Gujarat

Technological
University

COLLEGE NAME:-DR. S. AND S.S. GHANDHY

GOVERNMENT ENGINEERING COLLEGE,SURAT.

BRANCH : Environmental Engineering

SUBJECT : Summer Internship at Sumul
Dairy,Surat.

NAME : RUSHIL ASHOKBHAI KATHIRIYA

Enrollement No. : 190230113023

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 Table of content

Sr. No. Name Page No.

1 Acknowledgement 3
2 Introduction Of The Sumul Dairy 4

3 Executive Summary Of Dairy 5

4 Introduction of the ETP Plant 6

5 Various unit of ETP plant 6

6 Flow diagram and introduction of 7

main units and its function

7 Introduction to Hydro Plant 14

8 Conclusion 16

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 Acknowledgement
The internship opportunity I had with SUMUL DAIRY(SURAT) was a
great chance for learning and professional development. Therefore, I
consider myself as a very lucky individual as I was provided with an
opportunity to be a part of it. I am also grateful for having a chance to
meet so many wonderful people and professionals who led me though
this internship period.
Bearing n mind previous, I am using opportunity to express my deepest
gratitude and special thanks to Mr. Hardik Gamit who spite of being
extraordinarily busy with his duties, took time out to hear, guide and
keep me on the correct path and allowing me to carry out my project at
their esteemed organization and extending during the training.

I express my thanks to Mr. Vijay Benjaliya and Mr. Shailesh Hadya,

plant incharge for taking part in useful decision & giving necessary
advices and guidance to me. I chose this moment to acknowledge their
contribution gratefully.

I am thankful to Laboratory Manager, Mr. Chirag Unagar for giving

detailed Information of different chemical process taking place in the
industry.

I am heartly thankful to my teachers and parents eho have always

inspired nd encouraged me throughout my life through all odds and
blessed me to achieve my goals.I perceive as this opportunity as a big
milestone in my career development. I will strive to use gained skills and
knowledge in the best possible way, and I will continue to work on their
improvement, in order to attain desired career objectives.

RUSHIL A. KATHIRIYA

GEC,SURAT

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 Introduction Of The Sumul Dairy
Sumul or Surat Milk Union Limited, which is now renamed as The
Surat District Co- operative Milk Producers’ Union Ltd, is one among
the 17 district unions which acts as manufacturing units of dairy
products for Gujarat Co-operative Milk Marketing Federation
Limited, the marketers of Amul brand of products.

Sumul Dairy has planned to develop this project with minimum

stresses on resources and environment. As a part of this planning,
Sumul has upgraded an Effluent Treatment Plant(ETP) from 600 KLD
to 1500 KLD for treat the effluent generated from its unit. The
installed capacity of the ETP is 1500 m3/day. Sumul produced many
milk products.

There are some sections in the plant:-

1. Milk production section

2. Milk powder section
3. Dahi production section
4. Sweets production section
5. Paneer production section
6. Butter production section
7. Ghee production section

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 Executive Summary Of Dairy
The Environment Audit scheme is introduced by the Hon’ble Gujarat
High Court vides its order dated 20-12-1996 & 13-03-1997 and vides
order dated 16-09-1999 “Environmental Audit”is an environmental
management tool comprising a systematic, documented and periodic
evaluation of how well Environment Management System is
performing.

The seasonal (three) site visits and inspection were conducted during
audit period which covers site activities, functions, products,
processes, examination of relevant documents and collection of
relevant samples. Based on above all data submitted by the client,
adequacy and efficacy of Environmental Management System is
evaluated and observations/recommendations are suggested in the
report for better improvement.

Effluent generated from process and other ancillary operation is

treated in its own ETP. Treated effluent is partially re-use in
gardening, washing, toilets and remaining is discharged into Surat
Munucipal Coeporation Drain.

In a nutshell, production, water consumption, Waste water

generation, Air emission and Hazardous waste generation/disposal
falls well within the permited quantity of CCA prescribed by GPCB.

Last but not least ECS is extremely grateful to the staff members of
the industry whose extended cooperation in providing necessary
details has helped us to prepare the audit report satisfactory and in
time.

