DDGS
DDGS Processing & Drying Solution
Integrated Separation, Evaporation, Drying and Waste Heat Recovery for Efficient DDGS Production
Producing ethanol from corn, wheat and other starch-based feedstocks generates large volumes of stillage. Rather than treating this nutrient-rich stream as a disposal burden, ethanol producers can convert it into Dried Distillers Grains with Solubles (DDGS)—a valuable feed ingredient and an important source of additional plant revenue.
The challenge is energy.
Stillage contains a large amount of water, making evaporation and drying major utility consumers in a conventional DDGS plant. At the same time, excessive thermal exposure can negatively affect DDGS color, nutritional quality and storage stability.
Myande provides integrated DDGS processing and drying solutions combining solid-liquid separation, multi-effect evaporation, tube bundle drying, cooling and waste heat recovery.
The objective is simple:
Recover More Feed Value | Use Less Steam | Maintain DDGS Quality | Improve Ethanol Plant Economics
Complete DDGS Production Process
1. Stillage Separation
Whole stillage from ethanol distillation enters a two-phase decanter centrifuge, separating wet distillers grains from the clarified liquid fraction, commonly referred to as thin stillage.
Efficient mechanical separation reduces the amount of water that must subsequently be removed thermally.
2. Thin Stillage Evaporation
The clarified liquid is concentrated through multi-effect evaporation, recovering soluble nutrients as concentrated syrup while removing a significant portion of the water before drying.
3. Syrup & Wet Grain Mixing
The concentrated solubles are mixed back with the wet distillers grains, helping retain valuable nutrients in the final DDGS product.
4. Tube Bundle Drying
The mixed material enters a tube bundle dryer, where moisture is efficiently removed under controlled conditions to achieve the required final product moisture.
5. DDGS Cooling
After drying, DDGS is cooled to a suitable storage temperature, improving handling and reducing the risk of quality deterioration during storage.
Efficient Indirect Drying for Large-Scale DDGS Production
The tube bundle dryer has a major impact on both energy consumption and final DDGS quality.
Myande's tube bundle dryer transfers heat efficiently through the heating surfaces while allowing drying conditions to be controlled according to material characteristics and target moisture.
The system is designed for:
- Efficient heat transfer
- Continuous industrial operation
- Controlled product drying
- Stable discharge moisture
- Integration with waste heat recovery
- Reliable large-scale processing
More importantly, the dryer is engineered as part of the complete plant energy balance. Its exhaust heat becomes a useful energy source for upstream evaporation rather than simply an exhaust stream.
They trust and choose Myande
More than 1,600 complete plants have been supplied under Myande’s name in over 80 countries since 2003.
Behind every successful project is a great team. Our team is comprised of skilled individuals that share one common goal – Help our clients succeed.
What can we do for you?
We focus on supplying one-stop engineering service covering general layout plan, process design, R&D, equipment manufacturing, automatic control system, data integration, installation, supervision, commissioning, training and etc.
Our custom solutions come from a deep understanding of your needs, and we have the capability to complete each project from the design of the initial concept to manufacturing, installation, commissioning and delivery.
Solution Tailored to Your Needs
General Layout Plan
With a land prepared, the next thing you should consider is planning the general layout, which is a crucial foundation of a sustainable and cost-effective manufacturing.
Turn to us for help and we will present you the design for your plant by considering water, steam, electricity supply and etc.
Process Design
Combining our engineering expertise, industry know-how and practical skills with your knowledge, we provide the optimized and customized process design for your plant.
3D Plant Design
On the basis of plant layout design, combined with real situation, we can design a three-dimensional model of the entire plant. All the equipment, piping and instruments, any detail can be shown in the model, not only allowing you to have an intuitive understanding of the plant, but also providing overall information support for plant construction, equipment installation and future expansion.
Automatic Control System
We offer economical and most effective process automation solutions for the entire production line. Our RES automatic control system is developed based on PLC/DCS system.
Data Integration
From the perspective of the overall operation of the factory, Myande intelligent data integration management system collects basic data from raw grain procurement, warehousing, processing, inventory, sales and logistics, relying on the interconnection network system of each workshop. It provides real-time, accurate and traceable data reports for the current storage, processing and shipping.
Equipment Manufacturing
We owns in-house manufacture base of more than 130,000㎡ integrating R&D, production, project management which represents advanced engineering capability in the industry.
Installation and Commissioning
After finishing the installation of all machines, we offer on-site commissioning service to ensure compatible functioning.
Every move of the machine needs strong technical support from our experienced engineers. The only principle is that you can start manufacturing right after the commissioning.
Training and After-sales Service
Myande 360° Service Portfolio covers all your needs throughout the life cycle of your project. By minimizing your total cost of ownership, we help you stay ahead of the competition.
