Author: microbial

Shilpa Medicare ETP Case Study
Background
Shilpa Medicare is one of the reputed pharmaceutical company. This is world class manufacturing facility is 100 export oriented API unit and spread over 22 acres. Shilpa Medicare Limited started its operations as API manufacturer way back in 1987 at Raichure, Karnataka – India. The commercial production in the Shilpa Medicare was started in November 1989.
Today Shilpa Medicare is a global brand in manufacturing and supplying of affordable API and formulation globally in different
regulated markets. Shilpa Medicare having two streams as HTDS and LTDS ETPs generating about 80 – 85 kl per day. Two different effluent wastreated separately.

Objectives –                                                                                                                                                                                                            Objectives of this project was to demostrate the effectiveness of MiCroBial Aqua & MiCroBial Odor by developing biomass
and sustain that biomass to improve wastewater quality and to provide plant stability along with odor control from ETP. Second object of this program was to degrade the dead sludge present in anaerobic digester and provide plant stability.                         

MiCroBial Technologies Solutions                                                                                                                                                                    MiCroBial Aqua is a natural biocatalyst made via novel fermentative process that has been refined by microbiologist in India. MiCroBial Aqua consists of selected consortium of bacteria and enzymes that degrade organic matter as carbs, proteins and fats. These microbes produces different types of enzymes as amylase, protease, lipase, cellulase etc.MiCroBial Aqua works in both aerobic and anaerobic conditions as it contents aerobic and facultative microbes in waste water treatment.

Dosing Program
Recommended Product                       MiCroBial Aqua & MiCroBial Odor
Volume of wastewater                         80,000 liters/day
Product quantity required                  1 kg/day
Fresh water required                           100 liters/day
Dosing point                                          Inlet of Anaerobic digester
Mode of application                            Application thru dosing tank of 100 liters capacity tank

Unit Description
ETP has different units like Collection tank, Anaerobic digester, Soar reactor, Secondary clarifier, Aeration tank 1st/2nd wtih
with daily flow rate of 80,000 liters of wastewater.

Existing Problems Before MiCroBial Technologies Treatment –
Anaerobic digester was completely inactive & dead and having solid organic sludge which was not able to remove from the tank.
Anaerobic digester was not playing any active role in the treatment and reduction of different parameters. The digester
outlet piping and internal system was blocked due to the dead organic sludge which was very hard to remove from the tank.
Dead sludge present in digester was producing odor in nearby environment. Odor nuisance was the primary concern for
the management. Our main objective were to digest the solid dead sludge from tank and activate anaerobic process.
Dead Sludge Before Treatment.

 

Dead Sludge before Treatment of MiCroBial Technologies – 500 KLD

Installation of Dosing System & Aeration System
For dosing of MiCroBial technologies product into the system, dosing system was installed at the base of anaerobic digester
where feeding of effluent to digester was done to facilitate microbes addition. Dosing system contains two tanks of 100 L
capacity along with dosing pump and piping with flow rate of 4.1 liters per hr.

Dosing System for MiCroBial Aqua
Compressed air was provided to digester to facilitate mixing of microbes with effluent and to loosen up the dead organic sludge
Once solid organic sludge digested with MiCroBial Aqua, compressed air was discontinued.

Implementation Protocol
Once dosing system and compress air system was installed at the inlet point of anaerobic digester, effluent from FRP tank was
added at flow rate of 3 kl per hr to fill up the anaerobic digester. PH of effluent was adjusted to its optimum along with addition
of compressed air. required quantity of MiCroBial Aqua culture was added to dosing tank with 100 L fresh water. Nutrient like
DAP, Urea and jaggary was added into second dosing tank which was dosed to digester along with culture. Activation of anaerobic digester was done in two parts.
1) Digestion of dead organic sludge
2) Development of sludge blanket and biomass
After addition of MiCroBial Aqua and nutrients into respective dosing tank, it was stirred and mixed for 30 min to get it dissolved. After 30 min, activated solution was dosed to anaerobic digester. During dosing care was taken that microbes were mixed properly with the effluent during feeding. Dosing of microbes and nutrient was done as per the program provided to client.