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 Introduction of the ETP Plant
The dairy industry is generally considered to be the largest sources
of food processing waste water.

Although the dairy industry is not commonly associated eith

severe environmental problems, it must consider its
environmental impact particularly as dairy pollutants are mainly if
organic origin.

In general, wastes from the dairy processing industry contain high

concentrations of organic material such as:-

- Proteins
- Carbohydrates
- Lipids
- High concentration of suspended solids
- High nitrogen concentration
- High suspended oil and grease contents in sumul
Source of wastewater in ETP :-
- Spilled milk, spoiled milk, sour milk
- Wash water from milk cans, equipment, bottles, plant washing
flow
- Overflows, spillages and leakages from pump

Units of ETP plant

1. Screen chamber
2. Collection tank
3. Equalization tank
4. DAF
5. Conditioning tank
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 6. IC-reactor
7. Bio Reactor
8. MBR system
9. Treated water tank
10. Sludge tank
11. Decanter
12. Sludge Drying Bed
13. Gas Ballon
Flow Diagram of ETP Plant :-

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1. Screen chamber- (1*1*1.3)
- Bar screen
-
2. Collection tank & Equalization tank – (8.5*4.0*3.5)
- To avoid fluctuation in temperature & organic loading in stream.
- To equalization of hydraulic as well as mass load.

3. DAF (Dissolved Air Flotation)

-Dissolved air floatation is a water treatment process that clarifies

wastewaters by the removal of suspended matter such as oil
solids.

-Chemical adding poly ( anionic polyelectrolyte powder), Poly

Aluminium Chloride(PAC), lime.

-It operate with a pressurized recycle flow and generate fine

bubbles of 30 micron size which lift the suspended particles to the
top surface from where it picked up by a scoop.

- sludge from flocks shall be pumped to sludge tank.

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4. Conditioning tank-(7.5dia*3.0)
- Providing three dosing – urea dosing, NaOH dpsing, DAP
nutrients dosing. For mixing we provides the air.
- Conditioning tank required to prepare effluent for IC reactor. It
provides favorable condition to microorganism which grow in IC
reactor.

5. IC Reactor- (4.7dia*24)
- It used to remove COD and BOD anaerobically.
- It is based on attached growth process.
- In the ICR flow is upward direction.
- In the ICR methane, Carbon dioxide and other gases are
generated.

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- Gas collect in ballon and sludge collect in sludge tank.

6. -(15.0*12.0*4.0)&(18.5*5.8*4.0*)
- It requires stabilizing colloidal particles and dissolved organic
matter.
- In the bioreactor submersible pump are used to provide mixing.
- F/M( food-Microorganism) ratio maintain in the Bio- Reactor.
- It degraded organic impurities.
- In Bio-Reactor MLSS value is between 9000-10,000 mg/l.

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- In the MBR tank members caseettes are provide toseparate
clear water from the mixed liquor from bio-reactor.
- Membranes are made from hollow fiber tube.
- Zeeweed*500D module is used in the MBR.
- Backwash of membrane by additionally sodium hypochlorite
and citric acid.

7.Treated water tank-(10.1*6.25*4.0

- After MBR water collected in treated water tank.
8.Fat Digester-
- The excess Fat/oil, settled sludge and other floating matter from
the DAF are transferred to FAT digester for sludge digestion
through sludge sump. This unit operatio employs
microoraganisms to convert high COD effluent/solids into
readily disposal digested sludge.
- Anaerobic digestion is a bacterial process that breaks down
organic material within waste in the absence of oxygen. It is
generally run in closed circular tanks.

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- Geerally biomass consisting of sludge or processing waste slurry
red into the digester without air. The waste stream generally
contains FATS,Oils,grease and other organic materials.
- The gas contain mainly methane(CH4) and carbon dioxide(CO2).
9. Sludge tank-(5.0*4.0*4.0)
- Its required to collect sludge from IC Reactor, DAF, aeration
tank.
10. Decanter-(7.5m3/hr)
- In decanter centrifuge the thick slurry is kept in centrifugal
action for solid liquid separation of sludge.
- Polyelectolyte dosing system is provided to enhance solid liquid
separation.
- Than thick sludge cake will be disposed off.

