In early 2024, Crystal Balaji commissioned its maize-based ethanol production plant, with a 150 KLPD production capacity. As one of the few 100% corn-based production units in India, the plant could have faced challenges in achieving full production capacity. Working hand-in-hand with Crystal Balaji’s production team, even before the plant’s commissioning, we were able to provide recommendations on capacity and process optimization.
The ambitions were clear: reaching the plant’s 150 KLPD production capacity. Our technical service team worked closely with the Crystal Balaji team – led by Sir Kartik Swarup, Owner. In such cases, one of the keys to success lies in the plant’s design. However, fine-tuning the fermentation process is also critical in unleashing the unit’s potential to produce ethanol efficiently. By optimizing propagation, fermentation batch cycle, and other parameters, the team was able to achieve full production capacity, and even slightly exceed it. Identifying areas for improvement, and smartly implementing process optimization were essential in this approach.
As Crystal Balaji looks to the future, this partnership laid the foundation for continued growth, with the plant’s operational capacity exceeding expectations. The future looks bright for this unit as we step into yield optimization efforts to further improve production.
“Working with the Leaf’s technical support team has been a very positive experience. Their expertise, hands-on approach, and commitment to our success have been instrumental in helping us achieve our production goals. We are grateful for their support and look forward to continued success in our partnership.”
– Kartik Swarup, Owner