Dosing System of MiCroBial Technologies Product

Results
After dosing of MiCroBial Aqua for 10 days, it was observed that dead solid organic sludge was digested and got liquified. Solid
organic sludge was digested and converted to liquid. Blockages of pipes and internal system was completely removed opening
all the system for smooth operation of digester. After liquification stage, MiCroBial Aqua dosing was continued to for further
treatment. Optimum conditions were started to maintain to its optimum level like PH, VFA, Temperature, Alkalinity. with the
treatment of 2-3 months, we got results as per below,                                                                                                                                                Following parameters are maintained,
SRT – 8 – 10 days
HRT – 4 days
VFA – 2810 ppm
Alkalinity – 4620 ppm 

Reduction in COD mg/L 

Sr No	Date	Inlet COD mg/l	Outlet COD mg/l	Reduction %
1	08/05/20	7840	5120	65.3
2	11/05/20	10000	3760	62.4
3	13/05/20	10000	4720	52.8
4	14/05/20	11120	3600	67.6
5	15/05/20	10133	3680	63.6
6	16/05/20	12571	2720	78.3
7	18/05/20	14560	3312	77.2
8	19/05/20	16800	2224	86.7
9	20/05/20	18240	2624	85.6
10	22/05/20	13280	2784	79.03
11	23/05/20	16640	3008	80.95
12	24/05/20	20800	2320	88.8
13	25/05/20	15840	3104	80.4
14	26/05/20	13600	2208	83.7
15	28/05/20	13120	3136	76.09
16	29/05/20	15040	3056	79.6
17	30/05/20	13840	2544	81.6
18	01/06/20	18720	2640	86.4
19	02/06/20	20000	2720	84.05
20	03/06/20	16160	2576	84.5
	Average value	13607	2964	77.28

After few days of treatment, odor generation of odor from anaerobic digester was controlled tremendously. Sludge blanket &
biomass in anaerobic digester was developed with MiCroBial Aqua product providing optimum conditions.

Odor Control of Sludge Drying Bed
Excessive sludge of ETP was collected into sludge drying bed and it was dried and disposed further. Sludge drying bed was
producing odor nuisance that affects the working environment and health of workers. Management wanted to reduce the odor
from sludge drying bed

Application of MiCroBial Odor
250 gm of MiCroBial Odor was mixed with 100 L fresh water, stirred and mixed well to get it dissolved. Once it get dissolved,
activated solution was sprayed all over the sludge drying bed. Care was taken that microbes should get mixed properly with
the sludge present into bed.

Results
After couple days of application, officials was observed that there was good reduction in odor from the sludge drying bed.

Conclusion
The result of validation program demonstrated the effectiveness of MiCroBial Aqua in digestion & liquification of dead solid
organic matter was achieved by MiCroBial Technologies.
Secondly MiCroBial Aqua helped in development of sludge blanked and biomass in anaerobic digester. MiCroBial Odor was able to control the odor from sludge drying bed. Improvement in biomass, reduction in COD, TSS and water quality concludes that MiCroBial Aqua and MiCroBial Odor were very effective in wastewater treatment process.

Contact
Satish Bhandare – Microbiologist
MiCroBial Technologies
Tel – +91 8888885375
Email – satish@microbialtech.com

Kayempee Food Pvt Ltd Case Study
Background
Kayempee Foods Pvt Ltd is India’s top quality manufacturers of the finest chocolates. Our products are supplied to chocolate
makers and chocolate users across the Nation, from local bakeries to multi – national companies. The combination of Industrial Foods and Consumers foods creates a global powerhouse in wholesale supplier of chocolate products and chocolate confectionary in Andhra Pradesh and throughout the Nation. Currently, in India operates in three categories viz. Chocolate, Confectionery & Chocolate Products, In the Chocolate Confectionery business has maintained its undisputed leadership over the years. Some of the key products in India are Milk Chocolate, Bitter Chocolate, white Chocolate, Dark Chips, Milk Chips & White Chips, Plain Choco Paste, and Milk Choco Paste & Éclairs.Kayempee Foods Pvt Ltd.

Objectives
To treat the effluent coming from bakery and confectionary plant by using MiCroBial Technologies product.
Current system is treating about 80,000 liters of effluent @ your ETP. It’s having food stuff, oil, fats, grease, and other
organic and inorganic substances coming from sewage as well.

MiCroBial Technologies Solutions
The core MiCroBial Aqua is a natural biocatalyst made via a novel fermentative process that has been continually refined by
microbiologist in India. MiCroBial Aqua consists of a select consortium of bacteria, enzymes, nutrients and co-factors that
degrade organic matter as Carbohydrate, Proteins & Fat (FOG). These microbes produce different types of enzymes as amylase,
Protease, Lipase, Cellulase etc. MiCroBial Aqua works in aerobic and anaerobic conditions as it contents aerobic and facultative anaerobic microbes.

