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INTRODUCTION

Dudhsagar dairy, under Mehsana co-operative milk producers union being one of the prime
players in the co-operative dairy sector always gave special preference to its environmental
and waste management systems. This is obvious through the various recognitions and
certifications received by it strictly following the environmental parameters. Following all the
procedures to the maximum possible extent given its large processing capacity of 25 Lakh
litres per day is a difficult task; however Dudhsagar dairy with its unflinching attitude
towards environment and social concerns is successfully managing such problems.
DUDHSAGAR DAIRY WASTE MANAGEMENT

The waste management system in Dudhsagar dairy is not a linear system where we end up
with a waste product which has no further use. Its more of a circular system where there is
no concept of a waste product, its just an output which has no use has found out yet.

Linear system of waste disposal Not followed in Dudhsagar dairy, Mehsana

Disposing to
Raw Material Processing Waste environment

There is no proper disposal system for the waste produced through utility creation,
therefore contributes to the environmental pollution

Circular system of waste management Followed in Dudhsagar dairy, Mehsana

Disposal Recycle

Use Manufacture

Distribution

In Dudhsagar dairy we follow the three basic principles of circular economy in waste
management

PRINCIPLE 1: Preserving and enhancing natural capacity by controlling and


balancing finite stocks: Dudhsagar dairy maintains minimum inventory level so as to
contribute to managerial efficiency also to cause less wastage by obsolescence.
We follow inventory reduction by scientific management, where we estimate the future
demands, analyze the MIS data, consider potential opportunities in market.

PRINCIPLE 2: Optimise resource yields by circulating products, components and


materials in use at the highest utility: The water waste generated by the processing of milk
is circulated into different production cycle. The fat from effluent water is extracted and is
despatched to the soap industry, the dried sludge from the remaining is used as a fertilizer in
the gardening activities in the plant. Thereby having a double benefit of waste disposal and
maintaining the greenery of the campus.

PRINCIPLE 3: Foster system effectiveness by revealing and designing out negative


externalities: Over the years, the fat extracted from effluent water is reduced considerably,
indicating the technological up gradation and the improvement in efficiency achieved by
Dudhsagar dairy. This contributes to lesser labour required in the waste management section
too.

Effluent water

Fat extracted -
Sludge (Dried) - Clarified water -
used in soap
used as ferilizer for gardening
industry

Waste Management in Dudhsagar Dairy, Mehsana

1. Liquid effluent:

Generated during cleaning vessels, equipment, machinery, floor area milk cans, boiler
blow down, and cooling tower blow down.
The maximum quantity of combined effluent is 3000 cubic metre/day
Contains milk constituents, cleaning compounds, sugar (from SCM plant), and dissolved
solids from blow down streams.

ETP UNIT DETAILS FOR WASTE WATER TREATMENT

The waste water coming out from the plant is of two types, Stream 1 and Stream 2, in
which stream 1 is the influent coming from ghee, butter, process, N3N4 Powder plant and
refrigeration section.

The effluent water is treated is subjected to all the processing stages as follows.

1. Fat trap
100 ml sample is collected, for lab analysis
Raw wastes are trapped and removed
2. V notch screen chamber
Height is measured to find the quantity flowing
To remove garbage and other wastes from screen chamber
3. Fat collection trap
Whole raw waste fat is transferred to vessel by pump
Heated for 8 to 10 hours
Good fat at the top and inferior fat at the bottom*
4. Fat despatch
Good fat is manually collected and inferior fat to fat collection sump
Both waste fats are sold to soap industry
5. V notch screen chamber
Height is measured to find the quantity flowing
To remove garbage and other wastes from screen chamber
6. Final fat trap
Removes fat wastes from stream 1 and 2
Transferred to vessel by pump and heated
7. Equalization Tank
Both streams of influent equalize and mixed with the help of aerators
Transferred to HRSCR by pump**
8. HRSCR***
Alum, lime dosing in HRSCR , causes suspended solids to settle down
Mechanical scrapers remove these by sweeping
The settled sludge is transferred to sludge thickener
9. Sludge thickener
Heavy particles at the bottom and light particles at the top
Light particles are removed by sweeping
To sludge drying beds, Influent to collection tank
10. Holding tank
Used as a spare collection tank in case of any operational failure

