A Mini Project Report

On
“Application of TADOX Technology in Water
Conservation in Food Processing Industry”
By
“Rajan Gupta”
“2300520700049”

Under the guidance of

“Dr. ASIF IQBAL”

In partial fulfillment of the requirement for the award of the

Degree of Master of Business Administration

Submitted at

DEPARTMENT OF BUSINESS ADMINISTRATION

INSTITUTE OF ENGINEERING AND TECHNOLOGY
JANKIPURAM LUCKNOW, UP-226021
2024
 Department of Business Administration
Institute of Engineering & Technology Lucknow

STUDENT DECLARATION

I undersigned, hereby declare that the project titled submitted inpartial

fulfilment for the award of Degree of Master of Business Administration

Application of TADOX Technology in Water Conservation in Food

Processing Industry is a bonafide record of work done by me under the

guidance of Dr.ASIF IQBAL.This report has not previously formed the basis

for the award of any degree, diploma, or similar title of any University.

Place : Lucknow

Date :

Rajan Gupta
2300520700049
 Department of Business Administration
Institute of Engineering & Technology Lucknow

CERTIFICATE FROM INSTITUTION

This is to certify that Mr. Rajan Gupta, First semester student of Master of

Business Administration, Institute of Engineering & Technology, Sitapur Road,

Lucknow has completed the project report entitled Application of TADOX

Technology in Water Conservation in Food Processing Industry in partial

fulfilmentof the requirements for the award of the Degree of Master of

Business Administration.

Date:
Place: Lucknow

Dr. Durgawati Kushwaha

Co-convener
 Department of Business Administration
Institute of Engineering & Technology Lucknow

CERTIFICATE FROM FACULTY GUIDE

This is to certify that Mr. Rajan Gupta, Second semester student of Master

of Business Administration, Institute of Engineering & Technology, Sitapur

Road, Lucknow has completed the project report entitled Application of

TADOX Technology in Water Conservation in Food Processing Industry

towardspartial fulfilment of the requirement for the award of the Degree of Master

of Business Administration under my supervision.

Date:
Place: Lucknow

Dr. Asif Iqbal

 PREFACE

This project report explores sustainable water management and advanced

wastewater treatment technologies in the food processing industry. It highlights

the significance of TADOX (The TERI Advanced Oxidation Technology) and

Clean-in-Place (CIP) systems in achieving zero liquid discharge and maintaining

process efficiency. The report presents insights into the principles, advantages,

applications, and future prospects of these technologies. It also addresses

limitations and challenges while envisioning a more sustainable future for the

industry.
 ACKNOWLEDGEMENT

This report is an outstanding prospect to convey my gratefulness to those people

whose timely help and guidance went a long way in finishing this project work

from commencement to achievement.

I would like to thank the Director of Institute of engineering and technology,

Lucknow: Prof. Vineet Kansal and our Coordinator of Department of Masters of

Business Administration: Prof. Virendra Pathak. This was really a good way of

learning and I really learned a lot from this project.

I would also like thank to my mentor and Co-Convener of Masters of Business

Administration: Dr.Durgawati Kushwaha and my mentor Dr.Asif Iqbal for

rendering their valuable time and providing me full knowledge which was

needed in order to successfully completion of this report.

 TABLE OF CONTENTS

PageNo.

CHAPTER I
1.1 Introduction 1-3
1.1.1 Issues & Challenges Faced By Food Industry 4-6
1.1.2 Application of Emerging Tech. to Overcome Challenges 7-11
1.2 Problem Statement 12
1.3 Significance of Study 13-14
1.4 Objectives of Study 15
CHAPTER II
2.1 Impact of Technological Advancement 16-31
CHAPTER III
3.1 Limitations 32-33
3.2 Conclusions 34-35
REFERENCES 36
 CHAPTER : I
1.1 Introduction

The food processing industry plays a crucial role in transforming raw agricultural materials into
processed food products that meet the diverse needs and preferences of consumers. This project
focuses on analyzing the food processing industry to identify key challenges and explore potential
solutions for water conservation within this sector.

