In today’s industrial landscape, effective wastewater treatment is no longer just a best practice—it is a legal requirement and a crucial step toward environmental sustainability. Industries, especially in sectors like dairy processing, generate high-strength wastewater that must be treated before discharge or reuse.
V Aqua, a trusted name in industrial water treatment solutions in India, successfully designed and installed a 50 KLD Effluent Treatment Plant (ETP) for Ekta Dairy, a growing dairy manufacturer based in Noida. This project stands as a strong example of how proper engineering, planning, and execution can solve complex wastewater challenges while ensuring full regulatory compliance.
This detailed case study explains the challenges faced by Ekta Dairy, the customized solution delivered, the treatment process, and the measurable results achieved after commissioning.
Project Overview
- Client Name: Ekta Dairy
- Industry: Dairy Processing (Ghee Manufacturing)
- Location: Noida, Uttar Pradesh
- Plant Capacity: 50 KLD (50,000 Litres per Day)
- Project Type: Effluent Treatment Plant (ETP)
- Solution Provider: V Aqua Water Treatment Company
- Project Status: Successfully Commissioned & Operational
- Compliance Standard: CPCB / HSPCB Norms
Ekta Dairy operates a mid-scale ghee production facility. As production increased, the volume and strength of wastewater also grew significantly. The existing infrastructure was not sufficient to handle the high organic load, leading to operational inefficiencies and regulatory issues.
Recognizing the need for a reliable wastewater treatment system, Ekta Dairy partnered with V Aqua to design a solution that would ensure compliance, efficiency, and sustainability.
Challenges Faced by Ekta Dairy
Wastewater generated from dairy operations—especially ghee manufacturing—is particularly difficult to treat due to its high organic content. Before implementing the ETP, Ekta Dairy faced several critical issues:
1. High Organic Load (BOD & COD)
The effluent contained large amounts of fats, oils, proteins, and lactose, resulting in extremely high Biochemical Oxygen Demand (BOD) and Chemical Oxygen Demand (COD).
2. Fluctuating Wastewater Flow
Variations in production cycles led to inconsistent wastewater flow rates, making it difficult to maintain stable treatment conditions.
3. Odour Problems
Untreated and partially treated wastewater produced strong foul odours, affecting the surrounding environment.
4. Regulatory Pressure
The facility received notices from pollution control authorities due to non-compliance with discharge standards.
5. Space Constraints
Limited available land required a compact and efficient plant design.
6. Lack of Technical Expertise
The absence of trained personnel meant the system needed to be simple to operate and maintain.
Project Objectives
After conducting a detailed site inspection and wastewater analysis, the engineering team defined clear project goals:
- Treat 50,000 litres of effluent per day consistently
- Achieve discharge standards as per CPCB and HSPCB
- Reduce BOD to below 30 mg/L
- Reduce COD to below 250 mg/L
- Minimize sludge generation and ensure proper disposal
- Design a space-efficient plant layout
- Enable reuse of treated water within the facility
- Ensure easy operation without specialized manpower
Tailored Solution by V Aqua
Based on wastewater characteristics and site conditions, V Aqua designed a multi-stage Effluent Treatment Plant combining physical, chemical, and biological treatment processes.
Instead of relying on a single advanced technology, the approach focused on a proven and reliable treatment train, ensuring:
- High performance
- Cost-effectiveness
- Operational simplicity
- Long-term reliability
The system included:
- Physico-chemical treatment for primary contaminant removal
- Extended Aeration biological process for organic degradation
- Tertiary polishing for final water quality improvement
The entire project—from design and civil work to installation, commissioning, and training—was handled end-to-end by V Aqua.
Step-by-Step Treatment Process
1. Bar Screening and Grit Removal
The incoming wastewater first passes through a bar screen to remove large solids such as food particles and debris. A grit chamber then removes sand and heavy inorganic matter, protecting downstream equipment.
2. Oil & Grease Trap
Dairy wastewater contains significant fats and oils. The oil and grease trap removes floating contaminants before biological treatment, preventing system failure.
3. Equalization Tank
The wastewater is collected in an equalization tank to stabilize flow and pollutant concentration. Diffusers ensure proper mixing and prevent septic conditions.
4. Flash Mixing & Clariflocculation
Coagulants like alum and polyelectrolyte are added to destabilize suspended particles. These particles then settle in the clariflocculator, reducing turbidity and COD.
5. Aeration Tank (Extended Aeration Process)
This is the core of the treatment system. Aerobic bacteria break down organic pollutants in the presence of oxygen supplied by aerators. The extended retention time ensures effective treatment.
6. Secondary Clarifier
Biological sludge settles here. A portion is recycled back as Return Activated Sludge (RAS), while excess sludge is sent for further treatment.