11. Anaerobic Digester


Influent from HRSCR to anaerobic digester
Digested organic material reduces BOD and COD up to 30-70%
12. Aeration Tank - 1
Provide aeration by 6 surface aerators
Retained for 36-38 hours
13. Aeration Tank 2
Provides aeration, holding for 16-17 hours
14. Final clarification
Water is mixed with bio mass
Biomass at the bottom
15. Final V-notch Chamber
Disposal to garden

Plant design criteria

ETP Plant in Mehsana is designed to have an optimum level of several parameters they are
called as ETP Design Criteria.

1. Design flow = 3000 cubic meter/day


2. Design PH = 6.5-9.8
3. Design TSS = 800 mg/l
4. Design COD = 8000 mg/l
5. Design BOD = 5000 mg/l
Quality tests done at various stages

ETP Laboratory daily analysis chart of sample

No Paramete Unit Raw Influent HRSC HRSC Final G.P.C. Aerate


. r Strea Strea R Inlet R Outle B d
m-1 m-2 Outlet t Norms Lagoon
1 PH ........ Yes Yes Yes Yes Yes 6.5-8.5 Yes
2 Temp. Celsiu Yes Yes Yes Yes Yes 40 Yes
s
3 T.S.S Mg/l No No No Yes Yes 100 No
4 T.D.S Mg/l No No No No Yes 2100 No
5 C.O.D Mg/l Yes Yes Yes Yes Yes 250 No
6 B.O.D Mg/l No No No Yes Yes 100 No
7 Oil & Mg/l Yes Yes Yes Yes Yes 10 No
Grease
8 M.L.S.S Mg/l No No No No No ....... Yes
9 D.O Mg/l No No No No Yes ....... Yes

Remarks

GPCB means Gujarat Pollution Control Board


Yes means analysis carried out at ETP laboratory everyday
No means analysis not carried out at ETP laboratory
Also we have to carry out all G.P.C.B required parameter by external GPCB registered
laboratory on every month and accordingly the Xerox copy for the same submit to
G.P.C.B every month
B.O.D analysis test is carried out on daily basis.
Also we are daily carried out analysis from fat trap outlet (Stage A&B) Oil and Grease
Above analysis are being carried out once in a day
Checking for the legal requirement of standards

As far as the ETP is concerned, its important to stick to the basic limits of all the parameters
provided by G.P.C.B. The inlet water should be very well within limits of these standards. By
analysing the data from ETP its found that none of the parameters havent exceeded by the
ETP Mehsana Dairy on any day of its functioning, for a brief view, data of the outlet water
coming out after aeration is provided below. The same water is used for gardening purpose.

Final Water outlet analysis as on 19-06-2017*

Parameter Unit Final Outlet G.P.C.B Norms


PH ........ 8 6.5 8.5
Temperature Celsius 32 40
C.O.D Mg/l 53 250
B.O.D Mg/l 10-17 100
T.S.S Mg/l 28 160
T.D.S Mg/l 1800 2100
Oil & Grease Mg/l 1 10
Dissolved Oxygen Mg/l 6.4

Line study to understand the change brought in stages of treatment

The most effective way to have an idea about the relevance of each stages in waste water
treatment is by conducting a line study. In a line study the first step is to identify all the stages
of treatment, afterwards a sample is taken from all these. The analysis of all these samples is
done in ETP laboratory. This enables us to know how much effective each stage is having in
increasing the final water quality. Here are the synopses of the line study done on ETP plant
Mehsana .This data is taken for 19-16-2017

