS INSTALLED INTEGRATED EVAPORATORS OF SPENT WASH

NO EXTRA STEAM IS REQUIRED, EVAPORATION IS CARRIED OUT

USING ALCOHOL VAPOURS.

COMPACT PROCESS & SMOOTH OPERATIONS IN HANDLING &

CONCENTRATING SPENT WASH. STRUCTURAL COST IS REDUCED AS

THE STRUCTURE FOR EVAPORTION PLANT IS MERGED WITH THAT

OF THE DISTILLATION PLANT.

LESS MANPOWER IS REQUIRED, BOTH DISTILLATION & EVAPORATION

PLANTS CAN BE OPERATED BY A COMMON OPERATOR.

• Reduced Effluent Generation through Multi Effect Evaporators and RO Plant.

• Recycling of Lees, Process Condensate and Permeate.

• Treatment of Recycling stream based on it’s Characteristics.

• Challenges of TSS reduction :

Improved efficiency of RO plant by improved TSS reduction system through installations of series of Degasser, Settlers, Lamella Clarifier and Diffused Floating Aeration (DAF) Mechanism with the help of Special Polyelectrolyte.

• Radico has implemented all the above with a significant Capital Investment, now it’s the time for Technology providers to establish the design norms to achieve 60% Permeate from RO

• Project is under delayed stabilization phase with Technology Provider since last 4 month .

• Radico is one of the Pioneer

to accept and introduce the

new Technologies.

• For the First Time in India

we have installed the DAF

System on Distillery Effluent.

• TSS Reduction thru DAF is

around 38%.

Project is under establishment with Technology Provider

1. Installation of Degasser and

Series of Clarifiers with

Filter press.

2. An additional 90M3/Day of

Thick sludge will be

separated through this

Filter Press.

3. Above Separated sludge can

be directly sent for mixing in

Biocompost.

Project is under establishment with Technology Provider

1. High TSS in Digester

Outlet (20000 ~22000 )

2. Low Efficiency of RO System due to High TSS in Digester Outlet Effluent.

3. Permeate recovery only

about 45%.

1. Installation of Degasser and Series of Clarifiers with Filter press.

2. Addition of Special Poly-electrolyte for better settling and Series of Lamella Clarifiers Followed by DAF System.

3. Designed to achieve Up to 60% high grade permeate recovery after commissiong of above systems.

4. The equipment has been recently

commissioned and expected to achieve the design norms

Lamella

Degasser

Filter

Press

RO-II

RO-I

RO-II

NO Bio-Composting in

Rainy Season

• Molasses Distilleries

face problem in Bio-

Composting in Rainy

season.

Covered Bio-Composting

• Radico is having ~50 Acres of Total Bio-

composting Area.

• About 6 acre Area was utilized as Covered

Bio-composting since two years and

practicing uninterrupted composting in

rainy season in covered area.

• Further 8 Acres Covered Bio-composting

area added during current year.

• Now we have 14 acres of covered Bio-

composting..