• Industry Overview

The food processing industry holds significant importance in world’s economy, contributing to

job creation, value addition, and export earnings. It encompasses various sectors, each playing

a vital role in meeting the demands of the population and contributing to the world's agricultural

and economic development.

The dairy processing sector is one of the largest and most well-established segments of the food

processing industry in India. Companies like Amul (Banas Dairy) and Parag are prominent

players in this sector, known for their quality dairy products and extensive distribution

networks. They source milk from local farmers, process it into various dairy

products, and supply them to consumers across the country.

Fig-1.1 Vegetable Processing Fig-1.2 Dairy Industry

Another significant sector is fruits and vegetables processing, with companies like Dabur and

ITC leading the way. They specialize in processing and preserving a wide range of fruits and

1
vegetables, making them available throughout the year in various forms, such as juices, purees,

and frozen products. These companies work closely with farmers to ensure the procurement of

high-quality produce.

The meat and poultry processing sector is also a vital part of the food processing industry in

India. Companies like Venky's and Suguna Foods play a crucial role in processing and

supplying poultry products to meet the growing demand for chicken and other meat products

in the country. They follow strict quality standards and maintain hygienic processing facilities

to ensure safe and healthy products for consumers.

Grains and cereals processing is another significant sector, with companies like Britannia

Industries and Parle Agro leading the market. These companies manufacture a wide range of

products, including biscuits, snacks, and beverages, using various grains and cereals. They have

established popular brands that cater to the diverse tastes and preferences of Indian consumers.

The beverages sector, dominated by companies like Coca-Cola India and PepsiCo India,

produces a wide range of non-alcoholic beverages, including carbonated drinks, juices, energy

drinks, and packaged water. These companies focus on innovation, brand building, and

extensive distribution networks to reach consumers across urban and rural areas.

Other sectors within the food processing industry in India include confectionery (e.g., Cadbury

India, Parle Products), bakery products (e.g., Britannia Industries, Bakers Circle), seafood

processing (e.g., Avanti Feeds, Waterbase), and packaged foods (e.g., ITC, Mother Dairy).

Each of these sectors contributes to the overall growth and development of the food processing

industry in India.

2
• Market Trends & Challanges

The food processing industry in India operates within a dynamic market environment,

influenced by evolving trends and facing several challenges. One significant trend is the

growing consumer demand for healthy and nutritious food products. This trend has prompted

companies to develop innovative offerings and diversify their product portfolios to meet these

changing preferences.

There is also a rising demand for convenience and ready-to-eat food products, driven by

changing lifestyles and urbanization. This trend has led to the development of packaged and

processed foods that offer convenience, easy storage, and longer shelf life.

Online platforms provide consumers with convenient access to a variety of food products, while

companies leverage digital tools for efficient inventory management, order fulfillment, and

delivery logistics.

However, the food processing industry also faces various challenges. Changing regulations and

compliance with food safety standards are critical concerns for companies operating in this

sector. Adhering to stringent quality control measures, ensuring food traceability, and

managing supply chain complexities are crucial for maintaining consumer trust.

Environmental sustainability has emerged as another significant challenge for the food

processing industry. As the industry continues to grow, there is a need to minimize its

environmental footprint, particularly in terms of resource consumption and waste generation.

Water conservation, including minimizing freshwater consumption in cleaning and food-

making processes, has become a priority for achieving sustainable operations within the

industry.

3
1.1.1 Issues & Challenges Faced by Food Processing Industry
1. Water Consumption and Management: The food processing industry faces significant

challenges related to water consumption and management. During an industrial visit to

Banas Dairy (Amul India), it was revealed that a substantial amount of water,

approximately 5 lakh litres daily, is used solely for cleaning machines and maintaining

hygiene. This high water consumption poses environmental concerns and

increases operational costs for the industry as a whole.

