Table of Contents
In the thriving heart of India’s food processing industry, from the spice factories of Kerala and Karnataka to the dairy plants of Gujarat, managing wastewater is a critical factor in ensuring sustainable operations and regulatory compliance.
With the sector generating 10,000-50,000 litres of wastewater daily per facility, laden with organic matter, oils, and chemicals, untreated sewage risks environmental pollution and fines of ₹50,000-₹5 lakh from the Central Pollution Control Board (CPCB).
A sewage treatment plant food factory transforms this challenge into an opportunity, enabling water conservation in food industry and cost savings. For factory owners, plant managers, and compliance officers, a Food processing STP saves ₹50,000-₹10 lakh annually while enhancing efficiency.
This blog explores why food processing plants need sewage treatment, details how to set up STP in food industry, and provides actionable steps to implement the best STP plant for food processing factories with SKF Elixer’s robust solutions.
The Critical Need for Wastewater Management in Food Processing
India’s food processing industry, valued at ₹2.5 lakh crore in 2024, produces vast wastewater as dairy plants discharge 10-15 litres per litre of milk processed, and fruit processing units generate 5,000-20,000 litres daily.
This wastewater, with high BOD (1,000-2,000 mg/L) and TSS (500-1,000 mg/L), pollutes rivers and risks 37 million waterborne illnesses yearly if untreated. Traditional disposal methods incur costs of ₹500-₹1,000 per kg of sludge and face CPCB fines for non-compliance (BOD <30 mg/L, TSS <100 mg/L).
A sewage treatment plant food factory treats organic waste water treatment, enabling 30-50% water reuse and saving ₹50,000-₹2 lakh yearly on freshwater. Let’s uncover the advantages of STP for food factories and why it’s essential for sustainable operations.
How a Food Processing STP Works?
A Food processing STP processes wastewater through multiple stages tailored to high organic loads:
- Preliminary Treatment: Screens remove debris like peels or packaging (50-200 kg/day for 50 KLD), protecting equipment.
- Primary Treatment: Sedimentation and flotation remove 50-60% solids and oils, using coagulants (₹50-100/kg) to reduce TSS.
- Secondary Treatment: Biological processes like MBBR degrade 85-90% BOD using microbes on plastic carriers.
- Tertiary Treatment: Ultrafiltration (UF) or reverse osmosis achieves CPCB standards (BOD <30 mg/L, TSS <100 mg/L).
- Sludge Management: Dewatering produces 100-300 kg/day sludge, reusable as fertilizer or landfilled.
Why food processing plants need sewage treatment includes:
- Regulatory Compliance
CPCB mandates BOD <30 mg/L and TSS <100 mg/L, with non-compliance fines of ₹50,000-₹5 lakh. STPs ensure adherence, avoiding penalties. - Water Conservation
Water conservation in food industry: STPs recycle 30-50% of wastewater for cleaning or irrigation, saving ₹50,000-₹2 lakh yearly on freshwater. - Cost Savings
Reduces sludge disposal (₹500-₹1,000/kg) and freshwater costs (₹20-50 per 1,000 litres), saving ₹50,000-₹5 lakh yearly for 100 KLD. - Environmental Protection
Wastewater problems in food manufacturing units: High BOD/TSS pollutes rivers, harming aquatic life. STPs reduce pollution by 85-90%. - Equipment Longevity
Treated water prevents corrosion in boilers and cleaning systems, saving ₹50,000-₹2 lakh yearly in repairs.
These benefits highlight the advantages of STP for food factories.
Energy-efficient sewage treatment enhances STP viability:
- Low-Energy Systems: MBBR uses 200-300 kWh/day for 100 KLD, 20-30% less than traditional systems, saving ₹50,000-₹2 lakh yearly.
- Solar Integration: Solar panels cut grid reliance by 50%, saving ₹50,000-₹1 lakh yearly.
- Biogas Recovery: Sludge digestion produces biogas (100-200 m³/day), powering treatment or selling for ₹10,000-₹50,000 monthly.
Challenges and Solutions
Wastewater problems in food manufacturing units include:
- High Initial Costs: ₹10-50 lakh for STP installation food processing strains budgets.
- Solution: Start with 10-50 KLD systems and scale up.
- High Organic Load: Food wastewater’s BOD (1,000-2,000 mg/L) requires robust treatment.
- Solution: Use MBBR with high-capacity media.
- Maintenance: Regular sludge and equipment checks cost ₹50,000-₹2 lakh yearly.
- Solution: Implement IoT sensors for automation.
- Space Constraints: Factories lack room for large STPs.
- Solution: Use compact STPs (5-10 sq. meters).
How to set up STP in food industry:
- Assess Wastewater: Estimate volume (10,000-50,000 litres/day) and BOD (1,000-2,000 mg/L).
- Budget: Plan ₹5-50 lakh setup, ₹50,000-₹5 lakh maintenance.
- Select Vendor: Partner with SKF Elixer for sewage treatment plant food factory.
- Integrate Reuse: Recycle water for cleaning.
- Train Staff: Spend ₹10,000-₹50,000 on maintenance training.
Conclusion
A sewage treatment plant food factory is essential for addressing wastewater problems in food manufacturing units, delivering advantages of STP for food factories like compliance, cost savings, and water conservation in food industry.
SKF Elixer India Pvt. Ltd. offers robust Food processing STP solutions, ensuring CPCB-compliant organic waste water treatment. Contact SKF Elixer today to implement the best STP plant for food processing factories and enhance your operations.
FAQs
Q1: Why do food processing plants need sewage treatment?
Why food processing plants need sewage treatment: To manage high-BOD wastewater, ensure CPCB compliance, and save ₹50,000-₹5 lakh yearly on fines and water costs.
Q2: How do you set up STP in food industry?
How to set up STP in food industry: Assess wastewater, choose Food processing STP, budget maintenance, and partner with vendors like SKF Elixer.
Q3: What are the advantages of STP for food factories?
Advantages of STP for food factories: Saves ₹50,000-₹5 lakh yearly, recycles 30-50% water, ensures compliance, and protects equipment and the environment.
Q4: What are wastewater problems in food manufacturing units?
Wastewater problems in food manufacturing units: High BOD/TSS (1,000-2,000 mg/L), pollution risks, and fines, addressed by sewage treatment plant food factory.
Good reads are meant to be shared
