The New Frontier of Industrial Automation in the Corn Ethanol Sector: A Case Study on Technological Leadership and the Trajectory of Nova Smar

The global energy transition and the growing demand for low-carbon fuels have positioned corn ethanol as one of the protagonists of the contemporary bioenergy matrix. In Brazil, this rise is accompanied by a technological revolution where industrial automation ceases to be a mere operational support and becomes the strategic core of profitability and productive efficiency. In this scenario, Nova Smar, a company based in Sertãozinho, has established itself as a global benchmark, exporting technology and intelligence to the most demanding markets, including the implementation of complex control systems in giants of North American production since the beginning of the 21st century. This technical report analyzes in detail the company's trajectory, its solutions for the sector, the role of professional training via Smar Academy, and the innovations that will shape the future of the sector.

Introduction and Contextualization of the Bioenergy Sector

The corn ethanol sector in Brazil is experiencing a period of historic expansion. What was once seen as a seasonal byproduct or a niche alternative now represents more than 22% of the country's total ethanol production, with projections reaching 10 billion liters in the 2025/2026 harvest. Unlike sugarcane, whose processing is limited by the seasonality of the harvest and the impossibility of prolonged storage of the raw material, corn allows for continuous operation 350 days a year, requiring an automation infrastructure that supports uninterrupted high-performance cycles.

Nova Smar entered this market with the strategic advantage of its long experience in the sugar and ethanol sector, but understanding that corn demanded a distinct technical approach. While in sugarcane the central challenge lies in the extraction and purification of the juice, in corn the focus shifts to the biochemistry of starch hydrolysis, the thermal efficiency of distillers grain drying (DDG/DDGS), and the precision in controlling continuous or batch fermentation. Smar's ability to integrate these processes through advanced digital protocols such as Foundation Fieldbus and Profibus allowed Brazilian technology to compete on equal footing with global players in the United States and Europe.

Evolution of Corn Ethanol Production in Brazil

The rapid industrialization of corn for energy purposes is supported by massive investments and technological advancements. The table below demonstrates the progression of national production and the growing importance of modern biorefineries.

Source: UNEM / IMEA.

Theoretical Framework - The Essence of Process Automation

To understand Smar's contributions, it is necessary to define what constitutes the automation of modern industrial processes. This involves the synergistic integration between field hardware (sensors and actuators), control hardware (PLCs and multiloop controllers), and software systems for asset supervision and management. In a corn ethanol plant, automation acts as the central nervous system, ensuring that process variables such as pressure, temperature, flow rate, density, and concentration remain within optimized operating envelopes.

The most accurate analogy for this system is that of a symphony orchestra: each instrument (transmitter) must provide a precise note, while the conductor (controller) interprets the score (control strategy) and coordinates the inputs so that the final result (ethanol and co-products) is harmonious and efficient. Without automation, the variability inherent in biological and thermal processes would result in wasted energy and loss of fermentative yield.

Technical Contributions from Smar

Smar stands out for introducing digital field technologies that allow multiple data to pass through a single pair of wires. This not only reduces installation costs (CAPEX) but also provides diagnostic information that is crucial for predictive maintenance. Unlike 4-20mA analog systems, where only the process variable is known, Smar's digital protocols report whether the sensor is corroding, whether the valve positioner needs lubrication, or if there has been an internal failure, allowing interventions before plant shutdown occurs.

The Trajectory of Nova Smar in the Corn Ethanol Market

Nova Smar's history with corn ethanol dates back more than two decades. Although the company consolidated its base in sugarcane, the opening of the international market was the catalyst for the development of specific solutions for cereals.

The Emblematic Case of ACE Ethanol (USA)

A pivotal milestone in the company's history occurred in 2004 with the supply of a complete automation package for ACE Ethanol, located in Stanley, Wisconsin, USA. This plant, operated by one of the largest independent producers in the United States, processes 1270 tons/day of corn and produces 54 million gallons of ethanol per year. The choice of Smar's Brazilian technology in the United States was based on the robustness of the Foundation Fieldbus architecture, which offered greater reliability and precision than the local alternatives at the time.

ACE Ethanol operates 350 days a year, distributing its production via 90 railcars and 200 trucks monthly. To maintain this pace, the plant required a solution that would reduce operational risks and increase energy efficiency—objectives achieved through Smar's digital instrumentation, which allowed for more stable control of the distillation columns and evaporators.

