Improving Oxygen Transfer Efficiency in Chemical ETP
Improving Oxygen Transfer efficiency in a Chemical manufacturing plant
Background

A mid-size chemical manufacturing company situated in Madhya Pradesh was facing efficiency issues in improving oxygen transfer efficiency in its ETP, such as low efficiency, biomass suspension, and diffuser dysfunction. Despite maintaining a good overall diffused aeration system, their biomass was not developing, and MLVSS was very low.

As a result, the client incurred high CAPEX due to unnecessary diffuser replacements and remained non-compliant with regulatory COD/BOD limits.Facing challenges in improving oxygen transfer efficiency and facing high energy costs? Let Team One Biotech help.

ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow (current)750 KLD
Type of processASP
No. of aeration tanks1
Capacity of aeration tanks1150 KL
Challenges: 

Parameters Avg. Inlet parameters(PPM)Avg. secondary system outlet parameters(PPM)
COD180006000
BOD85002800-3000
TDS300002500
Problem Statement:

The client observed persistently low dissolved oxygen (DO) levels in the aeration tank despite extended blower run-times and increased air supply. This resulted in:

  • Sub-optimal biological treatment
  • Elevated energy costs
  • Occasional odor issues and inconsistent COD/BOD reduction

A preliminary diagnosis indicated biofilm accumulation and diffuser fouling, affecting fine bubble formation and limiting oxygen dispersion.

Our Approach

Team One Biotech initiated a comprehensive on-site audit including:

Diffuser Health Check

  • Inspected diffuser membranes for fouling
  • Identified scaling and microbial slimes affecting pore performance

Baseline Monitoring

  • DO levels across the tank: <1.5 mg/L
  • Specific Oxygen Uptake Rate (SOUR): <15 mg O₂/g VSS/hr
  • Blower energy use: ~65 kWh/day
  • OTE Baseline: Estimated OTE was 12%

Microbial Evaluation

  • Floc structure was loose, with filamentous dominance
  • Low settleability (SVI > 200)

To implement a cost-effective, eco-friendly bioremediation strategy that:

  1. Enhances the degradation of formaldehyde and glutaraldehyde.
  2. Restores biological treatment efficiency.
  3. Achieves compliance with CPCB norms.
Solution

We proposed a 2-fold intervention:

1.Application of T1B Aerobio Bioculture

  • Dose: 10 ppm daily for 10 days, 8 ppm for next 10 days, and 5 ppm for next 10 days, then 3 ppm as maintenance every day.
  • Objective: Enrich native microbial diversity and improve biomass quality T1b Aerobio bioculture solution by improving oxygen transfer efficiency

2. Aeration System Optimization

  • Conducted sequential backflushing of diffusers
  • Realigned blower duty cycles with microbial demand using DO automation feedback

Monitored DO, pH, and ORP to ensure a stable environment.

Results:

After 60 days of implementation:

Parameters Before interventionAfter Intervention
DO in Aeration Tank1.2 mg/L2.8 mg/L
SOUR1             3.6 mg O₂/g VSS/hr22.3 mg O₂/g VSS/hr
SVI210 mL/g120 mL/g
COD Reduction72%87%
Blower Runtime24 hrs/day16 hrs/day
Energy Use65 kWh/day38 kWh/day
OTE12 %21.4 %
Application results before and after

Conclusion

With the combined effect of T1B Aerobio bioculture and technical aeration optimization, the client achieved a 78.3% increase in oxygen transfer efficiency. This translated into:

  • Significant energy savings
  • Improved microbial activity and settleability
  • Stable effluent quality, meeting compliance standards

This case demonstrates how biology-driven solutions, coupled with system know-how, can deliver tangible performance and cost benefits in industrial wastewater treatment.

Ready to optimize your ETP performance? Connect with us today

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Seasonal Microbial Shifts Wastewater Treatment
Beating the Seasonal Drift — How a Textile Unit Stabilized ETP Performance with T1B Aerobio Bioculture
 
Background

A mid-sized textile dyeing and processing unit in Gujarat struggled with recurrent seasonal drift in ETP and it’s biological performance. Contact us today to learn how T1B Aerobio can revolutionize your ETP’s performance and help you overcome seasonal challenges effectively.

Despite having a decent system design, they were plagued by:

  • Winter ammonia spikes
  • Monsoon washouts
  • Summer bulking
  • Transitional season shock-loads

These issues led to frequent compliance failures and operational stress.

