RCM Thermal Kinetics has announced the successful completion of the first project under its NEXT (New Ethanol eXpansion Technology) engineering program, launched in early 2025.

 

The project transformed a Midwestern ethanol facility originally designed for 40 million gallons per year (MMGY) into a 105 MMGY powerhouse—making it the first standard 40 MMGY plant to surpass the 100-million-gallon mark without adding parallel distillation columns or replacing major equipment.

 

The facility had previously been expanded incrementally to 65 MMGY and then 86 MMGY, a ceiling long considered the practical limit for over a hundred plants of this design across North America. By applying the NEXT program, Thermal Kinetics shattered that ceiling, proving that legacy plants can achieve unprecedented capacity through advanced process optimization.

 

“Our senior engineer, Roy Viteri, utilized precision engineering techniques drawn from his extensive petroleum industry background,” said Christopher J. Brown, Founder of Thermal Kinetics. “Instead of replacing major equipment, we applied surgical upgrades and advanced system design methods that unlocked hidden capacity in the plant’s existing footprint.”

 

The leap to 105 MMGY sets a new benchmark for the ethanol industry. It demonstrates that existing plants can reach world-class performance levels without the capital cost of major equipment replacement.

 

“This project demonstrates what is possible when advanced process design meets real-world constraints,” added Viteri. “It opens the door for existing plants to dramatically increase output, reduce cost per gallon, and strengthen their competitive position in the renewable fuels market.”

 

Scott Yenzer, newly appointed General Manager of Industrial Markets, emphasized the broader impact: “As the first completed NEXT project, this installation validates the program’s potential. Thermal Kinetics currently has several NEXT projects underway, further evidence of the program’s rapid adoption and the company’s continued leadership in ethanol plant innovation.”