Shankarrao Kale Glass Bottle Washing Wastewater Treatment
Shankarrao Kale Shakari Sakhar Karkhana
OEM / Coordinator : Global Enviro, Pune
Sugar-Based Distillery | Maharashtra, India
Project Team
Ms. Urvashi Eklure
Mr. Shivkumar Gadlod
Shankar & Team
Deepak & Team
Tanuja Jagtap
Mukesh Fulore
1 │ PROJECT OVERVIEW
| End Customer | Shankarrao Kale Shakari Shakhar Karkhana |
| Industry | Sugar-Based Distillery (Alcohol Production) |
| Location | Maharashtra, India |
| OEM / Coordinator | Global Enviro, Pune (Contact: Mr. Madhukar Sawant) |
| Executed By | BlueMaarlin Environmental Pvt. Ltd. (BMEPL) |
| System | Ultrafiltration (UF) — Standalone Polishing System |
| Feed Source | Glass Bottle Washing Wastewater (~8,00,000 L/day) |
| Design Capacity | 800 KLD (50 m3/hr feed flow) |
| UF Feed Flow | 50 m3/hr |
| UF Permeate Flow | 45 m3/hr (90% recovery) |
| Flux Rate | 50 LMH |
| Automation | PLC-based customised automation |
| Membrane Make | HITEC (Model: RDMT-EM-XVI-81 MBM, PES, 100KD, In-to-Out) |
| No. of Membranes | 10 Nos. |
| Purchase Order Ref. | BM-19[UF-1123] — BlueMaarlin |
| Executive Assigned | Mrs. Tanuja Jagtap (Material Management) |
| Design Lead | Ms. Urvashi Eklure |
| Documentation | Mr. Shivkumar Gadlod |
| Case Study By | Rohit Shinde |
2 │ CLIENT REQUIREMENT & PROJECT BACKGROUND
Shankarrao Kale Shakari Sakhar Karkhana operates a sugar-based distillery in Maharashtra engaged in alcohol production from sugarcane molasses. The distillery's glass bottle washing operations generated approximately 8,00,000 litres of contaminated wastewater per day from multiple cleaning units used to wash glass bottles. The water contained residual detergents, organic matter, suspended solids, and dissolved salts, making direct disposal impractical and environmentally non-compliant.
The client approached Global Enviro (Pune) as the project OEM, who in turn engaged BlueMaarlin Environmental Pvt. Ltd. as the technology and supply partner for the UF-based water treatment system.
Client's Key Requirements
- Energy-efficient, long-running system with low maintenance cost suitable for continuous distillery operations
- Fully automated plant operation using PLC — minimum operator involvement to reduce manpower costs
- High water recovery from glass bottle washing wastewater to enable process water reuse within the facility
- Low initial capital investment with reliable performance over an extended operational life
- System capable of handling variable load from multiple bottle washing units across the distillery
| Sr. No. | Contaminant / Parameter | Value | Unit |
|---|---|---|---|
| 1 | TDS | <500 | ppm |
| 2 | Calcium | 25 | ppm |
| 3 | Magnesium | 15 | ppm |
| 4 | Sodium (as Na) | 150 | ppm |
| 5 | Bicarbonate (HCO3) | 210 | ppm |
| 6 | Sulphates (SO4) | 20 | ppm |
| 7 | Chloride (Cl) | 320 | ppm |
| 8 | Reactive Silica | <10 | ppm |
| 9 | BOD | <30 | ppm |
| 10 | COD | <60 | ppm |
| 11 | TSS | <30 | ppm |
| 12 | Turbidity | <5 | NTU |
3 │ CHALLENGES
- Feed water quality from glass bottle washing was relatively mild (TDS <500 ppm, BOD <30 ppm) compared to distillery effluent; however, variable detergent and organic loads from different washing units required robust flux and CIP design to protect membrane longevity.
- Flux rate selection of 50 LMH was deliberate — conservative design based on client's water report to ensure 3+ year membrane life and consistent 90% recovery without frequent backwash failures.
- Air blower integration for simultaneous UF membrane air scour (150 m³/hr, 5 cm wc) to prevent membrane fouling from surfactant residues typical of bottle washing streams.