7. Tertiary Treatment (PSF & ACF)
- Pressure Sand Filter (PSF): Removes residual suspended solids
- Activated Carbon Filter (ACF): Eliminates colour, odour, and trace organics
8. Disinfection
Final treatment is done using UV or chlorination to eliminate pathogens and make water safe for reuse.
9. Sludge Management
Sludge is thickened and dewatered using a filter press. The solid cake is disposed of as per regulatory guidelines, while filtrate is recycled.
Key Equipment Installed
- Bar Screen Chamber
- Oil & Grease Trap
- Equalization Tank with Diffusers
- Flash Mixer & Clariflocculator
- Aeration Tank with Aerators
- Air Blowers
- Secondary Clarifier
- Pressure Sand Filter
- Activated Carbon Filter
- UV Disinfection System
- Chemical Dosing Units
- Sludge Thickener & Filter Press
- Electrical Control Panel with Monitoring Instruments
- Pumps, pipelines, and valves
Project Execution Timeline
The project was completed in just 24 days, ensuring minimal disruption:
- Day 1: Site survey and design
- Days 2–10: Civil construction
- Days 11–16: Mechanical installation
- Days 17–19: Electrical and instrumentation
- Days 20–22: Commissioning and trials
- Days 23–24: Training and handover
Performance Results
After stabilization, the plant achieved consistent results:
| Parameter | Raw Effluent | Treated Effluent | CPCB Limit |
|---|---|---|---|
| pH | 4.5 – 6.0 | 7.2 – 7.8 | 6.5 – 9.0 |
| BOD (mg/L) | 1200 – 1800 | 18 – 22 | ≤ 30 |
| COD (mg/L) | 3500 – 5000 | 180 – 210 | ≤ 250 |
| TSS (mg/L) | 800 – 1200 | 28 – 35 | ≤ 100 |
| Oil & Grease | 400 – 600 | 4 – 6 | ≤ 10 |
| TDS (mg/L) | 2000 – 3000 | 1100 – 1400 | ≤ 2100 |
Before vs After Installation
| Aspect | Before | After |
|---|---|---|
| Compliance | Non-compliant | Fully compliant |
| BOD | 1200–1800 | 18–22 |
| COD | 3500–5000 | 180–210 |
| Odour | Severe | Eliminated |
| Water Reuse | None | 30–35% reuse |
| Sludge Handling | Unmanaged | Proper disposal |
| Costs | High penalties | Optimized |
| Environmental Impact | High | Minimal |
Benefits Achieved by Ekta Dairy
1. Full Regulatory Compliance
The facility now meets all pollution control standards, eliminating legal risks and penalties.
2. Water Conservation
Approximately 15,000–17,000 litres per day is reused for non-potable purposes.
3. Cost Savings
Reduced freshwater consumption and elimination of fines improved financial efficiency.
4. Improved Brand Image
The company is now seen as environmentally responsible.
5. Scalability
The system can be expanded to 100 KLD in the future.
6. Ease of Operation
User-friendly controls allow smooth operation without specialized staff.
Why Choose V Aqua for ETP Installation?
V Aqua stands out in the wastewater treatment industry due to:
- 15+ years of experience
- Expertise in dairy wastewater treatment
- Complete turnkey project execution
- Compliance with CPCB, SPCB, and NGT norms
- Transparent pricing
- AMC and 24×7 technical support
- Projects delivered across India
Conclusion
The 50 KLD ETP installed at Ekta Dairy demonstrates how a properly designed wastewater treatment system can go beyond compliance to deliver real operational and environmental benefits.
For industries dealing with high-strength effluent, investing in an efficient ETP is not just about avoiding penalties—it is about ensuring long-term sustainability, reducing costs, and maintaining a responsible business image.
If your facility is facing wastewater challenges, this project serves as a proven reference for what can be achieved with the right expertise and approach.
Get a Free Consultation
Looking for a reliable ETP solution?
- Call: +91-9560654995
- Email: sales@vaqua.in
- Website: www.vaqua.in
Take the first step toward compliance and sustainability today.
Frequently Asked Questions (FAQs)
Q1. What is a 50 KLD ETP Plant?
A 50 KLD ETP treats 50,000 litres of wastewater daily using multiple treatment stages to meet discharge norms.
Q2. What is the cost of a 50 KLD ETP in India?
Typically ranges between ₹25 lakhs to ₹55 lakhs depending on design and site conditions.
Q3. Why is ETP mandatory for dairy units?
Due to high organic pollution load, regulations require treatment before discharge.
Q4. Installation time?
Usually 20–28 days. This project was completed in 24 days.
Q5. Required discharge standards?
- pH: 6.5–9
- BOD: ≤30 mg/L
- COD: ≤250 mg/L
Q6. Can treated water be reused?
Yes, for gardening, washing, and cooling applications.
Q7. Why choose V Aqua?
Reliable performance, strong expertise, and long-term support.
