TM

Dairy Industry

Client profile
XXXX company a joint venture formed in 2004 India’s first advanced processing and packaging
technology to partner leading food and beverage players like PepsiCo, Nestle, Danone, Britannia
and Hector Beverages. Aseptic beverages offer high quality and safe products with long shelf
life, without the need for refrigeration or preservatives. Currently, brands like Tropicana, Nestle
and Paper Boat are processed and packed in plant at Maharashtra.

Prominent & Leading Manufacturer from Maharashtra, They offer :-

Cookie Cutter Career, Process Cheese and Cream Cheese, Butter. Crud, Cheese, Lactose, Milk
Powder etc.

Operations Processes Sources of waste

Preparation Stages
Pasteurization/ ultra heat
treatment
Milk receiving/Storage
Pasteurization/ ultra heat
treatment
Homogenization
Separation/ Clarification
( Centrifuge, reverse
osmosis)
Poor drainage of tankers
• Spills and leaks from hoses
and pipes
• Spills from storage silos/ tanks
• Foaming
• Cleaning operations
• Liquid losses/leaks
• Recovery of downgraded
product
• Cleaning operations
• Foaming
• Deposits on the surfaces of
pasteurization and heating
equipment
•Liquid losses/leaks
• Cleaning operations
•Foaming
• Cleaning operations
• Pipe leaks

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com
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Product processing Market milk •Foaming

stages • Product washing
• Cleaning operations
• Overfilling
• Poor drainage
• Sludge removal from
• Clarifier/Separators
• Leaks
• Damaged milk packages
• Cleaning of filling machinery

Cheese making • Overfilling vats

• Incomplete separation of whey
from curd
• Using salt in cheese making
• Spills and leaks
• Cleaning operations

Butter making • Vacreation and salt use

• Product washing
• Cleaning operations

Powder manufacture • Spills of powder handling

• Start-up and shut-down losses
• Plant malfunction
• Stack losses
• Cleaning of evaporators
• Bagging losses

Plant parameters :-

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com
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a) Inlet characteristics
Daily Flow 1000 m3/day

pH 5.5-9.0

Total Suspended Solid 800-1500 mg/L

BOD 3 days@27°C 1600 mg/L

COD 3200 mg/L

Oil & Grease 150 mg/L

Ammonical Nitrogen 950 ppm

b) Outlet characteristics
pH 6 to 8

Total Suspended Solid ≤30 mg/L

BOD 3 days@27°C ≤30 mg/L

COD ≤250 mg/L

Oil & Grease <10

Ammonical Nitrogen <50 ppm

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com
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Plant Flow Diagram :-

Raw Effluent

Equalisation tank 1 & 2

DAF

UASB Reactor

Aeration

Clarifier Tank

Sand & Carbon Filter

Treated water for further

treatment

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com
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Problems faced By Client :-

 Volatile fatty acids are beyond control due that not able treat design quantity of effluent.
 Despite of having required MLSS, they are not able to achieve cod reduction more than
80%.
 Odour from biological system.

Solution :-

Advised to use Bacta cult Bio-culture “Anaerobic & Aerobic” with 60 days dosage,

Dosages schedule

S.No Days Bacta Cult Qty dosed Quantity

1 Day 01 to Day 05 10 kg/ Day 50 kg

2 Day 06 to Day 10 4 kg/ Day 20 kg

3 Day 11 to Day 30 1.5 kg/Day 30 kg

4 Day 31 to Day 60 1 kg/Day 30 kg

Total requirement for 10 days 130 kg

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com
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Observation after complete dosage of BactaCult

Bioculture:-

3500 3200

3000
2500
2000 1600 Untreated wastewater before
1500 950 BactaCult

1000 Treated wastewater after

BactaCult
500 187 35
21
0
mg/Lit mg/Lit mg/Lit
COD BOD Ammonical
Nitrogen

Result :-

The treatment plant achieved COD removal rates between 90 to 95% within the first month of
using Bacta Cult. The customer called the performance of the Bacta Cult quite satisfactory in
increasing the COD reduction. Use of Bacta Cult drastically reduced the odour also.

Apart from these, 20% reduction in sludge generation was achieved.

Amalgam Biotech, A Division of Amalgam Engineering, +91 20 65000758 www.amalgambiotech.com

A-201, Vastushilp Building,Sr. No. 90/4/1/2, admin@amalgamengg.com www.amalgamengg.com
Veerbhadra Nagar, Baner, Pune - 411045 MH INDIA sales@amalgambiotech.com www.amalgamtrainings.com