About Myande
Myande Group is a globally leading supplier of complete plants, equipment, and services for Oils & Fats, Starch & Derivatives, Fermentation, Evaporation & Crystallization, Material Storage and Handling and Smart Factory industries.
Myande Group currently has 1,600+ employees including 800 technical staff and 800 manufacturing workers. More than 1,600 complete plants have been supplied under Myande’s name in over 80 countries since 2003.
World-leading manufacturing base
In-house manufacture base of more than 130,000㎡ that integrates R&D, production, and project management, representing world-class engineering capability in the industry.
No Compromise on Quality
We are highly committed to Quality Assurance.
Our facilities and processes adhere to the highest local and international industry standards and certifications and are audited regularly for compliance.
With a global quality management system, we ensure that our customers all over the world receive high-quality, reliable products and solutions. We are well aware that our equipment have to function safely and efficiently for decades.
To effectively carry on the spirit of artisanship, improve the overall quality of front-line employees, we hold the “Workmanship Skills Competition" every year.
Certificates & Patents
At Myande, innovation is the result of the total process of developing an idea into a product or a new way of working which adds value to the business.
Over 600 registered patents and utility models demonstrate the company's innovation potential.
Our Global Presence
We focus on supplying one-stop engineering service covering general layout plan, process design, R&D, equipment manufacturing, automatic control system, data integration, installation, supervision, commissioning, training and etc.
Our custom solutions come from a deep understanding of your needs, and we have the capability to complete each project from the design of the initial concept to manufacturing, installation, commissioning and delivery.
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Lifecycle Service
Technical expertise and innovative products form the basis of your success. But we offer you even more: our extensive range of services gives you optimum support for your requirements and objectives in the long term.
Myande News & Insights
2,000TPD Rapeseed Crushing Plant Launched
Recently, a 2,000 t/d rapeseed crushing plant built by Myande Group for Daodaoquan Grain and Oil Co., Ltd. started operation successfully and started to yield qualified rapeseed oil and meal. Daodaoquan Grain and Oil Co., Ltd. is a comprehensive oil processing enterprise integrating production, scientific research, trade, warehousing and logistics of edible vegetable oil and its related by-products. This new rapeseed crushing plant incorporates a wide range of Myande core equipment possessing independent intellectual property rights, including the E-type extractor, hydraulic flaker, DTDC, conditioner, and other key equipment. To achieve flexible material incoming and discharging, Myande CCJL series sweep auger and CQJL series reclaimer are used. In addition, advanced energy-saving technology, negative pressure draining technology and intelligent safety technology are used to ensure the stable operation of the entire production line and excellent product index. With the concept of "creating the best performance for our customers", Myande cooperates with DaoDaoQuan to build a modern, energy-efficient, and environmentally friendly factory.
600,000 T/A Wheat Starch Deep Processing Project Successfully Launched
Recently, the 1st phase of Henan Hanyong's 600,000 tons (annual output) wheat starch deep processing project, designed by and installed under the guidance of Myande, has been smoothly commissioned, and contract for the 2nd phase was signed with Myande, marking the further extension of the domestic wheat deep processing industry chain. Henan Hanyong Biotechnology Co., Ltd. is one of the leading enterprises in agricultural industrialization of Henan province. It mainly produces edible alcohol with strong competitiveness and a high reputation in the market. Starch deep processing is one of Myande’s important business segments. After years of technology and experience accumulation in the field of starch deep processing, Myande has formed a complete set of production design system with a high degree of automation, stable operation and high product quality. In recent years, Myande has successfully established long-term strategic cooperative relations with multiple famous domestic and international enterprises. Combining with Hanyong's own industrial advantages, after in-depth research, efficient communication and repeated demonstrations, Myande has designed a set of production plan (as shown in the following figure) specially for the customer, and it can not only produce gluten and wheat starch, but also make better use of the mixed nutrient solution of process water and pentosan to produce alcohol, which will bring considerable economic benefits. The 1st phase project is a 500tpd wheat flour processing project, including a 3tpd gluten drying system and a 12tpd starch drying system. From beginning to end, the whole project lasted for 10 months. During the whole implementation process, from the plant layout planning, process design, intelligent automation design in the early stage, project service in the mid-term, to the installation, commissioning and training in the post stage, Myande’s rigorous, attentive and efficient one-stop service has won the unanimous praise of Hanyong. Through the joint efforts of Myande and Hanyong employees, a brand-new starch deep processing production line was successfully commissioned and started running smoothly, and all indicators were superior to the technical level of the same industry. In view of the pleasant cooperation in the 1st phase, Hanyong decided to cooperate with Myande again to expand its wheat starch deep processing output, and signed the 2nd phase project with Myande resolutely, namely 5t/d gluten drying system and 20t/h starch drying system. After which, Hanyong will become a high-quality gluten high-value conversion base with "the largest scale, the best environment protection and the highest level of research and development" in the industry in Asia.