Stream Recycle TO

1. Rectification, Pre-rectifier column

Lees Recycle

Fermentation Recycled

2. Vacuum Pump water recycle Fermentation 95% recovery

3. Steam Condensate Recycle Boiler 98% recovery

4. Process Condensate recycle Fermentation 95% recovery

5. CO2 Scrubber Water recycle Fermentation 98% recovery

6. RO Permeate recycle Cooling tower ,

Fermenters and

Gardening

100% recovery

Water Consumption / BL of

Alcohol Before adopting

recycling Systems

12 Liter / BL

Targeted Water Consumption

/BL of Alcohol

7 Liter / BL On achieving 100%

guaranteed norms

supplied by Technology

Provider

S.No Stream Recycled Year -2013-14 Year -2014-15 Year -2015-16

under

Implementation

1 Pre-rectifier & Rectification

Column Lees

Recycled to

Fermentation

House

2 Vacuum Pump water Recycled to

Fermentation

House

3 Steam Condensate Recycled to Boiler

Section

Recycled to Boiler

Section

4 CO2 Scrubber Water Recycled to

Fermentation

House

5 Process Condensate Recycled to

Cooling Tower

6 RO Permeate Recycled to

Cooling Tower

Water Consumption /

BL of Alcohol 18.0 12.0 7.0

Total Water Savings = 95 %

Process Pumps

From All Sections

Tank

Make up

Vacuum Pump /

Air Blower

Tank

CWR

CWS

Cooler

Make up

Total Water Savings = 95 %

• Radico has conceived the optimum utilization energy resources available in the complex by setting up TBW boiler. Biogas is a bio product in the distillery and by utilized importance of energy conversation of firing the same in boiler.

• Also we have one rice husk fired CBL Boiler for making steam and then making power out of it by feeding into turbine.

• Radico has set up a good profit center in the form of Cogeneration Plant and two Bio Gas Gensets. At present Cogeneration Plant and Bio Gas Gensets caters 100% Captive Consumption of Steam and Power to Radico.

• Radico is conducting periodic Energy Audits and implementing the Energy Efficient Programmes.

• Radico is continuously participating in the National Energy Award nominations of Bureau of Enginery Efficiency (BEE) arranged thru Ministry of Power.

• With the implementation of various energy conversation measures as an ongoing practice, there is steady decline of specific energy consumption. Last three years specific energy consumption figures are shown below:

Note : During Q2 of FY 2012-13 Integrated Evaporators were installed at both

sections of Alcohol Plant.

SN DESCRIPTION UNIT 2013-14 2014-15 2015-16

(Targetted )

A: Steam Saving

1 Specific Steam Consumption

in Wash to ENA (Molasses)KG/BL 3.43 3.41 3.38

1 Specific Steam Consumption

in Wash to ENA (Grain) KG/BL 3.74 3.58 3.54

B: Power Saving

1 Specific power Consumption in

Wash to ENA (Molasses) Kwh/KBL 114 135 132

2 Specific power Consumption in

Wash to ENA (Grain)Kwh/KBL 301 300 294

• Replaced all the old un-efficient motors and pumps with the new

highly efficient pump and motors.

• Adopted Dyno Drive Systems for Flexibility in loads.

• Overhead Cooling Tower Basins to provide positive suction head

for pumps.

• Power Generation through highly efficient Bio-Gas Engines of

MWM, GERMANY.

• Installation of VAM Integrated Chilled Water System for Air

Conditioning requirement from Bio-Gas Engines.

• Installation of Temperature Sensors at Cooling Tower Fans to save

the power during Winter Season.

• Timer installation on Street and Plant Lights

• Replacement of Copper Chocks with Electronic Chocks.

Savings achieved through above Heat Integration

is equivalent to 1800 Kg/Hr of Dearator Steam.

Biogas Engines ( Two Nos.)

Rated Capacity - 1200 Kwh

Maximum Capacity– 1080 Kwh

(@ 90% Efficiency)

Captive consumption – 114 Kwh

Net Generation – 966 Kwh

• We have replaced all the manual and low

speed bottling lines with most modern high

speed washing and bottling machines.

• We have our own PET bottle production unit

in order to ensure food grade quality of PET

bottles.

• We have our own Frosting and Bottle printing

facilities .

• By adopting continuous modernization and

UP-gradation we have been able to convert

our very old distillery into a largest potable &

Most Modern distillery of the country.

PRINTING MACHINE

• We are pleased to inform that CONTESSA RUM has

won GOLD MEDAL at the New York World Wine & Spirits

Competition held in Sept 2014.

• Other Winners from our Brand Portfolio include:

• Magic Moments Premium Grain Vodka – Silver Medal

• M2 Remix Chocolate Vodka – Silver Medal

• M2 Remix Orange Vodka – Silver Medal

• M2 Remix Green Apple Vodka – Bronze Medal