Dosing Program
Recommended Product                    MiCroBial Aqua
Capacity of AD                                    1,97,000 liters per day
Product quantity required               1 kg/day ( 4 ppm)
Fresh water required                         200 liters of fresh water
Application point                                Inlet Point of anaerobic digester
Mode of application                           Application thru dosing tank of 200 liter capacity tank

Wastewater Treatment Process                                                                                                                                                      Wastewater treated by three different technologies as give below,
• Primary Treatment Process – Treatment with chemicals like coagulant & Flocculants
• Secondary Treatment Process – Biological treatment with MiCroBial bioculture
• Tertiary Treatment Process – Filtration system

Primary Treatment Process –
• Currently PH of influent was about 3.5 – 4
• PH adjustment was carried out by adding of base or acid was done into equalization tank to get the optimum PH 7 – 7.5
• PH of all ETP units was adjusted to 7 -7.5 throughout the process.
• Addition of chemicals like coagulant and flocculants was done in flash mixture to develop coagulation and flocculation
process in the flash mixture to reduce the suspended solids from the effluent.

Biological Treatment Process – Unit Description 
• Collection tank & Grease separation tank
• Equalization tank
• Flash mixture
• Primary settling tank
• Feeder for anaerobic digester
• Anaerobic digester
• Aeration tank 1st and 2nd
• Secondary clarifier
• Filtration system
• Treated water tank

During process development, MiCroBial Technologies will develop the biomass and sludge bed in anaerobic digester. All the
criteria like Sludge bed development, Biomass development, SRT, HRT, anaerobic digestion of organic matter, VFA, total SS,
all the parameters will be monitor for anaerobic digestion. It includes four processes as below
• Hydrolysis
• Acidogenesis
• Acetogenesis
• Methanogenesis

Application Method – 
Added recommended dose of MiCroBial Aqua into 100 liters of fresh water and kept it for 12-24 hrs. After 24 hrs start dosing
of MiCroBial solution at inlet point of anaerobic digester. Maintained the flow rate of 4.1 liter/hr dosing solution so that it will
be used in 24 hrs.
Once maintained optimum conditions, microbial growth will start to appear and add effluent to the ETP with good PH with
proper flow so that ETP will not get shock when effluent enters.
If effluent was having deficiency of nitrogen and phosphorus, we recommended adding source of nitrogen and phosphorus
as these are micronutrients for the biomass development.
Daily flow rate of effluent was optimized as the digester design or 3.3 kl/hr. to avoid shock dosing.
It was essential to added, urea and Jaggary to the anaerobic digester, it will source of nitrogen, phosphorus and carbohydrates

Aerobic Digestion
Aerobic process will be carried out in aeration tank in the presence of oxygen in the tank. Aerobic digestion is one of the
most important process in biological process.

Dosing Program
Recommended Product – MiCroBial Aqua
Capacity of aeration tank – 2,52,000 liters/day
Quantity of Product – 1 kg/day
Fresh water required – 100 liters of fresh water.
Application Point – Inlet Point of aeration tank
Mode of Application – Application thru dosing tank of 100 liter capacity tank

Application Method                                                                                                                                                                                     Added recommended dose of MiCroBial Aqua into 100 liters of fresh water and kept it for 12-24 hrs. After 24 hrs start dosing
of MiCroBial solution at inlet point of aerobic digester. Maintained the flow rate of 4.1 liter/hr dosing solution so that it will be
used in 24 hrs.
Once maintained optimum conditions, microbial growth will start to appear and add effluent to the ETP with good PH
with proper flow so that ETP will not get shock when effluent enters.
If effluent having deficiency of nitrogen and phosphorus, we are recommending adding source of nitrogen and phosphorus
as these are micronutrients for the biomass development.
Daily flow rate of effluent will be optimized as the digester design or 3.3 kl/hr. to avoid shock dosing.
If required, it was essential to add urea and Jaggary to the aerobic digester, it will source of nitrogen, phosphorus and
carbohydrates.

Benefits of MiCroBial Aqua
Reduce in sludge production
Reduce BOD, COD, TSS, Biological nutrients
Improve MLSS, Biomass in the system
Reduce odors
Reduce need for chemical additives
Reduce hydrogen sulfide, ammonia and nitrates
Enhance nitrogen and phosphorus removal
100% natural and non-toxic

List of equipment’s are given below
Four 100 liter capacity tank with tote at the bottom
400 liters of fresh water
MiCroBial Aqua product

Notes: No special training is required to mix and dose MiCroBial product is non-hazardous and no special personal protection
equipment is required in regards to activation or dosing.

