CO2 Extraction System for a Distillery | Case Study

The Project

Valve & Process Solutions worked in partnership with Fostec Engineering to supply valves and sight glasses for a CO2 extraction system installed at a UK distillery. The system was designed to safely capture carbon dioxide (CO2) generated during fermentation so it could be processed and reused, rather than vented directly into the atmosphere.

The installation included extraction pipework, ventilation lines, valve packages and sight glasses creating a safe, efficient, and environmentally responsible solution for CO2 management within the distillery’s production process.

The Challenge

The client tasked Fostec Engineering with designing and installing a CO2 extraction and ventilation system for a distillery. The system needed to handle variable CO2 generation rates from multiple fermenter tanks, while ensuring reliability, maintainability, and compliance with environmental standards.

Key challenges included:

Specifying valves in accordance with P&ID drawings.

Managing limited design information for the sight glass assemblies.

Ensuring the system could both extract CO2 during normal operation and safely vent to atmosphere when the CO2 processing plant was offline.

Delivering a robust and maintainable installation with reliable component performance.

The Solution

Working collaboratively, Fostec Engineering and Valve & Process Solutions delivered tailored packages for the CO2 extraction system designed for both performance and durability.

VPS supplied:

Emerson Keystone GR Series butterfly valves and Keystone 89 Series actuators fitted with Westlock Controls AccuTrak 3549 switchboxes and Pneumatrol C1518 solenoids. All chosen for their proven reliability, ease of maintenance, and strong service record in process environments.

Sight glasses, specified and supplied by VPS despite limited initial design information, enabling clear visual monitoring of CO2 flow in the extraction line.

The vent line was fitted with an automatic valve to allow safe atmospheric venting when the processing plant was offline, while the extraction pipework drew CO2 from the fermenter tanks during standard operation. The combined setup ensured safety, operational control, and environmental compliance.

What is CO2 Extraction in Distilling?

During fermentation in distilleries, yeast converts sugars into alcohol and carbon dioxide (CO2). Traditionally, this CO2 would be vented into the atmosphere. However, a CO2 extraction system captures and redirects the gas for processing, purification, and reuse — helping reduce waste and improve sustainability.

A CO2 extraction system captures this gas directly from the fermenter tanks, allowing it to be purified, compressed, and reused elsewhere in the production process or stored for future use.

In this application:

The extraction pipework removes CO2 from fermenters during normal operation.

The sight glass provides operators with real-time visual confirmation of gas flow.

The auto-vent valve ensures safe venting to atmosphere if the CO2 recovery system is not active.

This approach improves sustainability, reduces waste, and aligns with the distillery’s environmental and operational objectives.

The Outcome

The project was completed successfully, delivering a clean, reliable, and easy-to-maintain installation that met both process and safety requirements.

Key results:

A high-quality CO2 extraction system with robust, proven components.

Easy maintenance and excellent spare part availability.

A professional, well-presented installation praised by both Fostec Engineering and the end user.

By combining Fostec Engineering’s installation expertise with Valve & Process Solutions’ product knowledge and technical support, the distillery now benefits from a dependable, efficient, and environmentally responsible CO2 recovery system.

Looking to improve efficiency and sustainability in your brewing or distilling process? Get in touch with Valve & Process Solutions to discuss reliable valve and control solutions for CO₂ extraction and recovery systems.