T1B Aerobio-One Stop solution to seasonal drift:

T1B Aerobio – a blend of robust microbes especially bacteria , is the ultimate Thor’s hammer for seasonal cahllenges in any ETP. With a bank of 76+ different strains , T1B Aerobio was customized according to the challenges face by ETP in every season. It also consist various elements and enzymes which make it more efficient and a single solution for various challenges which no ordinary bioculture/microbial culture can deliver.

T1B Aerobio
ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow150 KLD
Type of processASP
No. of aeration tanks3 
Capacity of aeration tanks650 KL each
Total RT hours
Season-Wise Breakdown of Challenges & Solutions

🌨️ Winter Challenges (Dec–Feb)

Problems:

  • Nitrifier slowdown → High ammonia (>20 mg/L)
  • Low microbial activity → Increased F/M ratio
  • Reduced floc formation → Poor settling, turbid outlet
Solutions:
  • Pre-winter bioaugmentation with cold-active nitrifiers from T1B Aerobio Bioculture.
  • Increased MLVSS through controlled culture addition
  • Fine-tuned aeration to maintain DO around 3 mg/L
  • Reduced F/M by optimizing sludge wasting
Results:

Ammonia was reduced to <5 mg/L within 10 days. Sludge quality improved, and the outlet was consistently clear.

☀️ Summer Challenges (Apr–Jun)
Problems:
  • High temperatures → Oxygen depletion
  • DO <1.5 mg/L → Filamentous bulking
  •  anti-filamentous dominant cultures through T1B Aerobio bioculture to suppress filaments
  • Boosted DO levels by adjusting blower run hours
  • Added foam control microbes to reduce surface scum and bulking
Results:

SVI normalized to 95–100 mL/g. Sludge settling and clarity improved; odor complaints dropped significantly.

🌧️ Monsoon Challenges (Jul–Sep)
Problems:
  • Heavy rainfall → Dilution & shock load
  • Surface runoff → Toxic load spikes
  • MLSS washed out → From 3500 to 1800 mg/L
  • Sudden pH shifts due to drainage ingress
Solutions:
  • Pre-monsoon culture buildup plan to fortify biomass using T1B Aerbio bioculture’s High-MLVSS variant
  • pH stabilization buffer introduced during heavy rains
  • Equalization tank aeration was increased to handle shock loads better
Results:

MLSS restored to 3100 mg/L within 7 days. COD removal stabilized at 90–92%. No emergency bypass required.

🍂 Transitional Season Challenges (Mar, Oct–Nov)
Problems:
  • Frequent influent variability due to batch changes
  • Occasional toxicity due to dyeing chemical overuse
  • Rapid shifts in temperature and pH → Microbial lag
Solutions:
  • Weekly parameter tracking and real-time microbial health checks
  • Targeted detoxifier blend dosing with Aerobio during chemical overload
  • Gradual culture build-up before full-load restart after holidays
Results:

The biological system became more resilient, absorbing fluctuations without crashing. No major deviations in any parameter

Parameter Snapshot Before vs After Aerbio Intervention
ParameterBeforeAfter T1B Aerobio
(Winter)>20 mg/L<5 mg/L
MLSS (Monsoon)~1800 mg/L~3100 mg/L
SVI (Summer)>160 mL/g90–100 mL/g
COD Removal~78%~92%
Outlet ClarityTurbid frequentlyClear, consistent
Odor ComplaintsFrequentAlmost Nil
Conclusion

Microbial performance doesn’t follow a flat line—it fluctuates with the weather. But with a season-wise microbial management plan, your ETP can remain compliant, efficient, and stress-free year-round.T1B’s Aerbio bioculture adapts where standard systems struggle—empowering your ETP to beat the seasonal drift, naturally.

👉 Contact us to implement a customized, season-wise microbial strategy with T1B Aerobio and keep your ETP biologically stable and compliant—year-round.

📧 Email: sales@teamonebiotech.com

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Bioremediation of Aldehyde-Rich Wastewater from a Pharmaceutical Manufacturing Unit
Bioremediation of Aldehyde-Rich Wastewater from a Pharmaceutical Manufacturing Unit
Background

A leading pharmaceutical company situated in Madhya Pradesh in India was facing challenges in treating its aldehyde-laden wastewater, particularly with glutaraldehyde and formaldehyde content.Bioremediation of aldehyde-rich wastewater emerged as a sustainable and effective solution to this issue. Contact Us to learn how we can transform your wastewater challenges into sustainable solutions.

