Recover corn oil from your distillery’s syrup stream.
Chemosphere Engineering Consultancy delivers turnkey Distillers Corn Oil (DCO) plants for grain ethanol distilleries, from feasibility to commissioning, and supplies the emulsifiers, demulsifiers, dosing systems and oil marketing that keep them profitable. You earn more from every tonne of grain, with no extra feedstock.
Smarter Chemistry. Faster Separation. Better Recovery.
Consultancy, turnkey plants and process chemicals
One accountable partner for the whole corn oil business: we study your stream, build the plant, supply the chemistry and help you sell the oil.
Consultancy
Feasibility studies, syrup and oil-droplet analysis, process audits and troubleshooting to find where oil is being lost and how much you can recover.
Turnkey DCO plants
Process design, equipment supply, erection, commissioning and operator training for a corn oil plant integrated with your existing distillery.
Emulsifiers & demulsifiers
Formulated chemistry for emulsion breaking and emulsion stability, supplied with dosing systems, telemetry and ongoing technical support.
A second revenue stream from the grain you already process
Distillers Corn Oil is a valuable co-product of ethanol production. A DCO plant recovers it from the stillage syrup without changing your existing process or adding any feedstock.
Additional revenue
Sell recovered corn oil while your ethanol production carries on as before, improving resource use and profitability.
Better DDGS
Removing oil from the syrup produces reduced-fat DDGS that better suits the nutritional needs of many livestock diets.
Growing demand
As industries move to renewable inputs, DCO has become a sought-after co-product in domestic and international markets.
Future potential
India’s maize output grew from about 12.4 million tonnes in 2000 to an estimated 43–55 million tonnes in 2025, and is projected to reach 55–60 million tonnes by 2030.
Where DCO goes
Animal feed
A high-energy ingredient for livestock and poultry diets that raises dietary energy and supports animal health.
Biodiesel & renewable diesel
Its triglycerides are converted to fuel through chemical and hydroprocessing routes, making DCO an important feedstock.
Industrial uses
Oleochemicals, paints and coatings, inks, soaps, surfactants and emulsifier manufacturing.
Fits between your evaporator and dryer
The corn oil plant takes the syrup from evaporation, separates the oil, and sends the de-oiled syrup on to the dryer. The rest of the distillery runs unchanged.
- Syrup preparationSlurry received from evaporation
- Heating & dosingPreheating and demulsifier addition
- Treatment & reactionAgitated reactor with controlled residence time
- Oil–syrup separationHigh-speed disc separator
- Oil clarificationPolishing of the recovered oil
- Moisture & wax removalCooling and filtration
- Oil storageDay tanks and bulk storage
- Syrup to dryerDe-oiled syrup returns to DDGS
Why pretreatment matters
Most DCO technology was developed for US corn. Indian maize has more crude fibre and less fat, which raises syrup viscosity, lowers alcohol concentration and brings wax into the oil. Our process and chemistry are tuned for these conditions.
What drives oil recovery
| Component | Indian corn | US corn |
|---|---|---|
| Starch | 60 | 64 |
| Fats / oil | 3 | 4 |
| Ash | 1.5 | 1.5 |
| Crude fibre | 13.5 | 8.5 |
| Moisture | 13–18 | 14 |
US corn is largely genetically modified; Indian maize is not.
Break the emulsion, free the oil
Our demulsifier formulations are engineered for the specific emulsion-breaking challenges of distillery syrup. They work at optimised injection points and process temperatures to speed up separation and cut residence time.
In-house oil droplet analysis and absorbency testing show where your process is losing oil and which formulation suits your stream, so you use less chemical and get consistent results.
- Formulations tailored to your emulsion
- Better separation through optimised injection points and conditions
- Shorter residence time and higher throughput
- Lab testing to choose the most effective chemistry
- Reliable dosing systems for controlled, consistent application
- Real-time data telemetry and operator training
Small, stable oil droplets coalesce into a free oil layer that is cleanly separated and recovered.
Emulsifiers for stable, consistent blends
Alongside demulsifiers, we supply emulsifier formulations for industrial processes that need oil and water phases to stay blended. We match the chemistry to your oil phase, water quality and temperature, and confirm it with lab trials before supply.
Tested on your stream, not a datasheet
Every recommendation starts with a sample. Droplet analysis and bench trials tell us which formulation and dose work, so you pay for results rather than trial and error.
Higher oil yield
More corn oil recovered from the same syrup stream.
Less residence time
Faster emulsion breaking and higher throughput.
Consistent output
Stable recovery with controlled, monitored dosing.
A single-point solution for the corn oil business
From feasibility to commissioning to selling the oil, one team is accountable for results.
Technical expertise
Fast execution, with little or no additional utilities and no effluent generation.
Operator friendly
Low maintenance, compatible with multiple feedstocks, and low operating and chemical cost.
Chemical supply
High-grade demulsifiers at an optimum price, with dosing systems and telemetry.
Oil marketing
A sustainable market for the oil you produce, at premium rates.
Corn oil plant equipment
- Reactor with agitator and pump
- Syrup preheater
- Dosing system with tank, agitator and pump
- Disc-stack oil separator
- Oil collection tank with pump
- Oil cooler and filters
- Slurry collection tank with pump
Storage section
- Two day collection tanks
- Bulk collection tank
In continuous operation the plant runs as a closed system: heat comes from about 7 tonnes/day of steam condensate, with no additional heating required.
Estimate your payback
Defaults are for a 110 KLPD distillery with 3% oil in about 96 m³/day of post-evaporation syrup. Change the numbers to match your plant.
Get a free syrup analysis
Send us a sample of your syrup stream. We’ll analyse oil droplet size and free oil content and recommend a dosage and formulation for your plant, free of charge.
- Phone / WhatsApp+91 98225 27757
- OfficeSarthak Banglow, Sr. No. 90/A/1/1C,
Near Kukreja Heritage, Anand Nagar,
Vishrantwadi, Pune 411015 - Webchemosphereindia.com