1. Identifying all the stages of waste water treatment

Raw
Raw influent HRSCR HRSCR Aeration Aeration Final
influent after fat Inlet Outlet Tank - 1 Tank - 2 Outlet
trap
Raw Influent

No. Parameter Unit Desired range Actual Value


1 PH ........ 9-12 9.5
2 Temperature Degree Celsius 50 47
3 COD Mg/l 5000 4640
4 Oil and Grease Mg/l 600 168

Treatment by HRSCR

No. Parameter Unit HRSCR Desired HRSCR Desired


Inlet Range Outlet Range
1 PH ........ 8 6-8.5 8 6-8.5
2 Temperature Degree 40 40 39 35
Celsius
3 COD Mg/l 2700 3500 1760 2700

Treatment by Aeration tank

No. Parameter Unit Aeration Desired Aeration Desired


Tank - 1 Range Tank - 2 Range
1 PH ........ 8 7-8.5 8 6-8.5
2 Temperature Degree 33 30 39 35
Celsius
3 MLSS Mg/l 3600
4 Dissolved Mg/l 2 6
Oxygen

Final Outlet

Same as that of the readings in table Final Water outlet analysis as on 19-06-2017*
Quantity of Water in KLPD
60000
53017
51062 51704 51769 51889 50360
49414
50000 47150 48394 47280 47195

40420
40000

30000

20000

10000

0
Apr/17 May/17 Jun/17 Jul/17 Aug/17 Sep/17 Oct/17 Nov/17 Dec/17 Jan/18 Feb/18 Mar/18

Usage of water for gardening purpose and disposal for the month of June - 2017

Sl No. Gardening Municipal Drainage Disposal


1 800 480 100
2 800 685 100
3 800 680 100
4 800 660 100
5 800 715 100
6 800 620 100
7 800 451 100
8 800 634 100
9 800 665 100
10 800 730 100
11 800 765 100
12 800 760 100
13 800 735 100
14 800 709 100
15 800 751 100
16 800 780 100
17 800 765 100
18 800 765 100
19 800 740 100
Average 800 689 100
Average Usage of water In KLPD
100

Gardening
Municipal Drainage
800
689 Drainage

Power Used In ETP Plant in KWH


140000
114987
120000
100473.6 102799.8 104135 101483.4 104553.8 103158.6 101835
97856.8 99620.6
100000 87352

80000

60000

40000

20000

0
Legal Recognitions

Received consent from Gujrath Pollution Control Board, in exercise of the power conferred
under section 25 of the Water (Prevention and Control of Pollution) Act 1974, under
section 21 of the Air (Prevention and Control of Pollution) Act 1981 and Authorization
under rule 5(4) of the hazardous waste (Management, Handling and Transboundry
Movement) Rules 2008, framed under the Environmental (Protection) Act 1986

Environmental Concern

On environmental day (June 5th) and World earth day (22nd April world) and the ETP
maintenance department plant around 50-70 trees and rear them with care.

Knowledge dissemination

The well functioning ETP plant is DSD is considered to be a model ETP plant. It has
perfection from start to end, thanks to the efforts from the management and workers.
In DSD Mehsana all kind of support and explanation is given as per the requirement of
the client. This is how we maintain the culture of knowledge dissemination in the plant.

This well functioning model of this plant makes it so famous which enables us to attract
various dairy and non-dairy players to replicate the same model. Plant is not only a model for
replication but also a favourite destination for consultants. Various entities which have visited
our plant is given below.

Punjab Co-operative dairy

Rajasthan Co-operative Dairy

Haryana Co-operative Dairy

Karnataka Co-operative Dairy

Hinz Dairy

Mother Dairy Gandhi Nagar

Banas Dairy

Vasundhara Dairy
Bagga Oil and Chemicals (Non - Dairy)

Suzuki motors (Non Dairy)

Apart from all these various companies from countries like Saudi Arabia; Mauritius visits the
plant to gain information about the plant.