Ethanol Production Doubled Without New Plant Thanks to Smart Technology Upgrade
Published: 16 Mar 2026
Author: Precedence Research
Ethanol Production Doubled Without a New Plant
In March 2026, RCM Thermal Kinetics, a company that specializes in improving industrial plants, has completed NEXT (New Ethanol eXpansion Technology). They upgraded an ethanol plant so that it can now produce 105 million gallons per year, up from 40 million gallons. That’s more than double the old production, all without building a completely new plant. Also, the RCM focused on making the existing plant smarter and more efficient. They looked at every part of the process, from fermentation to distillation, and figured out how to get more out of the equipment that was already there. RCM redesigned these systems so that energy is reused more effectively. This not only reduces costs but also helps the plant operate in a more environmentally friendly way.
Smarter Plant Boosts Efficiency and Safety
This project shows that older plants can still be extremely valuable. With the right planning and technology, even existing facilities can produce much more, run more efficiently, and lower their energy use. Local communities benefit too, because more production means more jobs and economic activity
According to Towards Chem&Materials, the renewable ethanol market size accounted for USD 118.15 billion in 2025 and is predicted to increase from USD 125.06 billion in 2026 to approximately USD 208.61 billion by 2035, expanding at a CAGR of 14.45% from 2026 to 2035, due to shift towards the sustainability and reduction carbon emissions.
RCM Thermal Kinetics’ upgrade is a great example of how smart engineering can transform an industrial facility. Instead of tearing down old plants, it’s possible to make them stronger, faster, and greener. This approach could inspire other ethanol producers to modernize their plants and meet growing demand in a smarter way.