FermAxiom LLC — Home Page E-Modules Slides v1.1

E-Modules

Products 2026

Electronic Training Materials in the form of E-Modules and Video Tutorials provide focused, topic-specific,
self-paced learning of the bioprocess principles that underlie industrial ethanol manufacturing. The library
is offered at two levels. The Introductory E-Module is free and is available directly below this panel.
It introduces the format of the library and the overall structure of a dry-grind ethanol plant, so that
new users can judge the depth and style of the material before subscribing. Subscription
E-Modules make up the full library. Each module is organized around a single plant unit
operation or bioprocess topic and can be studied independently, so that plant personnel,
process engineers, laboratory staff, and research groups can go directly to the material
relevant to the problem in front of them. The modules draw on the same scientific basis
and worked examples that FermAxiom applies in its industrial support engagements,
and the video tutorials walk through calculations and interpretation step by step.
Content is continuously updated to cover new scientific and technological
developments, and subscribers receive revised material as it is released.
The four subscription series are shown on the following slides.

E-Modules: Ethanol Plant Unit Operations

Products 2026

Subscription library — one E-Module for each unit operation of a dry-grind ethanol plant, from grain receiving to product loadout.

01Grain Receiving & StorageTruck and rail unloading, sampling, aeration
02Grain Cleaning & MillingScalping, hammer mills, particle size distribution
03Slurry PreparationMixing, solids loading, backset ratio, pH control
04Cooking & LiquefactionJet cooking, alpha-amylase, viscosity, DE
05SaccharificationGlucoamylase dosing, SSF, residual starch
06Yeast PropagationPropagator design, aeration, nutrients, pitching rate
07FermentationBatch, fed-batch, continuous; kinetics, yield, cooling
08Contamination ControlBacterial load, antimicrobials, sanitation, monitoring
09Beer Well & CO₂ RecoveryBeer storage, scrubber recovery, CO₂ capture
10DistillationBeer column, rectifier, side stripper, energy balance
11DehydrationMolecular sieves, regeneration, water spec
12Stillage SeparationDecanter centrifuges, wet cake, thin stillage split
13Evaporation & SyrupMultiple-effect evaporators, fouling, syrup solids
14Corn Oil ExtractionSyrup oil recovery, demulsifiers, oil yield
15Drying & DDGSRotary dryers, WDGS/DDGS quality, thermal oxidizer
16Tank Farm & LoadoutDenaturing, storage, ASTM D4806, loadout
17UtilitiesSteam, cooling towers, process water, CIP
18Process Control & LaboratoryDCS, HPLC analytics, mass balance, QA/QC

E-Modules: FermAxiom Electronic Tools

Products 2026

Tool-specific E-Modules — step-by-step guidance for each FermAxiom calculator and model: inputs, method basis, and results.

01Cell Counter Calculator BasicHemocytometer counts, dilution factors, viability, and cell concentration
02Advanced Yeast Cell CounterImage-based counting, staining, budding index, and count statistics
03Yeast Pitching & Inoculum CalculatorPitching rate, inoculum volume, and propagation sizing
04Ethanol Suite: Inoculum & Seed TrainStage-by-stage scale-up, transfer criteria, and seed-train design
05Ethanol Suite: Medium FormulationCarbon, nitrogen, mineral, and vitamin requirements by stage
06Ethanol Suite: Fermentation SimulatorKinetic model structure, inhibition terms, and scenario runs
07Ethanol Suite: Yield CalculatorTheoretical and actual yield, carbon balance, and losses
08Fermentation Heat CalculatorHeat of fermentation, cooling duty, and heat exchanger capacity
09Ethanol Industrial Plant ModelInteractive 3D dry-grind plant, unit operations, and stream flows
10HDYC Yeast Plant ModelInteractive 3D fed-batch yeast plant, P&ID, and equipment layout
11Linking Tools into a WorkflowCarrying results from cell count to pitching, medium, and simulation
12Interpreting Tool ResultsUnits, assumptions, validity ranges, and comparison with plant data

E-Modules: Analytical Methods

Products 2026

Laboratory E-Modules — the analytical methods used to monitor ethanol fermentation, from sampling through coproduct and product quality.

01Sampling & Sample PreparationRepresentative sampling, quenching, filtration, and sample storage
02HPLC Analysis of Fermentation BrothSugars, ethanol, glycerol, and organic acids
03Yeast Cell Counting & ViabilityHemocytometry, vital staining, and automated cell counting
04Microbial Contamination TestingPlate counts, lactic acid bacteria detection, and molecular methods
05Starch & Residual SugarsEnzymatic starch assay, dextrins, and residual starch in stillage
06Solids, Moisture & DensityTotal and dissolved solids, refractometry, and density
07Ethanol DeterminationGas chromatography, density meters, and rapid in-plant methods
08Nitrogen & Nutrient AnalysisFree amino nitrogen, urea, ammonia, phosphate, and minerals
09Enzyme Activity AssaysAlpha-amylase, glucoamylase, and protease activity units
10DDGS & Coproduct AnalysisProtein, fat, fiber, moisture, and mycotoxins
11Fuel Ethanol QualityASTM D4806 parameters, water content, and denaturant
12Method Validation & QA/QCCalibration, linearity, LOD/LOQ, and control charts

E-Modules: Process Simulation, Modeling & Data Analysis

Products 2026

Quantitative E-Modules — building, fitting, and applying bioprocess models, and analyzing laboratory and plant data.

01Mass & Energy BalancesStream tables, component balances, and closure checks
02Stoichiometry & Yield ModelsTheoretical yield, biomass and byproduct carbon partitioning
03Microbial Growth KineticsMonod kinetics, substrate and ethanol inhibition
04ODE Fermentation ModelsBatch, fed-batch, and continuous model formulation and solution
05Parameter EstimationNonlinear regression, confidence intervals, and identifiability
06Fed-Batch Feeding StrategiesExponential feeds, oxygen- and RQ-based feed control
07Heat & Oxygen TransferkLa, oxygen uptake, cooling capacity, and transfer limits
08Scale-Up & Scale-DownPower per volume, mixing time, and similarity criteria
09Whole-Plant SimulationUnit-operation models linked into a plant flowsheet
10Techno-Economic AnalysisCapital and operating cost, cash flow, and sensitivity analysis
11Experimental Design & StatisticsDoE, ANOVA, regression, and response surface methods
12Plant Data AnalysisHistorian data, trending, statistical process control, and KPIs

Introduction to Ethanol Bioprocessing — FermAxiom E-Learning

FermAxiom E-Modules · Free example module

Introduction to Ethanol Bioprocessing

A narrated, animated video course on industrial ethanol manufacturing: from corn and starch chemistry to fermentation, distillation and co-products.

Free to watch
15 videos
1 h 53 min
Fundamental level
U.S. units with metric
English captions

About FermAxiom E-Modules

© 2026 FermAxiom LLC. All rights reserved. This module is offered free of charge as an example of FermAxiom E-Modules, for viewing on this website. It may not be downloaded, recorded, reproduced or redistributed without written permission.