Fig-1.3 Cleaning and Sanitation

2. Environmental Pollution: The water used in the cleaning processes often becomes

polluted with cleaning agents and contaminants, rendering it unsuitable for reuse.

Consequently, the polluted water is discarded, leading to water wastage and potential

pollution of water bodies if not treated properly. Addressing this environmental

pollution issue is crucial for sustainable operations within the food processing industry.

Fig-1.4 Water Waste From Food Processing Industries

3. Lack of Efficient Water Recycling Systems: One of the main challenges highlighted

during the industrial visit was the absence of efficient water recycling systems in

4
 many food processing facilities. As a result, the industry fails to optimize water

utilization and misses opportunities for sustainable practices. Implementing effective

water recycling systems, such as TADOX technology or other cost-efficient

alternatives, can help in minimizing water wastage and achieving sustainability goals.

4. Energy Consumption: The food processing industry is also confronted with high energy

consumption for various operations, including heating, refrigeration, and processing.

This results in increased energy costs and contributes to carbon emissions.

Implementing energy-efficient practices and adopting renewable energy sources can

help mitigate these challenges.

5. Waste Generation and Management: Food processing operations generate significant

waste, including packaging materials, byproducts, and organic waste. Proper waste

management strategies, such as recycling, composting, and responsible disposal, are

necessary to minimize the environmental impact and promote circular economy

principles.

6. Food Safety and Quality Assurance: Ensuring food safety and maintaining high- quality

standards is a continuous challenge for the food processing industry. Strict adherence

to regulations, robust quality control measures, and effective traceability systems are

essential to meet consumer expectations and maintain regulatory compliance.

7. Supply Chain Complexity: Managing complex supply chains involving multiple

stakeholders, such as farmers, suppliers, distributors, and retailers, poses challenges in

terms of logistics, quality control, and maintaining product integrity. Streamlining

supply chain operations and fostering strong collaboration among stakeholders are

critical for efficient and sustainable supply chain management.

5
 8. Technological Advancements: Rapid technological advancements present both

opportunities and challenges for the food processing industry. While innovative

technologies can improve efficiency, product quality, and traceability, their integration

and adoption require careful planning, investment, and training to ensure smooth

implementation and minimal disruption to existing operations.

9. Market Competition and Consumer Demands: The food processing industry faces

intense competition, with changing consumer demands for healthier, sustainable, and

convenient food options. Companies must continuously innovate and adapt to evolving

consumer preferences to maintain a competitive edge.

10. Regulatory Compliance: Adhering to evolving regulations and compliance

requirements related to food safety, labeling, advertising, and sustainability is a

continuous challenge. Companies must stay updated with regulatory changes and invest

in robust systems and processes to ensure compliance.

Addressing these challenges requires a comprehensive approach that includes implementing

water-efficient practices, adopting sustainable technologies, optimizing energy consumption,

improving waste management strategies, enhancing supply chain efficiency, fostering

innovation, and promoting a culture of compliance and continuous improvement throughout

the food processing industry.

1.1.2 Application of Emerging Technologies to Overcome the Challenges

As this project focuses on water conservation, minimising it’s uses and efficient recycling

process, so the identified challenges for this project are-

i) Process Optimization & Automation to Use Water Efficiently

ii) Recycling Waste Water with Zero Liquid Discharge (ZLD)

6
So we’ll consider a new technology named as TADOX for recycling waste water and will use

customize process optimization & automation tech to efficiently utilize the fresh water in

processes.

TADOX Technology

The implementation of Zero Liquid Discharge (ZLD) in wastewater treatment systems presents

several challenges. To overcome these challenges, there is a need to integrate novel approaches

and advanced oxidative treatment technologies into current systems. This integration can help

reduce the overall load on tertiary treatment and achieve ZLD in a more affordable, acceptable,

and sustainable manner.