- 10 HITEC RDMT-EM-XVI-81 MBM modules (In-to-Out configuration, 81 m² each) required precise skid layout and header piping design to ensure uniform flow distribution across all modules.
- Backwash system designed for 137 m³/hr (approx. 3× feed flow) using a dedicated submersible pump to maintain high cross-flow velocity for effective membrane cleaning.
- Client demanded high-level PLC automation for a sugar distillery environment — customised control logic developed covering automated backwash sequencing, CIP triggering, pressure alarms, and dosing interlocks.
- Project executed via OEM (Global Enviro, Pune) model — required close coordination between BlueMaarlin (supply and engineering), Global Enviro (project management), and end customer (Shankarrao Kale Karkhana) across three organisations.
- All supply, dispatch, and installation executed from Pune, requiring careful logistics planning for delivery to the sugar factory site in Maharashtra.
- Capital cost optimisation pressure from client achieved by selecting a standalone UF system (no RO stage), since feed water quality was within acceptable limits for process reuse after UF polishing alone.
4 │ ENGINEERING & DESIGN APPROACH
Based on the feed water report showing relatively low TDS (<500 ppm), BOD (<30 ppm), and COD (<60 ppm), the BlueMaarlin design team — led by Ms. Urvashi Eklure — determined that a standalone Ultrafiltration (UF) system was sufficient to treat the glass bottle washing wastewater to a quality suitable for reuse. Unlike the CRUX Biotech (grain distillery) and Shankarrao Kale Sugar (sugarcane distillery, RO case) projects which required two-stage RO for high TDS feed, this stream's mild characteristics allowed UF alone to deliver the required permeate quality.
HITEC PES polymer membranes (In-to-Out configuration) were selected for their proven fouling resistance against the surfactant-laden bottle washing water. A flux rate of 50 LMH was selected (slightly higher than the 45 LMH used in the 25 m³/hr RO project) as the cleaner feed quality could sustain this rate without compromising membrane life. A dedicated CIP system (2000L HDPE tank + CNP SS316 pump) with acid and caustic dosing ensures thorough periodic membrane cleaning.
UF Flow Balance
| Parameter | Value | Unit |
|---|---|---|
| UF Feed Flow | 50 | m3/hr |
| UF Permeate Flow | 45 | m3/hr |
| Backwash Flow | ~5 | m3/hr (reject) |
| UF Recovery | 90 | % |
| Daily Feed | 1,200 | m3/day (24hr basis) |
| Daily Permeate | 1,080 | m3/day |
| Daily Reject | ~120 | m3/day |
| Flux Rate | 50 | LMH |
| No. of Modules | 10 | Nos. (81 m2 each) |
| Total Membrane Area | 810 | m2 |
5 │ ULTRAFILTRATION (UF) SYSTEM — FULL SPECIFICATION
UF Membrane System
| Component | Specification |
|---|---|
| Membrane Make | HITEC |
| Membrane Model | RDMT-EM-XVI-81 MBM |
| MWCO | 100 KDa |
| Configuration | In-to-Out (Inside-Out flow) |
| Membrane Area | 81 m2 per module |
| Membrane MOC | PES (Polyethersulfone) |
| End Cap MOC | PPGF (Polypropylene Glass Filled) |
| No. of Modules | 10 Nos. |
| Total Membrane Area | 810 m2 |
| Flux Rate | 50 LMH |
| Recovery | 90% |
| UF Skid | MS Epoxy Painted (MSEP) — dosing tanks and CIP on ground |
| Piping | Astral UPVC SCH40 / SS304 SCH10 |
Pumps