These compounds, used in drug synthesis and as disinfectants, were found to be:

  • Inhibiting microbial activity in their conventional Activated Sludge Process (ASP), a common biological wastewater treatment method.
  • Causing non-compliance with regulatory COD/BOD limits—critical benchmarks in any sewage water treatment process.
  • Producing a persistent pungent odor at the ETP outlet, calling for odour control in wastewater treatment.
ETP details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow (current)900 KLD
Type of processASP
No. of aeration tanks2
Capacity of aeration tanks3180 KL and 2840 KL
Challenges: 
Parameters Avg. Inlet parameters(PPM)Avg. Outlet parameters(PPM)
COD120001500
BOD4500880-500
TDS40001200
Formaldehyde200145
Gluteraldehyde210182
Problem Statement:

Despite having a full-fledged ETP (Equalization → Primary → ASP → Clarifier), the system could not consistently bring down aldehyde levels due to their toxicity to standard microbial consortia. The system experienced:

  • Foaming and poor settling in the aeration tank.
  • Reduced BOD removal efficiency.
  • Increased sludge bulking and filamentous growth—issues typical in inefficient wastewater filtration and sludge management systems.
Objective:

To implement a cost-effective, eco-friendly bioremediation strategy that:

  1. Enhances degradation of formaldehyde and glutaraldehyde.
  2. Restores biological treatment efficiency.
  3. Achieves compliance with CPCB norms.
Solution: Bioaugmentation-Based Bioremediation
Step 1: Selection of Microbial Culture/Bioculture

A customized bio-culture T1B Aerobio blend was developed, containing aldehyde-degrading strains of:

  • Pseudomonas putida
  • Bacillus subtilis
  • Rhodococcus sp.

These microbes had been lab-tested for their aldehyde tolerance and metabolic capabilities..aerobio from t1b

Step 2: Dosing Plan in Full-Scale ETP
  • Initial Loading dose: For 1st 30 days to develop the population of bacteria and generate biomass 
  • Maintenance dose: For the next days and on, to maintain the population of biomass generated.
  • Nutrient balancing (C:N:P = 100:5:1) to promote growth.
Step 3: Acclimatization Phase (2 Days)
  • The culture was activated for two days separately for acclimatization.

Monitored DO, pH, and ORP to ensure a stable environment.

Results:

After 60 days of Bioculture addition/Bioremediation:

Parameters Avg. Inlet parameters(PPM)Avg. Outlet parameters(PPM)
COD12000500
BOD4500280
TDS40001200
Formaldehyde200>15
Gluteraldehyde210>30

60 days of Bioculture addition/ bioremediation of aldehyde-rich wastewater

60 days of Bioculture addition/ bioremediation of aldehyde-rich wastewater

Benefits Observed

✅ Rapid degradation of aldehydes without secondary pollutants
✅ Stabilized biomass and improved MLSS/MLVSS ratio
✅ Significant reduction in foaming and sludge bulking
✅ Odor control and improved air quality near the aeration tank
✅ Regulatory compliance achieved within 4 weeks

Conclusion

Bioremediation of aldehyde rich wastewater has proven to be a sustainable and economical solution for treating contaminated wastewater. With careful acclimatization, dosing, and nutrient balancing, the ETP was restored to optimal performance without requiring major infrastructure changes.This highlights the power of using the right wastewater treatment products and techniques to improve residential wastewater treatment systems and eco sewage treatment plants alike.

📩 Contact Us to explore how our waste water engineering solutions can support your sewage treatment plant maintenance needs.

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Implementation of SBR system in a CETP
Implementation of SBR System in a CETP with T1B Aerobio Bioculture
Introduction: 

The SBR system in a CETP situated in Rajasthan handles effluents from over 40 industries in the RIICO sector the system faces difficulty in handling the load of COD above 2000 PPM, owing to discharges from textiles and  chemicals. The SBR system with 4 biological tanks and 4 cycles a day was struggling with its efficiency in terms  of COD reduction, due to which the outlet COD was very high and the load was carried on to the RO, leading to  damage of membranes and high OPEX. Contact us today to learn how we can help optimize your industrial effluent treatment plant (ETP) with customized bioaugmentation solutions.

ETP details: 

The industry had primary treatment, biological treatment, and then a tertiary treatment. 

