Engineering of deep
grain processing plants
(biotechnology)

Deep grain processing refers to a technological process that allows obtaining dozens of high-tech, value-added products from grain crops.

During the biochemical breakdown of grain, starch, glucose, amino acids, bioethanol, protein concentrates, biogas, biomethane, and other components are extracted. This approach ensures maximum utilization of raw materials, minimizes waste, and creates closed production cycles — from agriculture to energy generation.

It is one of the key areas of bioeconomy development, combining energy efficiency, profitability, and environmental sustainability.

The technology involves complete decomposition of grain into its main components: starch, protein, fiber, and germ.

Key stages:

• cleaning and preparation of raw materials;
• milling and fermentation of starch to produce glucose or ethanol;
• extraction of proteins for feed or food industries;
• utilization of residues (husks, pulp) for biogas or biofertilizer production.

This approach makes it possible to obtain a range of products — from food ingredients to bioenergy solutions — with minimal resource loss.

Grain processing plants are complex, multi-level systems that include cleaning, separation, fractionation, fermentation, and drying processes. Unlike traditional mills, modern biorefineries transform grain not only into food products but also into raw materials for chemical, pharmaceutical, and energy industries.

Each stage is aimed at maximizing the extraction of useful substances and energy.

Pro-Energy implements integrated solutions where energy for production is generated from its own waste, making the enterprise almost energy independent.

Corn processing biotechnology makes it possible to obtain more than 20 types of end products — from starch, glucose, and sorbitol to bioethanol, feed proteins, and biogas. During fermentation and distillation, the grain components are separated with maximum efficiency.

By-products such as DDGS (dried distillers grains with solubles) are used in livestock farming, while gases are utilized for cogeneration of heat and electricity. This is an example of a closed processing system that integrates agricultural, food, and energy industries.

Deep wheat processing is a modern biotechnological process that allows obtaining a wide range of high value-added products from grain — from starch and protein concentrates to bioethanol and biogas.

Main stages of the technology:

• Cleaning and preparation of grain — removal of impurities, grinding, and moistening to separate fractions.
• Wet or dry milling — separation of starch, protein fraction (gluten), and bran.
• Fermentation of starch — production of glucose, fructose syrup, or bioethanol.
• Drying of by-products — production of protein feed additives (DDGS) for livestock farming.
• Energy use of residues — production of biogas or biofertilizers from waste.

Wheat processing technology turns traditional grain into a versatile raw material for bioenergy, food, and feed industries.

Deep corn processing is a multi-stage technological process that enables the production of dozens of valuable products from a single grain — for food, feed, chemical, and energy industries.

Main stages:

• Separation of grain into starch, protein, germ, and fiber.
• Fermentation of starch for the production of bioethanol, glucose, or fructose syrup.
• Separation of the protein fraction to create feed additives (DDGS, gluten, protein concentrates).
• Processing of corn germ into corn oil, used in food and industrial applications.
• Utilization of by-products (husks, fermentation residues) for biogas or biofertilizer production.

This approach transforms corn from an agricultural crop into a valuable industrial raw material for bioenergy, pharmaceuticals, and food technologies.

Deep soybean processing is a technological process aimed at fully utilizing the potential of soybeans to obtain high value-added products for the food, feed, energy, and pharmaceutical industries.

Main processing stages:

• Cleaning and preparation of soybeans — removal of impurities, dehulling, and grinding of the beans.
• Oil extraction — obtaining soybean oil used in the food industry and as a raw material for biodiesel.
• Defatting of meal — production of soybean meal, concentrates, and isolates that serve as protein additives for feed and food products.
• Use of by-products — extraction residues are used for the production of glycerin, biogas, or biofertilizers.

Dozens of products can be made from grain: flour, starch, bioethanol, protein concentrates, biogas, biomethane, bioplastics, animal feed, and organic fertilizers.

Modern Pro-Energy biorefineries allow integration of production processes so that from 1 ton of grain, not only food but also energy and industrial value can be obtained. This is the foundation of the “zero waste“ model — complete utilization of raw materials with economic benefit.

The grain processing cycle consists of several key stages:

• Cleaning and preparation of raw materials — removal of impurities, grinding.
• Enzymatic breakdown — conversion of starch into sugars.
• Fermentation — production of bioethanol or biogas.
• Distillation and rectification — purification of products.
• Drying and granulation of by-products.
• Waste utilization and energy generation.

This approach ensures waste-free production that meets European sustainable development standards.

The main products of deep grain processing include:

• food ingredients — starch, glucose syrup, gluten;
• bioenergy products — bioethanol, biogas, biomethane;
• feed components — DDGS, protein concentrates, bran;
• technical products — organic acids, glycerin, bioplastics.

All these products form the ecosystem of a biorefinery that ensures energy efficiency, profitability, and sustainable development of agricultural enterprises.

Dry and wet corn, wheat, rye, barley, as well as organic waste from sugar factories, grain processing, baking, etc. can be used for production.

A deep grain processing plant can be used for the sustainable production of food and feed, as well as chemicals, materials and energy. These resources are important for agriculture, manufacturing plants, the fuel industry, pharmaceuticals, and other industries.

The time for project implementation may vary depending on the volume of processing, geographical location, and other features of your request. We can calculate the exact construction time at the stage of creating a business plan. And the first step to determining the details is to sign up for a free consultation with a design engineer.

The average capacity of a plant can reach 70 liters per year. The actual production volume depends on the amount of biomass processed into bioethanol.

The average payback period for biogas projects is 5-6 years.

It doesn’t matter where your company is located. The plant eliminates dependence on the power grid and distribution networks. The plant is usually located near the raw material resource and consumers.

Pro-Energy bio-refineries do not require any special skills on the part of the customer. Our team will provide you with the necessary skills and operating instructions for safe and efficient use of the plant. After implementation, we stay with you to provide service and technical support.