| Pump | Make / Model | Specification |
|---|---|---|
| Raw Water / Openwell Submersible Feed Pump | CNP / Johnson / KBL / CRI (1W+1S) | Flow 50 m3/hr, Head 30m, CI body, SS316 Shaft & Impeller, 3-Phase |
| UF Backwash Pump (Submersible) | Johnson / KBL / CRI (1W+1S) | Flow 137 m3/hr, Head 28m, SS304, 3-Phase, No negative suction |
| CIP Pump | CNP / Johnson / Equiv. | Flow 33 m3/hr @ 34.5m, SS316, 3-Phase, No negative suction |
| Air Blower (UF / MGF / ACF) | Any CI make | Flow 150 m3/hr, Head 5 cm wc, 3-Phase |
Strainers & Filters
| Item | Specification |
|---|---|
| Basket Strainer — Feed | BMEPL SS304, 50 m3/hr, 3" (75NB) Flanged, 50 micron |
| Basket Strainer — Backwash | BMEPL SS304, 125 m3/hr, 150NB Flanged, 50 micron |
| Cartridge Filter — CIP | BMEPL SS304, 50 m3/hr, 3" Flanged, 5 micron, Spun PP |
6 │ DOSING SYSTEMS, VALVES & CONTROLS
Chemical Dosing
| System | Tank | Pump Specification |
|---|---|---|
| Acid Dosing (HCl) | Plasto HDPE 200L (×2), with Lid | Milton Roy / Positive — 2 nos. (1W+1S), 0–170 LPH, 3.5 kg/cm2, PP, Mechanically Actuated |
| Caustic Dosing (NaOH) | Plasto HDPE 200L (×2), with Lid | Milton Roy / Positive — 2 nos. (1W+1S), 0–120 LPH, 3.5 kg/cm2, PP, Mechanically Actuated |
Automated Valves
| Item | Make | Type / Size | MOC | Qty |
|---|---|---|---|---|
| Motorized Butterfly Valve (Backwash/reject) | Crane / L&T / Apollo | Normally Closed, 65NB | CI Body, SS Disc | 2 |
| Motorized Butterfly Valve (Feed/permeate) | Crane / L&T / Apollo | Normally Closed, 150NB | CI Body, SS Disc | 2 |
CIP System
| Component | Specification |
|---|---|
| CIP Tank | Plasto HDPE, 2000L |
| CIP Skid | BMEPL MSEP Skid with Astral UPVC piping |
| CIP Pump | CNP/Johnson SS316, 33 m3/hr @ 34.5m, No negative suction |
| CIP Filter | BMEPL SS304 Cartridge, 5 micron, 50 m3/hr, 3" Flanged |
7 │ INSTRUMENTATION & CONTROL PANEL
| Instrument | Make / Model | Specification | Qty |
|---|---|---|---|
| Pressure Gauge | Baumer SS304 | 0–7 kg/cm2, Glycerin filled, 100NB Dial, Online | 4 |
| Rotameter | Aster Polycarbonate | 2.5" Flanged, 60,000 LPH — Permeate & Feed | 2 |
| Digital Flow Meter (Backwash) | Aster / BSS FT-650 | Max 160 m3/hr, PP MOC, Relay output, 125NB | 1 |
| DP Switch | Danfoss KP35 | Differential Pressure Switch — UF | 1 |
| SDI Kit | Aster | Online SDI measurement | 1 |
| Float Switch | BS Plastic | 10m cable length — for tank level | 2 |
| UF Control Panel | Siemens / L&T | 2m height, MS Powder Coated, Floor mounted, PLC-based, Polycab wiring, Separate MCB per circuit | 1 |
PLC Automation Features
- Automatic UF backwash initiation based on trans-membrane pressure (TMP) rise or timed interval — configurable via PLC HMI
- Motorised butterfly valves (65NB and 150NB) controlled by PLC for automatic feed/backwash/CIP flow switching
- CIP sequence automation: drain → fill → heat (if applicable) → circulate acid/caustic → flush → return to service
- Alarm interlocks: low feed tank level (float switch), high DP (Danfoss KP35), pump overload protection
- Digital flow meter (Aster FT-650) on backwash line provides real-time volumetric data for PLC trending and reporting
- Separate MCB protection for each motor/pump circuit within the panel for independent fault isolation