Flow (current) 2 MLD
Type of process SBR
No. of aeration tanks 4
Capacity of aeration tanks 3 MLD each
Total cycles in 24 hrs 4
Duration of fill and Aeration cycle 1.5 hrs and 2.5 hrs respectively
Challenges:
Parameters Avg. Inlet parameters(PPM) Avg. Outlet parameters(PPM)
COD 3000 800
BOD 1800 280-300
TDS 3000 1200
Operational Challenges: 
  • The primary treatment was working at 5 % efficiency in terms of COD reduction 
  • The whole SBR system was lagging in COD degradation efficiency and sustainability of MLVSS as well. 
  • The Carryover COD and unsettled biomass was traveling to RO, damaging membranes. 
The Approach: 

The agency operating the SBR system in a CETP approached us to solve their current issues.  

We adopted a 3D approach that included : 

  1. Research/Scrutiny :  
  • Our team visited their facility during the winter season as they encountered many issues at that  

         time. Team scrutinized every aspect of the plant to analyze the efficiency of each element. 

  • The visit gave us a complete idea of their processes, current efficiency, trends, and our scope of  

         work.  

  1. Analysis : 
  • We analyzed the previous 6-month cumulative data of their ETP to see trends in the inlet-outlet  

         parameters’ variations and the permutation combinations related to it. 

  1. Innovation :  
  • After the research and analysis our team curated customized products and their dosing schedules  with formulation keeping in mind the plan of action to get the desired results. This process is            called  bioaugmentation. 
Desired Outcomes : 
  1. Reduction of COD/BOD thereby improving the efficiency of biological tanks. 
  2. Degradation of tough-to-degrade effluents and develop robust biomass to withstand shock loads. 
  3. Ensuring proper settling of Biomass to stop carryover to RO, thereby preventing damage to RO membranes.
Execution: 

Our team selected two products : 

T1B aerobio product

T1B Aerobio Bioculture: This product consisted of a blend of microbes as bioculture  

selected as per our analysis to degrade the recalcitrant COD, and ensure sustainability in  

the SBR system.  

Plan of action: 
  1. We devised a 60 days dosing plan, which was further divided into two phases: 
  • Day 1 to day 30 : Loading dose, to develop the population of bacteria and generate biomass.
  • Day 31 to Day 60: Maintenance Dose, to maintain the population of biomass generated. 
  1. Dosing pattern: We advised dosing in all 4 SBR tanks cycle wise viz. during filling and Aeration, to give  the bioculture proper mixing and necessary DO. 
Results: 
Parameters Inlet parameters Tank 4 outlet parameters (ppm)
COD 3000 ppm 280-300 ppm
BOD 1800 ppm 60-82 ppm

Before and after adding bioculture

The implementation of the bioaugmentation program resulted in significant improvements in the performance  of biological units in their WWTP: 

  • We were able to achieve around 90 % reduction from their current inlet parameters in COD & BOD,  which was only 70% earlier. 
  • The overall ETP OPEX was reduced by 20%. 
  • The ETP achieved full capacity operations in terms of hydraulic load. 
  • The biological process became more stable and resilient to fluctuations in the influent characteristics. 
  • The RO membrane health was restored and and their damage reduced up to 80%.

📧 Want similar results for your ETP or STP? Contact us for more Information.

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effluent treatment plant
Enhancing effluent treatment efficiency at a Nylon tyre cord company

Industry Overview

A leading manufacturer of Nylon Tyre Cord Fabric (NTCF) and Nylon Filament Yarn (NFY) in India. The manufacturing process generates waste water containing high BOD COD and complex organic pollutants, requiring an advanced effluent treatment system or compliance with environmental norms. 

To learn how our solutions can help optimize wastewater management and ensure regulatory adherence, contact us today.

ETP Overview

 The company operates a 650 KLD effluent treatment plant (ETP) with the following aeration tank capacities:

  • Aeration Tank 1: 450 KL
  • Aeration Tank 2: 800 KL
  • Aeration Tank 3: 400 KL

The wastewater treatment system includes equalization, primary treatment, biological treatment (aeration tanks), secondary clarification, and waste management through sludge treatment.

Challenges Faced by the ETP

  1. Frequent Upsets Due to Multiple Waste Water Streams 

The industry has multiple waste water streams, including:

  • ✅ Process wastewater treatment from Nylon production – Contains high COD, phenols, and recalcitrant organics.
  • ✅ Dye and finishing waste water – High in sulfates, surfactants, and residual dyes.
  • ✅ Boiler & cooling tower blowdowns – High in TDS and scaling compounds.