Results & Observation –
After providing optimum conditions for the application of MiCroBial Aqua, dosing of culture and nutrients started in
anaerobic digester on daily basis as per the biomass provided to the client. With the continues application for min 4 weeks
our team were observing different parameters and changes in anaerobic digester. After 4 weeks, sample of effluent removed
from bottom of anaerobic digester to see the sludge development and TSS in the bottom. A thick sludge was observed in a
bucket which was came out from the sludge bed or biomass developed in the bottom of anaerobic digester.
At the same time COD was tested at in house lab for reduction, after testing, it was observed that COD was reduced from
25,000 mg/L to 5000 mg/L. Odor of treated effluent was reduced coming from the anaerobic digester.
Same effluent treated from anaerobic digester was transferred to 1st aeration tank to 2nd aeration tank and 3rd aeration tank
respectively for aerobic digester. with provided optimum conditions in aerobic digestion, we observed good biomass or MLSS
development in aeration tank when we tested Sv30. Tested Sv30 was 300-400 ml/L.
ETP is now getting good performance with the help of MiCroBial Aqua and biomass development program provided to the
client. Initialy MiCroBial Technologies analysised every aspect of ETP like optimum conditions, done trouble shooting and
provided biomass development program mentioning PH, HRT, Flow rate, Dosing concentration, Feeding concentration, nutrient
addition, DO etc.
MiCroBial Technologies provided A to Z complete solution to the food ETP to get the plant stability along with the microbial
culture.

Conclusion
MiCroBial Technologies provided a well balanced microbial consortium for the treatment of food effluent with high COD
and BOD concentration in suspended and dissolved form. MiCroBial Aqua was able to develop sludge blanket and biomass
in the anaerobic digester to carry out all the steps of anaerobic digestion like hydrolysis, acidogenesis, acetogenesis and
methanogenesis. It was also observed that it has ability to control the odor from effluent.
MiCroBial Aqua is also able to develop biomass/MLSS in aeration tank (Image 1st). Aerobic process was developed with the
nitrification and denitrification process to reduce BOD. Briefly, MiCroBial Aqua is having ability to perform nitrification/
denitrification process in aerobic digestion and anaerobic digestion in food effluent treatment plant.

Contact –                                                                                                                                                                                                           

Satish Bhandare – Microbiologist
MiCroBial Technologie
Tel – +91 8888885375
Email – satish@microbialtech.com/support@microbialtech.com

Background
Ruby Hospital is one of the best and popular hospital in India located in pune, maharashtra. Ruby Hospital popularly known as Ruby Hall Clinic. It was established by K.B Grant in small nursing home in 1959 in the bungalow. Today Ruby Hall Clinic boasts of 500 inpatient bed including 130 intensive care beds with staff strength of 150 consultants, 500 panel of doctors and paramedical staff. Ruby Hall Clinic generate about 40,000 liters of wastewater coming from different department of hospital like operation. theater, Toilets, Urinals and equipment washing. This waste water treated at STP.

Objectives of validation program was to demonstrate the effectiveness of MiCroBial FOG & MiCroBial Aqua by developing biomass and sustain that biomass to improve wastewater quality and to provide plant stability along with odor control from STP.

Unit Description – 
STP has collection tank, aeration tank, clarifier and filtration system with treated tank. This STP treats 40,000 liters of wastewater with daily flow of 40,000 liters/day.

Dosing Program –

Recommended Product           – MiCroBial Aqua
Volume of wastewater             – 40,000 liters/day
Product quantity required        – 200 gms/day
Fresh water required               – 60 liters/day
Dosing point                            – Inlet of collection tank
Mode of application                 – Application thru dosing tank of 100 liters capacity tank

Implementation Protocol –
Before start of dosing of MiCroBial Aqua, test samples were taken for testing from inlet and Outlet point. Implementation team added 200 gms of MiCroBial Aqua product in 60 liters of fresh water and kept it for 24 hrs for activation purpose. Activated solution was dosed into inlet point of collection tank over the period of 24 hrs. Dosing of activated solution was started in such as way that dosing of 60 liters of solution should match with daily flow of wastewater into collection tank. It was also recommended to add 100 gms of DAP and Urea into aeration tank as a source of nitrogen and phosphorus. During addition of MiCroBial Aqua, Sludge volume was monitored regularly to see the biomass into aeration tank. PH of wastewater was also monitored regularly.

Results –
After few weeks of addition of MiCroBial Aqua product into collection tank, implementation team observed significant improvement in biomass ( sludge volume) and water quality. Based on initial monitoring of sludge volume of aeration tank which was below 100 mg/l, it was improved to more than 300 mg/l, it was concluded that MiCroBial Aqua helped to improve the biomass in aeration tank reducing different parameters and improving water quality and provide plant stability along with improved water quality.

 

Conclusion – 
The result of validation program demonstrate the effectiveness of MiCroBial Aqua in improving the water quality and biomass by increasing sludge volume of the aeration tank along with odor control from STP. Improvement of biomass and water quality concludes that MiCroBial Aqua is very effective in generating biomass in wastewater treatment process.