Geographic Expansion and Global Service

Smar's solutions are not limited to Brazil. The company operates as a multinational technology company, exporting to 56 countries and serving corn and wheat ethanol plants in Europe, North America, and Latin America. This global presence has required Smar to develop products that meet rigorous international standards, such as ATEX certifications for classified areas and interoperability standards dictated by the Fieldbus Foundation and PROFIBUS International.

Market Opening Strategy and Gaps

Breaking into the corn ethanol market required a change in mindset. In the early 2000s, the sector was dominated by North American dry milling technologies. In Brazil, the transition was driven by the need to utilize the surplus corn from the Midwest.

Identifying Technological Gaps

Smar realized there was a significant gap between basic instrumentation and the need for advanced control for managing co-products (DDG and corn oil). Many companies offered automation, but few fully understood the dynamics of distillation with concentrated vinasse and the need for humidity control in dryers, which are the plant's biggest energy consumers.

To overcome these challenges, Smar adopted a customer-centric strategy, sending application engineers to experience the difficulties of the plants in Wisconsin and, later, in Mato Grosso. This knowledge resulted in the development of specific instruments, such as the DT301 density and concentration transmitter, which uses differential pressure to measure alcohol content and solids concentration in real time, eliminating the need for manual laboratory sampling.

Competition and Specialized Positioning

Unlike other industries where specialized companies didn't exist, the corn sector has always had large global players. However, Smar positioned itself as the open field technology specialist. While competitors like Rockwell Automation focused heavily on predictive control algorithms (MPC) and optimization software like Pavilion8, Smar offered the communication infrastructure that allowed these algorithms to receive high-quality data.

The following table presents a strategic comparison between the main technology providers for the sector.

Modularity and Customization of Smar Solutions

A common question for corn ethanol producers is whether contracting Smar's solutions requires acquiring the brand's entire industrial ecosystem. The short answer is that modularity is one of the pillars of the company's commercial strategy, enabling interoperability and customization among various suppliers.

Hiring by Stages or Processes

Smar's clients can choose to automate only a part of the industrial process. It is common, for example, for plants that use control systems from other manufacturers (such as Rockwell or Siemens) to contract Smar exclusively for the instrumentation of critical areas or for the implementation of field networks.

The main modules that can be contracted separately include:

1. Distillation and Fermentation Module: Focused on temperature, pH, and concentration control;
2. Power Generation Module and Boilers: Where Smar offers combustion and steam pressure control, essential for cogeneration;
3. Asset Management Module ( AssetView ): Software that monitors the health of all field instruments, regardless of manufacturer, as long as they follow open protocols;
4. Plant Modernization (Technology Upgrade): Replacing old instruments with HART or WirelessHART technologies without the need to replace all the factory wiring.

This flexibility allows smaller or expanding companies to begin digitizing their operations gradually, according to the availability of CAPEX.

Innovation and the Near Future - What Can We Anticipate?

Regarding the near future, Nova Smar is investing heavily in the convergence between industrial automation and information technology (IT/OT). The biggest innovation under development is the full adoption of the OPAS (Open Process Automation Standard).

PAHO and the End of Closed Systems

Smar is one of the world's pioneers in implementing OPAS, actively participating in the Open Process Automation Forum (OPAF). The goal of this innovation is to eliminate technological "silos," allowing components from different vendors (hardware and software) to operate in a plug -and -play infrastructure. For the corn ethanol industry, this means that the plant will have complete freedom to choose the best sensors from one manufacturer and the best controllers from another, without being "stuck" in a proprietary ecosystem.

Advances in Hardware and Sensors

In the hardware field, the launch of pressure transmitters up to 700 bar and new Bluetooth interfaces (HI331) for instrument configuration via mobile devices represents a shift in how maintenance is performed in the field. The use of the DEVCODROID app allows technicians to diagnose instruments in hard-to-reach locations without the need for cables or complex physical interfaces.

Smar Academy - Education and Professional Training

One of the points most emphasized by Smar is the need for continuous training. The creation of the Smar Academy responds to a chronic challenge in the bioenergy sector: the shortage of qualified professionals who master digital automation technologies.

The Role of the Educational Arm

Smar Academy offers training ranging from basic instrumentation to advanced network protocols. This educational arm fully serves the corn ethanol industry, providing specific courses tailored to the needs of this segment.

Unique Differentiator in the Segment

Academy 's service is unique in the industrial automation segment in Brazil. While most companies offer manuals and reactive technical support, Smar Academy functions as a "direct from the source" educational institution, where learning takes place at the manufacturer's own facilities, with access to the engineers who developed the products and to didactic test plants. This model ensures that professionals not only learn to "use the software," but also understand the physics and electronics behind the process.