These varied streams led to fluctuations in pH, organic load, and microbial inhibition, making biological treatment inconsistent.

  1. Filamentous Bacteria Growth Leading to Bulking & Poor Settling 

The aeration tanks experienced frequent filamentous bacterial overgrowth, leading to:

  • ❌ Sludge bulking – Poor settleability in the secondary clarifier.
  • ❌ Reduced oxygen transfer – Filamentous microbes formed a mat, lowering aeration efficiency.
  • ❌ High MLSS but poor COD removal – Inefficient microbial metabolism caused high effluent COD.
  1. High COD and BOD in Final Discharge
    • COD levels >1200 mg/L after biological treatment (well above discharge limits).
    • BOD levels exceeded 250 mg/L, indicating poor organic degradation.
    • Fluctuations in ammonia and nitrate levels due to microbial stress.

Solution: Implementation of Our Customized Bioculture for Effluent Treatment System

To address these challenges, a customized culture solution was implemented in three stages:

  1. Bioaugmentation with Specialized Microbial Strains We introduced a high-performance microbial culture consortia designed to degrade recalcitrant organics and control filamentous growth.
Pollutant / IssueTargeted Bioculture StrainsMode of Action
High COD from dyes & finishingPseudomonas putida, Bacillus subtilisProduces oxidative enzymes to break down complex organics.
Phenolic compounds & nylon by-productsAcinetobacter sp., Comamonas testosteroniUses phenol hydroxylase to degrade toxic aromatics.
Surfactants & residual oilSphingomonas sp., Rhodococcus sp.Breaks down surfactants & hydrocarbons.
Filamentous bacterial overgrowthBacillus licheniformis, Nitrosomonas sp.Competes with filamentous microbes & improves sludge settling.
Ammonia & nitrate fluctuationsNitrobacter sp., Paracoccus denitrificansEnhances nitrification & denitrification for ammonia removal.

Dosage Strategy:

  • First 10 days: Shock dosing of bioculture for STP wastewater treatment (10 ppm/day) to quickly establish microbial dominance.
  • Post-10 days: Maintenance dosing (2–3 ppm/day) for stable microbial activity.
  1. Process Optimization in Aeration Tanks
    • Dissolved Oxygen (DO) Optimization: Increased DO from 1.5 mg/L to 2.5 mg/L by fine-tuning aeration rates.
    • MLSS & SRT Adjustments: Maintained MLSS at 3500–4000 mg/L for optimum microbial growth.
    • Sludge Recycle Ratio: Adjusted to 60% return rate to prevent sludge bulking.
  1. Enhanced Settling & Clarifier Performance
    • The addition of floc-forming microbes (Bacillus sp.) improved sludge compactness, reducing SV30 from 200 ml/L to 80 ml/L.
    • Sludge volume index (SVI) improved from >250 mL/g to <120 mL/g, indicating better sludge settleability.

Results Achieved

ParameterBefore TreatmentAfter Bioculture ImplementationReduction %
COD in Effluent1200 mg/L180 mg/L85%
BOD in Effluent250 mg/L35 mg/L86%
Phenol Concentration45 mg/L5 mg/L88%
Filamentous Bacteria IssueFrequent sludge bulkingFully controlled–
Dissolved Oxygen (DO)1.5 mg/L2.5 mg/L–
Sludge Settling (SVI)>250 mL/g<120 mL/g52% Improvement

Key Benefits for the Industry 

✅ Consistent Compliance with Environmental Norms

  • Effluent quality now meets CPCB discharge limits (COD < 250 mg/L, BOD < 30 mg/L).

✅ Reduced Operating Costs

  • Lower aeration energy costs due to improved oxygen transfer efficiency.
  • Reduced chemical usage (e.g., less need for coagulants & antifoam).

✅ Stable ETP Operation with No More Upsets

  • Bioculture created a robust microbial ecosystem that handled stream variations effectively.

✅ Improved Sludge Management

  • Better settling resulted in less sludge disposal & reduced maintenance costs.

Conclusion 

The implementation of our customized bioculture solution successfully transformed the effluent treatment system at Century Enka Ltd., Bharuch. By addressing COD BOD problems, filamentous bacterial issues, and inefficient aeration, the plant achieved stable treatment performance, reduced operational costs, and regulatory compliance. 