Myande Awards 2022 “Spring Sunshine” Scholarship
In order to motivate employees' children to study hard and to enhance employees’ sense of belonging and happiness, on August 19, Myande held 2022 Myande Spring Sunshine Education Scholarship ceremony. Mr. Wangmu, vice chairman and Mr. Mao Weijiang, director in charge of manufacturing, participated in this ceremony and on behalf of the company presented scholarship stipends to children of Myande employees who are enrolled by four-year universities this year. In his speech, Mr. Wang highlighted that Spring Sunshine Scholarship is one of several company welfare benefits. It represents the company’s vision of moving forward with its employees and creating a better future together, and it reflects the company's care for the education of its employees' children and its high sense of social responsibility.
FAQ
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What are the biggest operating costs in a DDGS processing and drying plant?
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Drying is typically one of the most energy-intensive steps in DDGS production. However, total operating cost is also affected by solid-liquid separation efficiency, evaporation load, incoming stillage concentration, final moisture target, and heat recovery.
When comparing solutions, ethanol producers should therefore evaluate steam and electricity consumption per ton of finished DDGS, rather than dryer capacity alone.
An integrated stillage processing, evaporation, and drying system can significantly improve overall plant economics.
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How can an ethanol plant reduce the energy consumption of DDGS drying?
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The most effective approach is to avoid sending unnecessary water directly to the dryer.
After solid-liquid separation, thin stillage can be concentrated in an evaporation system before the concentrated syrup is recombined with the wet distillers grains.
This transfers part of the water-removal duty from mechanical drying to a more energy-efficient evaporation process.
Myande further integrates waste heat between drying and evaporation, helping reduce dependence on fresh steam and lower the energy cost of DDGS production.
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How does Myande reuse waste heat in DDGS production?
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In Myande's integrated DDGS process, stillage is first separated using a two-phase decanter. The clarified liquid is concentrated through multi-effect evaporation and then mixed with the wet distillers grains before drying in a tube bundle dryer.
Importantly, exhaust gas from the tube bundle dryer can be utilized as a heat source for evaporation.
This creates a cascading heat-utilization system in which thermal energy is reused instead of simply discharged, reducing the requirement for fresh steam in the evaporation section and improving overall energy efficiency.
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How does evaporation system design affect DDGS production cost?
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Thin stillage contains a large amount of water that must be removed before its soluble nutrients can be efficiently returned to DDGS.
A properly designed multi-effect evaporation system can concentrate these solubles using significantly better thermal integration than relying on the dryer to remove all of the water.
Evaporator design should consider feed concentration, viscosity, fouling tendency, target syrup concentration, available waste heat, and cleaning requirements.
The objective is to achieve the optimum balance between evaporation duty and final drying duty.
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How can DDGS drying preserve protein quality and nutritional value?
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Higher drying temperatures do not automatically mean better drying economics.
Excessive thermal exposure can cause overheating, darkening, and deterioration of feed quality. Drying conditions should therefore be controlled according to product temperature, residence time, moisture removal, and final quality requirements.
Myande's DDGS process integrates controlled drying and subsequent cooling to achieve the required final moisture while maintaining stable product quality.
The objective is to produce saleable feed ingredients, not simply dry material.
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How can final DDGS moisture be controlled while avoiding over-drying?
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Over-drying wastes energy and may negatively affect product quality, while insufficient drying can reduce storage stability and increase the risk of deterioration.
Stable final moisture requires coordinated control of:
- incoming material moisture
- syrup addition
- dryer heat input
- material residence time
- exhaust conditions
- final cooling
Automation can continuously coordinate these variables to maintain the required product specification while avoiding unnecessary thermal energy consumption.
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Should I evaluate the dryer separately or the complete stillage-to-DDGS process?
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The complete process should be evaluated.
A highly efficient dryer cannot compensate for poor solid-liquid separation, excessive thin-stillage volume, inefficient evaporation, unstable syrup concentration, or poor heat integration.
Myande integrates decanter separation, multi-effect evaporation, syrup handling, tube bundle drying, cooling, waste-heat recovery, and automation as one system.
This allows optimization based on energy consumption and qualified DDGS output across the entire process, rather than the efficiency of a single machine.
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What should I compare when selecting a DDGS drying solution supplier?
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Do not compare suppliers only by dryer evaporation capacity or equipment price.
Ask for comparable indicators covering:
- stillage processing capacity
- solid-liquid separation performance
- evaporator configuration
- waste-heat recovery strategy
- steam consumption
- electricity consumption
- final DDGS moisture and quality
- operating stability and cleaning requirements
- automation
- integration with the existing ethanol plant
The best solution is the one that produces consistent, saleable DDGS with the lowest practical energy consumption and lifecycle cost.
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