In the IBUS process (Integrated Biomass Utilization System) lignocellulosic biomass is converted into ethanol at high dry matter content without addition of chemicals and with a strong focus on energy efficiency. This study describes optimization of continuous hydrothermal pretreatment of wheat straw at pilot scale (up to 100 kg h(-1)) where six different pretreatment conditions have been investigated; all pretreatment conditions have been evaluated with regards to recovery of sugars after pretreatment (both C5 and C6) and convertibility of the cellulosic part of the fibers into ethanol. The experiments show that the optimum pretreatment parameters are 195 degrees C for 6-12 min. At these conditions, a total of app. 70% of the hemicellulose is recovered, 93-94% of the cellulose is recovered in the fibers and app. 89% of the cellulose in the fibers can be converted into ethanol by commercial cellulase mixtures - increasing to 92% when adding a commercial xylanase. (C) 2009 Elsevier Ltd. All rights reserved.