Are you looking for expert solutions in effluent treatment and sustainable wastewater management?

Contact us to know more about how our customized bioculture solutions can help!

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Wastewater treatment plant for integrated textile industry
Effective Wastewater Treatment Plant for an Integrated Textile Industry in India
Introduction:

The Integrated Textile Industry is a leading cloth manufacturing company that involves denim production, cotton apparel manufacturing, and is also involved in the pulping of raw materials and paper manufacturing. With a strong commitment to environmental sustainability, the Integrated Textile Industry operates a waste water treatment plant (WWTP) at its textile manufacturing facility to treat the industrial effluent generated during its textile production processes.

However, the industry faced challenges in meeting the effluent discharge limits for certain pollutants, including the presence of components from reactive dyes, high chemical oxygen demand (COD), elevated biochemical oxygen demand (BOD), higher levels of color, and effluent temperature reaching up to 50°C. To address these challenges, the industry implemented a bioaugmentation program at its effluent treatment plant (ETP), which resulted in significant improvements in the wastewater treatment process and compliance with regulatory standards for industrial effluents.

Effluent Treatment Plant (ETP) Details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Flow500-600 KLD
Type of processMBBR
No. of aeration tanks2 (in parallel)
Capacity of aeration tanks650 KL each
Total RT hours
Challenges:
ParametersInlet parameters Outlet parameters (Secondary System)
COD13,000 to 10000 8500 to 6800 
BOD4000 to 25002800 to 1650
Colour750 to 900 Hazen560 to 700 Hazen
  • The primary treatment system was working at 20-30% efficiency in terms of COD reduction.
  • The biological treatment was working at an average of 10-15% efficiency combined in terms of COD removal.
  • The system was struggling to effectively treat pollutants originating from reactive dyes and to reduce color contamination in the textile effluent.
  • The mixed liquor suspended solids (MLSS) were very low, and the microbial population in the biological treatment tanks could not develop due to the high wastewater temperature of 50°C.
  • The conventional MBBR waste water treatment plant was not efficient enough to consistently meet the stringent effluent discharge standards set by local environmental regulatory agencies.

As a result, the textile manufacturing company faced the risk of non-compliance, which could lead to regulatory fines, reputational damage, and environmental pollution.

The Bioaugmentation Approach:

The Integrated Textile Industry partnered with us to enhance the efficiency of their biological units. They had two aeration tanks in parallel, equipped with diffusers, handling a daily wastewater flow of 500-600 KLD.

Bioaugmentation is a biological wastewater treatment technique that involves adding specifically selected microorganisms, such as bacteria and enzymes, to improve the biological degradation of pollutants in a waste water treatment plant. The team conducted a comprehensive wastewater assessment to analyze the industrial effluent characteristics and the WWTP’s operational parameters, identifying the best bioaugmentation strategy for this textile effluent treatment plant.

Based on the assessment, a customized bioaugmentation program was designed and implemented. The microbial cultures were carefully selected to target organic pollutants, particularly contaminants from reactive dyes in the industrial effluent stream. Thermophilic bacteria were introduced to withstand high-temperature wastewater conditions and enhance the biological treatment process.

The bioaugmentation process was seamlessly integrated into the existing wastewater treatment process, and the performance of the WWTP was monitored over the next three months.

Improved Effluent Quality After Bioaugmentation:

Parameters

Inlet Parameters (ppm)

Outlet Parameters (After Bioaugmentation) (ppm)

COD (Chemical Oxygen Demand)13,000 to 10,0002,500 to 1,800
BOD (Biochemical Oxygen Demand)4,000 to 2,500800 to 650
Color (Hazen Units)750 to 900150 to 300
Results and Benefits of Bioaugmentation in Wastewater Treatment:

The implementation of the bioaugmentation program resulted in significant improvements in the performance of biological units at the wastewater treatment plant:

✅ Achieved around 80-84% reduction in COD & BOD levels in the treated industrial effluent.
✅ Attained 80-85% color removal efficiency, demonstrating visible improvement in effluent clarity.
✅ Enhanced microbial population growth in biological tanks, even at higher wastewater temperatures.
✅ The biological treatment system became more stable, reducing process fluctuations caused by influents variability.
✅ Increased plant reliability, ensuring consistent compliance with regulatory discharge limits.
✅ Reduced operational costs through optimized biological treatment efficiency.