In line with this pursuit, TERI (The Energy and Resources Institute) has developed an end-to-

end wastewater treatment technology called The TERI Advanced Oxidation Technology

(TADOX). TADOX is a trademark-approved and patent-pending technology designed to treat

industrial and municipal sewage wastewater, achieve ZLD, enhance water-reuse efficiency, and

serve as an advanced decentralized wastewater treatment (DWTT) option.

TADOX is a clean, green, sludge-free, highly resource- and

energy-efficient technology. Its

objective is the oxidative

treatment of wastewater effluent

streams that contain high levels of

color, ChemicalOxygen Demand

(COD), Biochemical Oxygen Demand

(BOD), Total Organic Carbon(TOC),

dissolved organics, non-biodegradable compounds,

and persistent organic pollutants (POPs).

Fig-1.5 TADOX

7
Stage I: Primary Treatment cum Settling Tank In this stage, novel primary treatment

approaches are employed using newer formulations of coagulants and flocculants. The overall

use of chemicals in the treatment is significantly reduced compared to conventional methods.

The primary treatment involves the removal of suspended solids, sediments, and other larger

particles.

Stage II: UV/n–TiO2 Photocatalytic Reactor (PCR) The secondary treatment stage utilizes

UV/n–TiO2 photocatalysis as an advanced oxidation process (AOP). Nanomaterials are

employed as adsorbents and photo-catalysts to facilitate oxidative degradation and

mineralization of targeted pollutant dyes and auxiliary chemicals. The nanomaterials used in

the process are recovered through suitable filtration systems, regenerated, and reused. The

treated water obtained from this stage is colorless, odorless, and adequately treated, as verified

by testing conducted by NABL accredited laboratories.

Stage III: Reverse Osmosis (RO) Unit and Evaporators The tertiary treatment stage may

require the use of an RO unit, followed by the utilization of evaporators, depending on the

specific application and point of use. RO helps further purify the water by removing dissolved

impurities and salts. Evaporators are employed to concentrate the remaining wastewater to

produce solid residue, ensuring zero liquid discharge.

Fig-1.6 TADOX Process

8
The TADOX technology has received recognition through various innovation and technology

development awards. The work on its development has been published in the Journal of Water

Process Engineering (Bahadur and Bhargava 2019).

The integration of TADOX technology into wastewater treatment systems offers a promising

approach to achieve ZLD, enhance water reuse efficiency, and provide advanced decentralized

wastewater treatment options. By implementing TADOX or similar advanced oxidative

treatment technologies, the food processing industry can make significant progress in

minimizing water consumption, improving water management, and promoting sustainable

practices.

CIP (Clean in Place)

Clean-in-place (CIP) systems are integral to maintaining a hygienic process environment in the

food, dairy, and beverage industry. CIP systems play a vital role in ensuring product quality

and purity by effectively cleaning and sanitizing process lines, vessels, and equipment without

the need for disassembly or

removal.

Fig-1.7 CIP Process

CIP systems work by pumping cleaning, rinsing, and sanitizing solutions through the same

piping path used for the product, thereby eliminating product soil from all internal surfaces.

9
This process helps remove bacteria, residues, and contaminants, ensuring that the processing

components remain free from microbial growth and preventing product contamination.

The benefits of CIP systems include:

1. Efficiency: CIP systems streamline the cleaning process by eliminating the need for

manual disassembly and cleaning of equipment, saving time and labor. The cleaning

process can be automated, reducing downtime and increasing overall production

efficiency.

2. Consistency: CIP systems provide consistent and controlled cleaning procedures,

ensuring that all internal surfaces are thoroughly cleaned and sanitized according to

defined protocols. This helps maintain product quality and reduces the risk of cross-

contamination.

3. Cost-effectiveness: By reducing the need for manual cleaning and minimizing

production downtime, CIP systems contribute to cost savings. Additionally, efficient

cleaning processes help extend the lifespan of equipment by minimizing wear and tear

caused by manual cleaning.