Key Points and Commitment of Smar

To complete this analysis, Nova Smar wishes to emphasize its commitment to sustainability and Brazilian technological sovereignty. In the corn ethanol sector, the company highlights that automation is the fundamental tool for meeting the goals of RenovaBio (National Biofuels Program). Through precise control of mass and energy balance, plants are able to issue more decarbonization credits (CBIOs), transforming industrial efficiency into direct financial assets.

https://www.gov.br/anp/pt-br/assuntos/renovabio

Another highlight is the integration with the production of biogas and biomethane from vinasse and other corn residues. Smar already provides monitoring technologies for anaerobic digestion reactors, allowing the ethanol plant to transform into a complete renewable energy hub, generating liquid, solid (DDG), and gaseous fuel.

Results Analysis and Strategic Discussion

The application of Nova Smar technologies in the corn ethanol sector has demonstrated tangible results. In terms of industrial performance, the transition to digital control systems has enabled:

1. Variability Reduction: Reducing the variability of the final product quality by more than 50% through multivariable control strategies;
2. Energy Savings: Reduction of 2 to 4% in total energy costs and up to 15% specifically in steam consumption during distillation;
3. Maximizing Yield: Increasing ethanol production by up to 12% with the same equipment, simply by optimizing control loops and reducing losses during cooking.

Discussion about Investments and Projections

The future scenario points to Brazil consolidating its position as the world's largest exporter of technological solutions for bioenergy. The BioMilho Brasil 2026 event demonstrated that the integration of sugarcane and corn is the path to financial resilience for sugar mills. Nova Smar, through its executives, has been leading international discussions on how automation can mitigate operational risks in new investments of R$ 1.65 billion, such as those recently seen in the sector.

https://jornalcana.com.br/especiais/biomilho-br-2026/

Conclusion

Nova Smar not only followed the development of corn ethanol; it was one of the architects of the technical viability of this sector in Brazil and abroad. From its bold entry into the North American market in 2004 to its current leadership in open automation (OPAS), the company has proven that Brazilian technology possesses global competitiveness.

The challenges of serving an industry that operates 24/7 have demanded innovations in robustness and diagnostics that now benefit the entire industrial sector. The modularity of its solutions allows producers to contract the most modern technology according to their needs, while Smar Academy ensures that technical knowledge remains within the client's plant. With the arrival of Industry 4.0 and the complete digitalization of the field, Smar reaffirms its role as a strategic partner in transforming corn into energy, food, and sustainability for the future.

Appendix

Synthesis of Industry Data and Metrics

To provide a solid foundation for the information presented, the following are the indices gathered during the research on corn ethanol production and the necessary automation infrastructure.

Production and Market Data (Brazil)

Automation and Performance Parameters

This data structure proves that industrial automation, far from being an accessory cost, is the main driver of asset appreciation and guarantee of return on investment (ROI) in the dynamic corn bioenergy market.

Bibliographic References

The information presented in this report is based on the following research materials and institutional sources:

• UNEM / IMEA: Market Reports and Sector Data on corn ethanol production and projections for the 2024/25 and 2025/26 crop seasons.
• JornalCana: Technical coverage of Nova Smar's participation in the BioMilho Brasil 2026 event and the success story of ACE Ethanol (USA).
• Smar Academy: Technical description of training courses, including TC-103 (Density and Concentration) and TC-122 (Basic Instrumentation).
• Rockwell Automation / FactoryTalk Pavilion8: Performance data on predictive automation and dryer optimization in corn processing plants.
• Nova Smar (Official Website and News): Documentation on the new O-PAS line, strategic partnerships with CPLANE.ai and WEG, and multinational history.
• CanaOnline / TOTVS: Analysis of the challenges of biomass, energy efficiency, and logistics in the bioenergy agribusiness.
• Emerson Automation Solutions: Studies on fiscal measurement and custody transfer in industrial infrastructures.
• STAB Magazine: Technical articles on efficiency in distillation processes and biogas integration.
• BioEnergy Hub: Educational content about Industry 4.0 applied to the sugarcane and energy sector.

ADRIANO MARCELO CORTEZE  
NOVA SMAR S/A 
10/MAR/2026

Link

DT300Series - Density Transmitters - Technology - SMAR Technology Company

Line NOVA O-PAS - SMAR Technology Company

Home | Smart Academy