Banner-Jonny-Cropper

Can you beat three gallons per bushel?

Can you beat three gallons per bushel?

There are plenty of ways to increase your ethanol yields, but they all hinge on one key factor: knowing what’s happening inside your processes at every moment. 

That’s where the IRmadillo™ comes in. This powerful real-time analysis tool provides continuous, precise data for all your yield improvement projects.

“Increases plant stability and productivity”
“The most robust instrument we’ve seen in the market”
spacer2
IRmadillo-Logo-white
Irma-landing
spacer2

Real-time analysis for total process control

“Gives us better control … by providing real time information on how fermentation kinetics are progressing”

Introducing the IRmadillo: Revolutionizing Fuel Ethanol Production

Our latest animation showcases the innovative IRmadillo , designed to detect lactic acid, acetic acid, and much more in real-time during the ethanol production process. This cutting-edge solution enhances efficiency and accuracy, ensuring optimal production quality.

DOC1131 (email) Animated Ferm Plot

This video shows concentration traces for ethanol over time, DP4 and lactic acid. Watch how the batches progress:

- The first is fine – a perfect batch, with an ethanol drop of 14.1%.
- The second batch is low yielding. Something has gone wrong: its drop is only 12.7%. And watch the lactic beginning to trend upwards at the end – a warning of more trouble ahead?
- The third has a catastrophic lactobacillus infection. Its yield gets wiped out. The plant loses money. The operators lose time.

The graph shows the disaster as it unfolds. The IRmadillo sees the spike a full 8 hours before the HPLC does. Can you afford to wait 8 hours to know something’s gone wrong?

Built tough, the IRmadillo is designed for the rigors of industrial production – it can be installed directly into manufacturing lines without worry. With no moving parts, it stands up to vibrations, impacts, and general movement.

Despite its rugged nature, it delivers laboratory-grade accuracy, continuously measuring the concentrations of a huge range of chemical substances.

With the IRmadillo’s real-time monitoring, you get the reliable data you need to optimize every step of your production process, leading to higher yields and better overall efficiency.

If you want to exceed 3 gallons per bushel, there’s no better way.

"IRmadillos … have multiple benefits for an ethanol plant”
“Helps run fermentations [that are] more stable, and as close as possible to ‘golden batch’ conditions”
Process-Diagram-full-25
“An early warning system … to detect potentially faulty fermentation processes [when] correction is often still possible”
“Allows identification of small deviations from your standard fermentation curve that otherwise remain unnoticed”

What our users say

“The IRmadillo is the most robust instrument that we have seen in the market for real time monitoring of ethanol fermentation. It gives us better control of the fermentation process by providing real time information on how fermentation kinetics are progressing, in other words, how the sugars are being consumed and converted into ethanol”

Julian Parra, Engineering and Technology
Manager Pannonia Bio

"IRmadillo online analyzers, installed on fermentation vessels, have multiple benefits for an ethanol plant: because of their easy integration into the plant DCS system, they can work as an early warning system for plant operators to detect potentially faulty fermentation processes at a moment when correction is often still possible. Further, the continuous measurement allows identification of small deviations from your standard fermentation curve that otherwise remain unnoticed. This knowledge helps to run more stable fermentations, as close as possible to 'golden batch' conditions, which in turn increases plant stability and productivity. The system is also an ideal tool for process engineers when testing new fermentation recipes, like new yeast strains, new enzymes, or other chemicals, and different process settings”

Technical Director
Biofuels Plant in Western Europe

"We're excited to fully implement the IRmadillo with our operators and see its true potential, especially given the rapid advancements. I’m really excited to see where the technology will go in regard to fermentation monitoring. The Keit team’s impressive engineering and data analytics expertise have made them a pleasure to work with”

Dakin Nolan, Chemical Engineer and Environmental Specialist
United Wisconsin Grain Producers

About the IRmadillo

IRmadillo’s unique technology

The IRmadillo was actually developed for use on Mars, as part of the UK’s contribution to the Mars space program. Manufactured by Keit Industrial Analytics, the device now has a secure and practical commercial niche in many earth-bound industrial processes.

What can IRmadillo measure?

If there's any chemical you’d like to measure in real-time, it’s likely that IRmadillo is the tool to do it. It's not designed to replace HPLC in terms of error margins or detection limits, but it offers far more frequent data over shorter intervals. This means you get real-time insights that guide you when to take HPLC extracts, helping to deploy staff more efficiently and effectively.

How does IRmadillo fit into my processes?

The IRmadillo’s diamond-tipped probe is built to handle Clean-In-Place (CIP) practices, including caustic washing. Rated for up to 600 psig (40 barg), it can withstand direct exposure to caustic streams. With an operating temperature range up to 430°F (220°C), it’s ideal for use in distillation or liquefaction.

Sealing options for the probe include a straightforward port and flange assembly for secure tank integration. For added safety, an intermediate ball valve can be provided to allow probe removal mid-fermentation if necessary.

Install-web

What output will I see when I use it?

The IRmadillo’s software includes built-in calibration and performs real-time measurements that provide continuous updates on chemical concentrations (typically in %wt, but adjustable to your preferred units) throughout the process. Data can be exported as text files for further analysis, aiding in process optimization.

Real-time concentration data is sent directly to your DCS, PLC, or SCADA via standard communication protocols like OPC-UA or Modbus TCP over Ethernet, seamlessly integrating with existing control systems.

Installation and calibration

The IRmadillo is designed for seamless integration into your processes with a “fit and forget” setup. It can be installed directly through an existing flange into tanks, with or without a ball valve for isolation, or fitted into recirculation pipework. The instrument communicates directly with your DCS or control system, making it an easy addition to plant operations. Calibration and maintenance support programs are available to keep everything running smoothly.

“An ideal tool for process engineers testing new fermentation recipes … and different process settings”
“The Keit team's impressive engineering and data analytics expertise have made them a pleasure to work with”
“I’m really excited to see where the technology will go”

Rent or buy

Rental

Want to try out an IRmadillo? We can bill you monthly for an agreed span of time. Easy to renew, you have control over how long you keep it – from a few months to an even longer rent-to-own plan.

Purchase

Own your IRmadillo to monitor any process on-line and in real time as you see fit.

I’m interested. What’s next?

Fill out the form below or email us at info@irmadillo.com. A local representative will be in touch to see how IRmadillo could help improve your yields.