4. Hygiene and Food Safety: CIP systems are designed to meet strict sanitary standards

and ensure compliance with food safety regulations. By effectively removing

contaminants and bacteria, CIP systems help maintain a hygienic process environment,

reducing the risk of product recalls and maintaining consumer confidence.

5. Traceability and Documentation: CIP systems can be integrated with process control

systems to monitor and record cleaning parameters, ensuring traceability and

documentation for quality assurance purposes. This helps in meeting regulatory

requirements and facilitates audits and inspections.

10
Proper design, implementation, and maintenance of CIP systems are crucial to ensure their

effectiveness. Factors such as the selection of appropriate cleaning agents, temperature control,

flow rates, and adequate rinsing are critical considerations in optimizing CIP system

performance.

By employing well-designed CIP systems, food, dairy, and beverage processors can maintain

high levels of cleanliness and hygiene, meet regulatory requirements, and safeguard product

quality, ultimately contributing to consumer satisfaction and brand reputation.

11
1.2 Problem Statement
The food processing industry faces challenges in minimizing water consumption and managing

wastewater during cleaning and sanitation processes.

Conventional methods like Clean-in-Place (CIP) systems result in significant water

wastage and pollution due to the use of large volumes of fresh water and chemical

cleansers.

Inadequate systems for water utilization and inefficient recycling processes further

exacerbate the problem.

During an industrial visit, it was observed that a single dairy plant alone consumed

approximately 5 lakh liters of fresh water per day for cleaning and sanitation.

This issue is not limited to a single dairy plant but extends to other players in the food

processing industry and various sectors.

The project aims to address the challenges by investigating and proposing solutions for

reducing fresh water consumption and enhancing water reuse efficiency.

Integration of emerging technologies like TADOX for wastewater treatment and

optimization of CIP systems will be explored.

The project aims to achieve zero liquid discharge (ZLD), improve water management

practices, and promote sustainable water utilization in the food processing industry.

12
1.3 Significance of Study
The significance of the study lies in its potential to address critical challenges faced by the food

processing industry regarding water consumption, wastage, and recycling. By investigating and

proposing solutions for reducing fresh water consumption and enhancing water reuse

efficiency, the study aims to bring about several important benefits:

1. Water Conservation: The study will contribute to the conservation of water resources

by identifying and implementing strategies to minimize water consumption in cleaning

and sanitation processes. This will help mitigate the industry's impact on freshwater

sources and promote responsible water management practices.

Fig-1.8 Population Distribution and Water Availability

2. Environmental Impact Reduction: By reducing water wastage and pollution associated

with conventional cleaning methods, the study will contribute to the reduction of the

food processing industry's environmental footprint. Implementing efficient water

recycling processes will minimize the release of wastewater and contaminants into the

environment.

3. Cost Savings: Adopting water-saving techniques and technologies can lead to

significant cost savings for food processing companies. By optimizing water usage
13
 and reducing wastewater disposal, companies can lower their operational costs

associated with water procurement, treatment, and discharge.

4. Sustainable Operations: The study's findings and recommendations will support the

industry's transition towards more sustainable and eco-friendly practices. Integrating

emerging technologies like TADOX for wastewater treatment and optimizing CIP

systems align with the industry's commitment to sustainability, resource efficiency, and

environmental stewardship.

5. Regulatory Compliance: With growing regulatory focus on water conservation and

wastewater management, the study's outcomes will assist food processing companies

in meeting and exceeding compliance requirements. Implementing efficient water

management practices can help companies stay ahead of regulatory changes and

maintain their reputation as responsible and compliant entities.

6. Industry Leadership and Innovation: By exploring and adopting emerging

technologies, the food processing industry can position itself as a leader in sustainable

practices. The study's insights can inspire further innovation and collaboration within

the industry, fostering a culture of continuous improvement and responsible resource

management.

