Process Automation

Ethanol – beverage quality

BCI worked with Golden Triangle Energy Cooperative (GTE) and Katzen International (Katzen) to turn a fuel ethanol plant into a high quality alcohol plant that provides the basic ingredient to both spirits companies that produce gin and vodka as well as pharmaceutical companies for products such as cough medicines, etc.

This project involved nearly 100 loops and a total of over 800 I/O.

The project required the replacement of a Bailey Symphony DCS system to a current platform that would permit an expansion from a fuel ethanol plant into a facility that could produce high quality alcohol. The project was executed in phases. The first phase addressed the grain handling front end of the plant in order to establish a proof of concept. The next phase was the rest of the plant and the start up was accomplished in a single week. Please see our video at —> high quality alcohol


Wild Turkey Bourbon

Since Wild Turkey had experienced an expansion of their market until they reached their full capacity, they needed to find a solution to increase their production capacity. Since they owned 700 acres, they were able to build an expansion nearby. BCI was selected to provide the automation for the expansion because we understood their need to maintain their organoleptic profiles and we understood their process.

This system involved over 1000 loops and over 2500 total I/O.

Please see our video at —> Wild Turkey Video


Other Processes

In addition to the showcase videos presented above, we have delivered emulsion processes for margarines, salad dressings, etc.

Modified starches resemble a specialty chemical process in that not only high-accuracy batching is required, but also sophisticated pH management along with the temperature control for both exothermic and endothermic reactions.

Cooking extrusion is a process in that ingredient additions are metered as a function of overall rate and the zone temperature controls for each of the barrel extrusion zones requires attention and the temperature control of the pre-conditioning cylinder so that the proper product characteristics such as mouth-feel, bowl-life, conversion-rate, etc. could be achieved.

Drying applications for both pet food and cereals involve both flow and temperature control whether it be spray drying, drum drying or multi-pass, plenum dryers.