The successful bioaugmentation application has helped the Integrated Textile Industry maintain regulatory compliance, improve wastewater treatment plant performance, and support their commitment to sustainable textile manufacturing.

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Chemical Industry Effluent Treatment with T1B Aerobio Bioculture
Introduction:

Effluent treatment is an essential process for the chemical manufacturing industry as it is a significant source of industrial wastewater pollution. Chemical industries produce a wide range of chemicals, and the effluent wastewater from these industries can contain a variety of pollutants that need to be treated before discharge into the environment. Biological wastewater treatment of effluent with bioculture for wastewater treatment is an effective and eco-friendly method for treating industrial effluent from the chemical sector.

A chemical processing industry located at Amaravati MIDC industrial area was perturbed by surging Chemical Oxygen Demand (COD), Biochemical Oxygen Demand (BOD), and Total Dissolved Solids (TDS) levels. Our client had an activated sludge process (ASP) wastewater treatment plant, which had 4 aeration tanks in series. The industrial effluent contained high levels of chemical pollutants such as phenol, formaldehyde, ammonia, and heavy metals like lead, cadmium, and chromium. The industry used microbial culture for effluent treatment to reduce effluent parameters. However, it was incompetent at treating wastewater discharge, which could not meet the Pollution Control Board (PCB) wastewater treatment guidelines.

The initial approach: After a complete study of the effluent treatment plant (ETP) through a questionnaire, an on-site effluent assessment, and discussions with the EHS (Environmental Health & Safety) team, our experts identified numerous challenges to be addressed:

Main Issues:
  • High COD levels in wastewater
  • High BOD levels in wastewater
  • High Total Ammoniacal Nitrogen (TAN) in effluent
Effluent Treatability Study:

Before planning a wastewater treatment scheme, it is crucial to perform an industrial wastewater treatability study to understand the characteristics of industrial effluent and devise an appropriate biological wastewater treatment regime specific to the chemical industry wastewater. Team One Biotech provided the sample for a pilot-scale wastewater treatment trial, which is a laboratory-scale effluent treatment study that confirms the suitability of the bacterial consortium for wastewater treatment present in our product and its development in the effluent stream. These trials were specifically designed to provide a clear indication of whether the microbial solution for wastewater treatment can grow in a given type of effluent without compromising the pollutant reduction efficiency.

Microscopic analysis reports of the sample revealed satisfactory bacterial growth in industrial effluent. Understanding and developing methodologies for the treatment of chemical industry wastewater is necessary due to the scarcity of freshwater resources. The four main constituents in pharmaceutical plant wastewater treatment that regulators are generally concerned with are Total Organic Carbon (TOC), Total Nitrogen (TN), Total Phosphorus (TP), and Total Suspended Solids (TSS).

Treatment Regime Using T1B Aerobio:
T1B Aerobio: A Complete Solution for Industrial Wastewater Treatment

Our team of researchers developed this unique biotech formulation for effluent treatment, T1B Aerobio, which has proven to be extremely beneficial in solving the most challenging industrial wastewater treatment problems over the years. T1B Aerobio is a microbial consortium for wastewater treatment, isolated from nature. The microbes secrete effective biodegrading enzymes, which are completely natural and safe for humans, plants, and animals. These microbes are highly efficient in degrading organic pollutants in wastewater, refractory wastewater contaminants, and toxic industrial effluents even under high TDS levels.

Our team of experts planned to move ahead strategically for maintaining transparency in effluent treatment implementation between us and the industry. Initially, there was a laboratory-scale study, followed by a pilot plant study to build the client’s confidence in our biological wastewater treatment technology. Finally, the treatment was implemented on the actual industrial wastewater treatment plant (WWTP).

Execution:
Plant Optimization:

Team One Biotech recommended some changes in the effluent treatment plant design for the smooth functioning of the biological treatment process.

Initial Dosing Plan:

We planned a 60-day dosing schedule with a higher microbial culture dosing in the first month and a maintenance dose in the second month.