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11. Sludge Drying Bed-(4.5*4.5)
- To sludge dryinf beds for natural sun drying in case at
maintenance of decanter centrifuge.

12. Gas Ballon-(5.2dia*6.6)

- Biogas generated is collected In gas holder from top of tank,
then stored into ballon.
- This biogas is utilized in sweet manufacturing section, Canteen
and also used in kitchen of prior.
- Alternative arrangement has been made to utilize excess biogas
by flaring it from flare stack.

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13. PRT tank-
- Working of PRT tank- Regulation of this stored biogas to end
users at intermittent or continuous intervals with a low or high
demand is controlled by PRT
- There are five operating syste.
- Pressure regulating tank, Gas blower, Pressure regulator,
Control panel.

There are three types of cycle in working of plant:-

1. Production Cycle.(600 sec)
2. Prime Cycle.(60 sec)
3. Back pulse Cycle.(60 sec)

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Water Parameters:-

Sr. No. Parameters Unit Inlet value Outlet

value
1 Inlet Flow m3/day 15000
2 pH - 6.5-8.5
3 BOD mg/l 2000-4000 30

4 COD mg/l 5000-11000 100

5 TSS mg/l 2000-3000 100

6 Oil & Grease mg/l 300-500 10

Introduction to Hydro Plant

Hydro plant is filtration system of water that’s providing in the
dairy. Hydro plant supplies purified water to each sections for
production and also in apartments.

The capacity of the Hydro plant is 10,000 to 15,000 lit/day.

 Unit of Hydro plant:-

1. Raw Water Tank
- Raw water store in the raw water tank.
2. PSF (Pressure Sand Filter)
- PSF are widely used to remove suspended solids and
remove the turbidity in water.
3. ACF(Activated Carbon Filter)
- An activated carbon filter(ACF) works on the principal of
adsorption filter medium absorbs or reacts with a pollutant
molecules then filtered water is drained out.Activated carbon
which is used as medium to remove contaminants is natural
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 material derived from coconut shell, lignite, bituminous coal
etc.
4. SMBS Dosing (Sodium Metabisulfite)
- Sodium Metabisulfite or Sodium Pyrosulphite(SMBS) is
often used as pretreatment to large RO systems for free
chlorine removal and as a biostatic. Carbon filters are a
common alternative for small systems, but SMBS has an
advantage for larger systems due to lower risk of bacteria
growth that can cause biological fouling.
5. MCf (Micron Filter )
- The MCf process involves the screening of raw water
through retention of micro particles & micro organisms on
spongy porous surface. MCF reduces the number of unit
processes for clarification.
6. HPP(High Pressure Processing)
- water is filled into the HPP vessel and pressurized to
pressure of 6,000 bar.
7. ROM (Reverse Osmosis Membrane)
- A reverse osmosis membrane is a semi-permeable
membrane that allows the passage os water molecules but
not the majority of dissolved salts, organics,bacteria and
pathogens.
8. Reject Water Tank
- Reject water tank store the water which comes from
membrane cleaning process, cleaning of sand filter and
activated carbon filter.
9. RO water storage tank
- Purified water collect in the RO storage tank and then they
distribute water the dairy.

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 Conclusion
During the course training at Sumul dairy . I got the chamce to
implement my theoretical knowledge with practical reality
especially while working in the ETP plant at Sumul dairy. I learned
many things such as common skills,sense tp responsibility ,etc. The
most important of all is about to know the working of ETP plant via
various stages. I also learned how the wast water is converted into
biogas which can be ised further as an energy source in sweet and
canteen section of Sumul dairy. Ths reduces the amount of waste
on the environment.

The most important thing I learn how waste water can be used to
produce energy which will be beneficial to the mankind in future. I
learned about the technological aspect and attained helpful to me
at present and also in future extremely enjoy my tranng with full
exposure to practical reality and am rather sure it will be a starting
confidence I the field and also came across new things which can
be encouraging period for me and will help me to familiar with
industrial knowledge. It was good time spent at Sumul.

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