8 │ BILL OF QUANTITIES — KEY EQUIPMENT SUMMARY
| Sr. No. | Component | Make | Qty |
|---|---|---|---|
| 1 | Raw Water / Openwell Submersible Feed Pump | CNP / Johnson / KBL / CRI | 2 (1W+1S) |
| 2 | Basket Strainer — Feed (50 m3/hr, 3", 50µ) | BMEPL SS304 | 1 |
| 3 | Basket Strainer — Backwash (125 m3/hr, 150NB, 50µ) | BMEPL SS304 | 1 |
| 4 | Cartridge Filter — CIP (5 micron) | BMEPL SS304 | 1 |
| 5 | UF Membrane (RDMT-EM-XVI-81 MBM, PES, 100KD) | HITEC | 10 |
| 6 | Motorized Butterfly Valve — 65NB, NC | Crane / L&T / Apollo CI/SS | 2 |
| 7 | Motorized Butterfly Valve — 150NB, NC | Crane / L&T / Apollo CI/SS | 2 |
| 8 | UF Control Panel (PLC-based, 2m, MS PC) | Siemens / L&T | 1 |
| 9 | Pressure Gauge (0–7 kg/cm2, 100NB, SS) | Baumer | 4 |
| 10 | Rotameter (2.5" Flanged, 60,000 LPH) | Aster Polycarbonate | 2 |
| 11 | Digital Flow Meter (FT-650, 125NB) | Aster / BSS | 1 |
| 12 | UF Skid (MSEP) | BMEPL | 1 |
| 13 | UPVC / SS304 Piping | Astral UPVC SCH40 / SS304 SCH10 | 1 Lot |
| 14 | Acid Dosing Pump (0–170 LPH, PP) | Milton Roy / Positive | 2 (1W+1S) |
| 15 | Caustic Dosing Pump (0–120 LPH, PP) | Milton Roy / Positive | 2 (1W+1S) |
| 16 | Dosing Tank (HDPE, 200L) | Plasto | 2 |
| 17 | Backwash Submersible Pump (137 m3/hr, SS304) | Johnson / KBL / CRI | 2 (1W+1S) |
| 18 | Float Switch (10m cable) | BS Plastic | 2 |
| 19 | CIP Tank (HDPE, 2000L) | Plasto | 1 |
| 20 | CIP Skid and Piping (MSEP / UPVC) | BMEPL | 1 Set |
| 21 | CIP Pump (SS316, 33 m3/hr @ 34.5m) | CNP / Johnson | 1 |
| 22 | SDI Kit (Online) | Aster | 1 |
| 23 | DP Switch | Danfoss KP35 | 1 |
| 24 | Air Blower (150 m3/hr, 5 cm wc, CI) | — | 1 |
| 25 | Wiring (Armoured, Site) | Polycab | 1 Lot |
| 26 | Chemicals | — | 1 Lot |
9 │ RESULTS & ACHIEVEMENTS
UF Recovery
Flux Rate
Total Membranes
Membrane Area
Daily Permeate
PLC Automation
- 800 KLD UF water treatment system successfully designed and commissioned at Shankarrao Kale Shakari Sakhar Karkhana for glass bottle washing wastewater polishing.
- Standalone UF solution (without RO) proved optimal for this application given the mild feed water quality (TDS <500 ppm, BOD <30 ppm) — resulting in lower capital cost while meeting permeate quality requirements for process reuse.
- 10 HITEC RDMT-EM-XVI-81 MBM modules (In-to-Out, PES, 100KD, 810 m² total area) operating at conservative 50 LMH flux for extended membrane life.
- PLC-based automation delivered client's requirement: fully automated backwash, CIP sequencing, valve switching, and alarm management with minimal operator input.
- High-capacity backwash pump (137 m³/hr Johnson/KBL SS304) ensures effective membrane recovery after each backwash cycle even with surfactant-laden feed from bottle washing.
- Air blower (150 m³/hr) provides simultaneous air scour during backwash, preventing compaction of the PES membrane surface — critical for long-term flux sustainability in this application.
- Complete project executed under a three-party model: BlueMaarlin (technology + supply), Global Enviro (OEM/coordination), Shankarrao Kale Karkhana (end client) — demonstrating BMEPL's channel-partner execution capability.
- Design led by Ms. Urvashi Eklure; documentation by Mr. Shivkumar Gadlod; site execution by Mukesh Fulore and Deepak's commissioning team.