Trusted Partner to Ethanol & Biofuels Producers
For more than three decades, IAC has been a trusted EPC contractor and OEM partner for ethanol plants, advanced biofuels facilities, and emerging Sustainable Aviation Fuel (SAF) projects. Our vertically integrated approach—engineering, fabrication, construction, commissioning, and lifecycle support under one roof—gives producers the speed, reliability, and accountability they need to stay competitive in a rapidly evolving energy market.
From corn ethanol facilities in the Midwest to next-generation SAF production plants, IAC delivers custom-engineered solutions that improve efficiency, reduce emissions, and maximize uptime. Our expertise spans air pollution control systems, bulk material handling, advanced drying technologies, and automated controls—backed by Adelphi Construction, our in-house construction arm, for seamless project execution.
As global demand for cleaner fuels accelerates, IAC provides the technologies and field-proven systems that help producers expand capacity, meet strict environmental standards, and capture new opportunities in renewable energy.
Industry Challenges
Ethanol and biofuels producers operate in a highly regulated, efficiency-driven environment. Success depends on balancing production throughput with compliance and cost control. Key challenges include:
- Meeting strict emissions regulations for SOx, NOx, HCl, and particulate matter, often requiring advanced sorbent injection and dust collection technologies
- Managing the high moisture content of feedstocks like corn, biomass, and distillers grains, which demand reliable and energy-efficient drying systems
- Reducing unplanned downtime and maintaining reliable operations across boilers, dryers, and material handling equipment
- Controlling operating costs in energy-intensive processes, while improving throughput and product quality
- Preparing facilities for future growth, including integration with emerging markets such as sustainable aviation fuel (SAF)
Core Capabilities for Ethanol & Biofuels
IAC delivers fully integrated solutions designed to keep ethanol and biofuels plants running at peak performance. Our engineered systems and OEM equipment address every stage of the production process:
Air Pollution Control Systems
- Custom-engineered baghouses, cyclones, and scrubbers sized for boilers, DDGS dryers, hammermills, and process ventilation to maintain continuous compliance.
- Low-maintenance designs with optimized airflow and filtration media to improve capture efficiency and extend bag life in high-dust, high-temperature environments.
- Integration with stack testing requirements and EPA MACT standards to help operators meet emissions limits with margin.
- Full lifecycle support including inspections, rebuilds, conversions, and emergency service through IAC’s Blue Crew.
Industrial Drying Systems
- Rotary and ring dryer systems engineered to optimize moisture removal for wet cake, DDGS, and biomass feedstocks.
- Custom flighting, gas handling, and heat distribution designed to improve energy efficiency and product consistency.
- Complete system supply including furnace, burner, cyclones, ductwork, and emissions integration for a reliable drying island.
- Retrofit and optimization programs that improve throughput, reduce fuel consumption, and extend equipment service life.
Sorbent Injection System
- Engineered dry sorbent and activated carbon injection systems to control SO₂, SO₃, HCl, HF, and mercury emissions from boilers and thermal units.
- Full-scale test equipment and CFD-backed injection design to validate performance and optimize sorbent use.
- Permanent storage silos, metering equipment, and injection lances designed for precise distribution and controllable feed rates.
- Proven integration with new or existing baghouses to enhance overall emissions control and lower operating costs.
Bulk Material Handling
- Dense and dilute phase systems engineered to transport corn, biomass, WDG, DDGS, and ash with minimal degradation and dust escape.
- Complete storage solutions including welded or bolted silos, domes, and loadout systems designed for safe material flow and NFPA-compliant handling.
- Integrated material handling networks connecting milling, drying, fermentation, and byproduct recovery operations.
- Automated controls, flow monitoring, and batching systems that maintain consistent throughput and reduce operator workload.
Automated Controls
- Custom PLC/HMI systems that monitor, coordinate, and optimize ethanol plant operations including dryers, conveyors, loadout, and APC equipment.
- MCCs designed and built to NEMA and NFPA standards, with VFD integration for precise motor and blower control.
- Seamless tie-in with existing DCS platforms to minimize disruptions and maintain operator familiarity.
- Remote diagnostics and IAC Smart Plant capabilities that reduce troubleshooting time and improve uptime.