Observation:

We observed that after adding T1B Aerobio, it significantly reduced the COD in industrial wastewater, BOD in chemical effluent, and TAN levels in wastewater. The table below shows the reduction:

Day 1Day 15Day 30 Day 45 Day 60
COD ppm250001408480152045243
BOD ppm1000040492510804110
TAN ppm4503581909844
Results:

We observed:

  • 99% reduction in COD levels
  • 99% reduction in BOD levels
  • 90% reduction in TAN levels
  • Achieved the desired Mixed Liquor Volatile Suspended Solids (MLVSS): Mixed Liquor Suspended Solids (MLSS) ratio of 0.7
  • Maintained the required Food to Microorganism (F/M) ratio
  • Improved overall effluent treatment plant efficiency
Conclusion:

The use of T1B Aerobio for industrial wastewater treatment in the chemical manufacturing sector proved to be an effective and eco-friendly method. The efficiency of the effluent treatment plant (ETP) improved significantly, stabilizing the biological wastewater treatment process quickly. The treated effluent successfully met the Pollution Control Board (PCB) compliance standards for wastewater discharge norms.

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Commisioning of ETP of a petrochemical industry
Restart and Commissioning of ETP of a Petrochemical Industry
Introduction: 

This petrochemical industry in West Bengal has a full-fledged Activated Sludge Process (ASP) system with two aeration tanks in parallel. This Effluent Treatment Plant (ETP) experienced shock loads and frequent upsets due to multiple streams and high Polycyclic Aromatic Hydrocarbons (PAH) in the effluent. Maintenance of a good biomass in the aeration tanks along with sustainability in shock loads was a challenge as the upsets were highly shock-inducing.

ETP Details:

The industry had primary treatment, biological treatment, and then a tertiary treatment.

Previous Capacity
Flow (current)450 KLD
Flow (design)450 KLD
Type of processASP (parallel tanks)
Capacity of AT-1350 KL
Capacity of AT-2350 KL
Retention Time37.33 hours(combined)
Challenges: 
Parameters (PPM)Avg. Inlet parameters Avg. Outlet parameters (MBR Outlet)
COD4000-80003200-6000
BOD2600-58001200-3800
TDS70001000
PAH14501000
Operational Challenges:
  • The primary treatment was working at 5% efficiency in terms of COD reduction.
  • The biological treatment worked at an average 20-25% efficiency in terms of COD reduction.
  • They were struggling to control the higher PAH levels, and it was inducing shock loads, as explained earlier.
The Approach:

The industry partnered with us to commission their Upflow Anaerobic Sludge Blanket (UASB) and Aeration Tank with increased capacity and restart the ETP at its full capacity in terms of hydraulic load.

We adopted a 3D approach that included:

Research/Scrutiny:

Our team visited their facility to go through the process of the new Effluent Treatment Plant (ETP) and to scrutinize the value-addition factors.

Analysis:

We analyzed the 3-month cumulative data of their ETP to see trends in the inlet-outlet parameters’ variations and the permutation combinations related to it.

Innovation:

After the research and analysis, our team curated customized products and their dosing schedules with formulation, keeping in mind the plan of action to get the desired results.

This process is called bioaugmentation.

Desired Outcomes:
  • Development of strong biology to withstand shock loads and prevent upsets.
  • Making ETP more efficient regarding COD/BOD and PAH degradation.
  • Reduction in FOG (Fats, Oils, and Grease).
Execution:

Our team selected the product:

For Aeration Tank:
  1. T1B Aerobio: consists of blends of several strains of aerobic and facultative microorganisms, usually bacteria, along with key trace elements on a complex inert media.
For Oil/Grease Trap:

2. T1B FOG BioBloc:

  

Our plan of action included:
  • The addition of T1B Aerobio was also done every day with a reduction in the dosing every 10 days.
  • A total of 150 kgs of T1B Aerobio was used for 60 days of treatment.
  • T1B FOG BioBloc was placed at the O/G trap for FOG reduction.
  • 4 blocks of T1B FOG BioBloc were used for 60 days.
Results:
Parameters
Parameters (PPM)Avg. Inlet parameters Avg. Outlet parameters (secondary clarifier outlet)
COD4000-80001200-2300
BOD2600-5800500-850
TDS70001000
PAH1450321

The implementation of the bioaugmentation program resulted in significant improvements in the performance of biological units in their Wastewater Treatment Plant (WWTP):

  • The COD/BOD degrading efficiency increased from 20% to 70% in the biological system.
  • PAH was also getting degraded up to 77%.
  • MLSS (Mixed Liquor Suspended Solids): MLVSS (Mixed Liquor Volatile Suspended Solids) ratio was optimized.
  • Biomass in the ASP system displayed great stability even during shock load situations.

This sustainable wastewater treatment approach has helped the industry optimize effluent quality, enhance microbial community stability, and ensure compliance with environmental standards.

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