7. Social Responsibility: The study's outcomes will contribute to improved social

responsibility by ensuring the availability of clean water resources for communities and

future generations. By reducing water consumption and minimizing pollution, the

industry can play a vital role in preserving water quality and supporting broader societal

well-being.

Overall, the significance of this study lies in its potential to drive positive change within the

food processing industry, promoting water conservation, sustainability, and responsible

practices.

14
1.4 Objectives of Study

Here are the objectives of the study:

• Assess current water consumption and waste water management practices in the food

processing industry.

• Investigate and evaluate emerging technologies like TADOX and optimized CIP

systems for minimizing water usage and enhancing water reuse efficiency.

• Promote industry-wide adoption of water conservation technologies and raise

awareness about the importance of water sustainability.

15
 CHAPTER : II
2.1 Impact of Technological Advancement
➢ TADOX Technology: Advantages and Applications

TADOX technology is an innovative and advanced oxidative treatment method developed by

The Energy and Resources Institute (TERI) for wastewater treatment in various industries,

including the food processing sector. It offers several advantages over conventional treatment

methods and plays a pivotal role in achieving Zero Liquid Discharge (ZLD) objectives.

• Principles of TADOX Technology and Zero Liquid Discharge (ZLD)

The principles of TADOX technology revolve around advanced oxidative treatment to break

down pollutants and organic compounds present in wastewater. The technology employs a

three-stage treatment process:

a) Primary Treatment: The primary treatment stage uses novel coagulants and flocculants,

reducing the reliance on conventional chemicals. This stage aims to remove suspended solids,

sediments, and larger particles from the wastewater.

b) Secondary Treatment: In the secondary treatment stage, UV/n–TiO2 photocatalysis is

utilized as an advanced oxidation process (AOP). Nanomaterials serve as adsorbents and

photo-catalysts, facilitating the oxidative degradation and mineralization of targeted pollutant

dyes and auxiliary chemicals. The use of nanomaterials allows for their efficient recovery and

reuse, promoting resource efficiency and reducing waste generation.

c) Tertiary Treatment: The tertiary treatment involves Reverse Osmosis (RO) andevaporators.

RO further purifies the water by removing dissolved impurities and salts, ensuring high-

quality treated water. Evaporators concentrate the remaining wastewater, resulting in solid

residue and achieving zero liquid discharge.

16
The ZLD approach of TADOX technology ensures that no liquid effluents are discharged,

mitigating the environmental impact and aligning with sustainable wastewater management

practices.

• Advantages of TADOX Over Conventional Treatment Methods

TADOX technology offers several advantages compared to conventional treatment methods,

making it a preferred choice in the food processing industry:

a) Reduced Chemical Usage: TADOX minimizes the need for chemicals throughout the

treatment process. The innovative coagulants and flocculants used in the primary treatment

significantly reduce chemical consumption, leading to cost savings and a lower environmental

footprint.

b) Sludge-Free Operation: Unlike conventional treatment methods that often generate

considerable amounts of sludge, TADOX technology operates in a sludge-free manner. This

eases the challenges associated with sludge management and disposal, promoting a more

sustainable approach to wastewater treatment.

c) Enhanced Resource Efficiency: The recovery and reuse of nanomaterials in the secondary

treatment stage promote resource efficiency. By recycling these materials, TADOX minimizes

resource consumption and waste generation, contributing to a more sustainable and eco-

friendly process.

d) High-Quality Effluent: The treated water obtained through TADOX technology is of high

quality, meeting stringent standards for discharge or potential reuse in food processing

operations. The colorless and odorless effluent ensures compliance with water quality

regulations and maintains product integrity.

17
 By leveraging these advantages, TADOX technology revolutionizes wastewater treatment

practices in the food processing industry, offering an efficient, cost-effective, and sustainable

solution for achieving zero liquid discharge and minimizing environmental impact.

