How did MCE's BioFuels Automation become the leading expert in ethanol processing?
Biofuels Automation, an MCE company, has been a trusted name in industrial process automation for over 60 years. Founded in Minnesota and steadily expanding across the Midwest, we’ve carved out our place in a specialized niche—providing advanced instrumentation and valve solutions for industries that measure and control flow, pressure, temperature, level, density, proof and liquid analytics.
In the 1990s, the birth of the dry grind ethanol industry and Minnesota’s progressive fuel policies complemented our strong agricultural ties and deep understanding of process automation. So, we transformed part of our business, becoming a driving force in the now booming biofuels sector. Our expertise and strategic location earned more than 80% of the automation business for early ethanol plants—including massive multi-million-dollar projects that helped define the future of U.S. fuel.
Biofuels Automation is MCE's dedicated business unit branded to reflect our commitment to the renewable fuels industry, while supplying equipment and support to ethanol plants.
In other words, we are the original ethanol automation expert.
The Rise of Ethanol Plants in the U.S.
For many years, suppliers relied heavily on a fuel additive known as MTBE (methyl-tertiary butyl ether) to boost octane. MTBE was valued for its energy, oxygen content, and high octane but was found to leak from underground storage tanks, contaminating groundwater. These findings initially led to 19 states banning MTBE from 2000-2006 before it was banned nationwide.
Minnesota—a major corn producer—enacted policy changes that gave financial incentives for local ethanol plant development, giving way to today’s growing ethanol market.
Today, we service many of the 175 active ethanol plants in the U.S., mainly located in the Corn Belt.
We Understand the Needs of the Dry Grind Ethanol Industry
What is dry grind ethanol? The dry grind ethanol industry refers to a method of producing ethanol—mainly from corn—using a process where the entire grain kernel is ground into flour before fermentation. It's the most common method used in the U.S. ethanol industry today.
Unlike the wet mill process (which separates the corn into components first), dry grind uses the whole kernel—making it faster and generally more cost-effective for production of fuel ethanol and animal feed. While dry grind is more efficient, it’s not without its challenges.
Top Challenges in Ethanol Plant Process Optimization
Many ethanol plants are automating and optimizing processes to improve efficiency, increase ethanol and corn oil production, and reduce energy usage. And since there haven’t been new ethanol plants built in recent years, much of that optimization is focused on expanding the capabilities of existing plants.
This means improving efficiency, increasing yield and profitability—while staying compliant with safety and environmental standards. However, a few key challenges often make this difficult:
- Variability in Feedstock
Corn and other feedstocks vary in moisture content, starch levels, and contaminants, affecting fermentation and output quality. - Fermentation Efficiency
Sub-optimal temperatures, pH levels, and contamination (like wild yeast or bacteria) can reduce ethanol yield. - Energy Consumption
Ethanol production is energy-intensive, especially during distillation and drying. Optimizing energy use without compromising throughput is a constant balancing act. - Water Usage and Waste Management
Managing water inputs and dealing with byproducts like stillage and CO₂ impact cost and elevate environmental concern. - Equipment Reliability and Maintenance
Downtime for maintenance or unexpected valve or equipment failures can severely impact output and profit margins. - Regulatory Compliance and Sustainability
Staying compliant with EPA and local emissions regulations requires tight process controls and continuous monitoring.
Who do you want by your side for process optimization? Do you want a transactional vendor or a collaborative partner who is insight-driven and outcome-focused?
How BioFuels Automation Optimizes Ethanol Plants
Our deep ties to agriculture and involvement in early ethanol projects have positioned BioFuels Automation as a key automation partner for plants looking to optimize their operations.
With over 25 years of experience focused solely on dry grind ethanol plants, BioFuels Automation is more than a supplier—we’re a dedicated partner in driving efficiency, yield, and compliance. Because we already support most of the equipment installed in U.S. ethanol facilities, we’re the logical choice for plants looking to upgrade, add-on, or modernize.
Whether you're increasing ethanol yield, recovering more corn oil, or planning a digital transformation, we bring deep application knowledge, plant-specific insight, and hands-on technical support.
Plant-Specific Consulting and Technical Expertise
No two plants are alike—and neither are our solutions. We offer:
- Process Audits & Site Analysis: We evaluate flow rates, temperature and pressure profiles, valve performance, and instrumentation bottlenecks to identify opportunities for performance improvement.
- Collaboration with Engineering Firms: As trusted advisors during upgrades and expansions, we help design and integrate control systems, instrumentation, and automation for new processes like CO₂ and corn oil recovery.
- Application Expertise: Our technicians and engineers understand every step of the dry grind process—from grain handling to drying distiller grains (DDGS). We don’t offer one-size-fits-all advice—we provide tailored, actionable recommendations.
Field Services and Onsite Support
BioFuels Automation technicians support plants during critical outages, shutdowns, and commissioning periods:
- Mobile Service Centers: Deployed during outage seasons, these on-site trailers include emergency inventory, ethanol-specific calibrators, and custom leak test stands.
- Certified Field Technicians: Our CCST Level 2/3 technicians are trained in safety compliance (including OSHA’s PSM standards) and well-versed in the standard plant designs used throughout the industry.
- Calibration and Compliance: We offer third-party calibration services on flow meters and transmitters to ensure accurate, unbiased readings that meet EPA, ATF, and RFS requirements.
Maintenance and Inventory Management
Proactive maintenance and strategic inventory support keep your plant running with minimal disruption:
- Preventive Maintenance: Routine valve and sensor testing, diagnostic analysis, and predictive maintenance scheduling based on failure intervals and equipment lifecycles.
- Smart Device Integration: Support for self-diagnostic devices that alert operators to issues before failure occurs.
- Vendor-Managed Inventory (VMI): We stock ethanol-specific valves and hard-to-source parts—ensuring plants have what they need, when they need it. Options include consignment and strategic stocking agreements.
With BioFuels Automation, you’re not just getting parts and equipment—you’re getting a committed partner who understands the unique demands of ethanol production and is ready to support your team at every step.
BioFuels Automation University
Since 2007, we’ve developed over 700 ethanol maintenance technicians through this program and continue to enroll new students every day. Our aim is to address the shortage of qualified technicians in rural regions, a crucial factor in plant success.
Our classes focus on maintaining and troubleshooting automation equipment such as valves, transmitters, flow meters, and more. Classes are offered in our training center or on-site at your facility, customized to your application and product lines. Learn more about BioFuels Automation University.
Ready to Optimize Your Ethanol Operation?
You don’t have time for trial and error. You need solutions that work.
If you’re looking to improve the profitability and efficiency of your plant, look to the experts. Generalist industrial suppliers can’t compete with over 25 years of plant-specific expertise. By partnering with BioFuels Automation, you can rest easily knowing you have the specialized support your plant requires, the kind you only get from decades in the field.
Reach out to schedule a comprehensive site review or discuss an upcoming optimization project.