Solutions for Ethanol & Biofuels Segments
IAC’s solutions are tailored to the unique requirements of different segments within the ethanol and biofuels industry. Whether building new capacity or optimizing existing plants, our systems are proven across a range of applications:
- Corn Ethanol Plants – Design and installation of baghouses, fly ash handling systems, boiler islands, and truck or rail loadouts to improve compliance and efficiency
- Advanced Biofuels Facilities – Thermal processing systems for biomass drying, torrefaction, and gas conditioning, engineered to handle diverse feedstocks
- Sustainable Aviation Fuel (SAF) Production – Supporting next-generation fuel plants with EPC capabilities, feedstock receiving and handling, rotary drying, and emissions control technologies. IAC’s biofuels and biomass experience provides a strong foundation for SAF projects, helping producers scale quickly and meet sustainability targets
- CHP and Boiler Systems – Integrated air pollution control, ductwork, and ash handling solutions for combined heat and power (CHP) and process boilers
- Plant Expansions & Retrofits – Energy-efficient dryer system retrofits, baghouse conversions, and upgrades that extend equipment life while reducing fuel use and maintenance costs.
Engineering, Procurement & Construction (EPC)
IAC is one of the few EPC contractors with full in-house integration—engineering, OEM equipment, fabrication, construction, and commissioning all managed under one roof. This approach eliminates costly miscommunication and ensures projects are delivered on schedule and on budget.
Our EPC experience in ethanol and biofuels includes:
- Turnkey plant design and construction with Adelphi Construction, IAC’s wholly owned subsidiary
- Completed ethanol facilities across the Midwest, including Corn LP (IA), Lincolnway Energy (IA), Red Trail (ND), and Heron Lake Energy (MN)
- Fast-track project delivery, with proven ability to meet accelerated schedules without compromising quality or safety
- Civil, structural, mechanical, and electrical expertise for greenfield plants, boiler islands, dryer systems, and emissions control upgrades
Whether building new capacity, expanding an existing facility, or integrating SAF production, IAC delivers single-source accountability and seamless execution from concept through commissioning.
Field Services & Aftermarket Support
Ethanol and biofuels plants demand consistent uptime and predictable performance. IAC supports facilities across their full operating life with services that extend equipment longevity, reduce downtime, and keep operations compliant.
Maintenance & Repair Services
- Scheduled bag change-outs, cage replacements, and leak testing for all baghouse brands
- Mechanical repairs including valve, damper, and fan replacement
- Equipment conversions to upgrade older reverse-air or shaker systems to modern pulse-jet technology
Training
- On-site or virtual seminars covering baghouse operation, troubleshooting, and maintenance scheduling
- Hands-on instruction from experienced IAC engineers to extend equipment life and avoid unplanned downtime
System Optimization
- Burner tuning and dryer flighting analysis to improve efficiency
- Airflow balancing and ductwork inspections to reduce emissions and wear
- Dust control retrofits for improved compliance and product recovery
Parts & Components
- 55,000+ stocked parts for baghouses, dryers, conveying systems, and controls
- Rapid shipment from strategically located warehouses to minimize downtime
- OEM and compatible parts available for multi-brand systems
By combining OEM expertise with ongoing service and training, IAC ensures ethanol and biofuels producers can focus on output and growth instead of unplanned downtime
Partnering with IAC
Ethanol and biofuels producers face constant pressure to maximize efficiency while meeting sustainability and compliance goals. IAC provides the experience, technology, and accountability to help plants succeed today and adapt for tomorrow.
- Proven industry expertise – Over 35 years of EPC and OEM experience, with successful projects at leading ethanol plants across the U.S.
- Integrated capabilities – Engineering, equipment manufacturing, fabrication, construction, commissioning, and service all delivered under one roof for seamless project execution
- Sustainability focus – Supporting the growth of renewable fuels, including advanced biofuels and sustainable aviation fuel (SAF), with systems that improve energy efficiency and reduce emissions
- Long-term reliability – Backed by a nationwide service team and a robust inventory of over 55,000 replacement parts, ensuring ongoing performance and minimized downtime
With IAC as a partner, ethanol and biofuels producers gain more than a solutions provider—they gain a trusted ally committed to their success throughout the lifecycle of their facility.
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Trusted Partner to Ethanol & Biofuels Producers For more than three decades, IAC has been a trusted EPC contractor and OEM partner for ethanol plants, advanced biofuels facilities, and emerging […]
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