Calgren Ethanol
At Calgren, ethanol production is central to our renewable fuel portfolio. Leveraging advanced dry-mill technology, we convert Midwestern–sourced corn into clean, low-carbon ethanol — while fully valorizing the rest of the corn kernel through co-products and carbon capture.
Gallons of US Ethanol Produced Annually
Using state-of-the-art dry milling, Calgren’s ethanol plants produce approximately 116 million gallons of ethanol per year.
Ethanol, when blended into gasoline, introduces oxygen into the fuel mix, promoting more complete combustion and reducing toxic tailpipe emissions.
Our process is designed for high efficiency and full utilization of feedstock, reducing waste and maximizing output.
Using state-of-the-art dry milling, Calgren’s ethanol plants produce approximately 116 million gallons of ethanol per year.
Ethanol, when blended into gasoline, introduces oxygen into the fuel mix, promoting more complete combustion and reducing toxic tailpipe emissions.
Our process is designed for high efficiency and full utilization of feedstock, reducing waste and maximizing output.
Ethanol Co-Products
Wet Distillers Grains (WDG)
Wet Distillers Grains (WDG) is a key co-product of our ethanol production process. WDG is a high-quality animal feed consisting of the remaining corn components after ethanol distillation is complete. Every year, Calgren produces 400,000 tons of WDG, which serves as a nutritious, high-protein feed for local dairy livestock. This co-product is rich in nutrients and energy, making it a valuable resource for dairy operations in the region.
By converting corn into ethanol and WDG, we create a circular system that not only provides renewable fuel but also supports the agricultural community. WDG minimizes feed costs for farmers while reducing the carbon footprint of the ethanol production process.
Key Benefits of Calgren’s WDG:
- Nutritional Value: WDG is a high-quality feed ingredient, providing essential proteins and nutrients for livestock.
- Cost Efficiency: Farmers benefit from reduced feed costs, contributing to more sustainable agriculture.
- Waste Reduction: Utilizing every part of the corn kernel ensures minimal waste and maximum resource efficiency.
Our WDG production exemplifies how we turn waste into value, supporting both renewable energy and agriculture.
Corn Oil
Corn oil is another vital co-product from our ethanol production process. At Calgren, we extract 1.5 million gallons of corn oil annually, using advanced separation technologies. This high-quality corn oil is utilized primarily in poultry feed, providing a high-energy ingredient that supports healthy growth and feed efficiency in the agricultural sector. The corn oil may also be used as a feedstock for biodiesel production.
The seamless integration of corn oil extraction within our ethanol production optimizes resource use, further reducing waste and enhancing our commitment to renewable, circular systems.
Key Benefits of Calgren’s Corn Oil:
- High-Energy Feedstock: Corn oil provides essential fats for animal nutrition, improving growth and production efficiency.
- Zero-Waste Approach: The extraction of corn oil from ethanol production aligns with our commitment to resource optimization.
- Agricultural Support: Corn oil contributes to more efficient and sustainable feed solutions for local poultry farms.
By maximizing the value of every corn kernel, we ensure that our operations support both renewable energy and local agricultural needs.
Carbon Capture and Utilization
Calgren is at the forefront of carbon capture and utilization technology, an essential tool in reducing greenhouse gas emissions. At our Pixley facility, we capture CO₂ produced during the ethanol fermentation process, preventing it from being released into the atmosphere. This captured CO₂ is then stored and repurposed for use in various industries, including food and beverage, agriculture, and manufacturing, offering a clean, sustainable source of carbon dioxide.
This synergistic approach supports a sustainable, closed-loop system, where every co-product is either repurposed or reintegrated into the production system, maximizing resource use while minimizing environmental impact.
Key Benefits of Calgren’s Carbon Capture and Utilization:
- Emission Reduction: Capturing CO₂ reduces fuel production emissions, contributing to climate change mitigation.
- Industrial Applications: Clean, captured CO₂ is used across multiple industries, providing an eco-friendly carbon source.
- Zero-Waste Approach: The capture and use of CO₂ from fuel production aligns with our commitment to resource optimization.
Through carbon capture and utilization, Calgren not only reduces its carbon footprint but also creates new value streams that contribute to a more sustainable, resource-efficient economy.
Community Impact
Ethanol production and co-product innovation reflect Calgren’s commitment to sustainability and community. By turning corn into low-carbon fuel and valuable co-products, we reduce waste, support regional agriculture, and advance cleaner energy—all in keeping with our mission to champion environmental stewardship and innovation.
Supporting Local Agriculture
Ethanol co-products like wet distillers grains and corn oil can serve as valuable feed options for dairies and poultry farms. This provides local producers with cost-effective nutrition sources while maximizing the value of every corn kernel.
Reduced Emissions
Ethanol blended into gasoline reduces harmful emissions by promoting cleaner, more complete combustion. Combined with carbon capture, Calgren’s ethanol production contributes to statewide greenhouse gas reduction goals.
Jobs & Economic Growth
Operating the ethanol facility supports skilled jobs in the local area and strengthens the broader renewable fuels supply chain. By creating demand for rail-delivered corn and generating high-value co-products, Calgren contributes to regional economic resilience.
Education & Awareness
The ethanol plant provides a hands-on setting for school tours, university research partnerships, and workforce training. Internship opportunities allow students and early-career professionals to gain experience in renewable energy and biofuels production.
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Ethanol
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RNG
Carbon Capture
Integration with Other Calgren Systems
At Calgren, ethanol and its co-products don’t stand alone — they’re woven into our broader energy ecosystem. Excess CO₂ from ethanol production is captured and directed to use, while connections with our biogas and RNG operations create a seamless, closed-loop system. This integrated approach ensures that every Calgren technology pillar works in synergy, maximizing value and minimizing waste.
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