This research adds to the understanding of the areas of residual starch and biomass conversion to alcohol, by providing data from pilot plant equipment of larger scale than the minimum required to give commercially scalable data. Instrumentation and control is in place to capture the information produced, for economic and technical evaluation. The impact of rheology, recycle streams, and residence time distributions on the technical and economic performance can be assessed. Various processes can be compared technically and economically because the pilot plants are readily modifiable. Several technologies for residual starch yield improvement have been identified, implemented, and patent applications filed. Various biomass-to-ethanol processes have been compared and one selected for technical optimization and commercialization. The technical and economic feasibility of the current simplified biomass conversion process is being confirmed by intensive pilot plant efforts as of this writing. Optimization of the feedstock handling and pretreatment is occurring to increase the alcohol yield above the minimum commercially viable level already demonstrated. Samples of biomass residue and reactor blowdown condensate are being collected to determine the technical and economic performance of the high-water-recycle waste treatment system being considered for the process. The project is of benefit to the public because it is advancing the efforts to achieve low-cost fermentable substrates for conversion to transportation fuels. This process combines the hydrolysis of agricultural residues with novel enzymes and organisms to convert the sugars released to transportation fuels. The process development is taking place at a scale allowing commercial development to proceed at a rapid pace.