➢ CIP Systems: Optimization and Efficiency

Clean-in-Place (CIP) systems are integral to maintaining a hygienic process environment in the

food processing industry. These systems play a vital role in ensuring product quality and purity

by effectively cleaning and sanitizing process lines, vessels, and equipment without the need

for disassembly or removal. To maximize the efficiency of CIP systems and minimize water

consumption, various key components and strategies can be implemented.

Fig-2.1 CIP Automated Machine System

• Key Components and Functioning of CIP Systems

CIP systems consist of several key components that work together to ensure effective cleaning

and sanitation:

a) Pumps: CIP systems utilize pumps to circulate cleaning, rinsing, and sanitizing solutions

through the process piping and equipment. The pumps create the necessary flow and pressure

for efficient cleaning.

18
b) Spray Balls: Spray balls are mounted inside tanks and vessels, distributing the cleaning

solution evenly over internal surfaces. They are designed to ensure complete coverage and

remove residues and contaminants effectively.

c) Sensors: Sensors, such as level transmitters, flow transmitters, and conductivity

transmitters, monitor and control various parameters during the CIP process. These instruments

ensure proper flow rates, chemical concentrations, and cleaning durations, optimizing the

cleaning efficiency.

• Strategies for Optimizing CIP Systems

To minimize water consumption and maximize cleaning efficiency, the following strategies

can be employed in CIP systems:

a) Proper Flow Rates: Controlling the flow rates of cleaning solutions is crucial to ensure

efficient cleaning without wasting water. Optimized flow rates should be based on the size and

complexity of the equipment being cleaned.

b) Temperature Control: Adjusting the temperature of cleaning solutions can enhance the

effectiveness of the cleaning process. Higher temperatures can improve the removal of

stubborn residues, reducing the need for excessive water usage.

c) Selection of Cleaning Agents: Choosing the right cleaning agents based on the specific

cleaning requirements and nature of contaminants can lead to more effective cleaning. Using

appropriate detergents can reduce the need for excessive rinsing, conserving water.

d) Adequate Rinsing: Ensuring thorough rinsing after the cleaning process helps remove

residues of cleaning agents and contaminants, preventing cross-contamination and reducing the

need for repeated cleaning cycles.

19
➢ Water Consumption and Wastewater Generation in the Food Processing Industry

Water is a critical resource in the food processing industry, serving various purposes such as

ingredient preparation, cleaning, and product cooling. However, the industry's extensive water

usage and the resulting wastewater generation pose significant environmental challenges.

Understanding the water consumption patterns and wastewater generation is essential toaddress

the environmental impact and implement sustainable water management practices.

• Water Consumption Patterns in the Food Processing Industry

Water consumption in the food processing industry varies depending on the type of products

and processes involved. Some key aspects of water consumption patterns include:

a) Production Volume: Larger-scale food processing plants typically require more water due

to their higher production volumes and processing capacities.

b) Process Requirements: Specific processes, such as washing, rinsing, cooling, and cleaning-

in-place (CIP), heavily contribute to water consumption.

c) Product Nature: Water-intensive products, such as beverages, dairy products, and frozen

goods, tend to have higher water consumption rates.

d) Water Quality: The quality of water required varies for different processes. Some

processes demand potable water, while others can use lower-grade water sources.

e) Seasonal Variations: Seasonal variations and fluctuations in demand may impact water

consumption patterns in certain food processing sectors.

f) Recycling and Reuse: The extent of water recycling and reuse practices in individual food

processing plants influences overall water consumption.

• Wastewater Generation in the Food Processing Industry

Wastewater generation is an inevitable outcome of food processing operations. The

composition of wastewater can vary significantly based on the products and processes

20
involved, but it typically contains organic matter, nutrients, suspended solids, fats, oils, and

chemicals used in cleaning and sanitization.

Wastewater generation is significant in various stages of food processing, including cleaning

and sanitation, product washing, and equipment flushing. In addition, processes such as

blanching, peeling, and cooling generate substantial wastewater due to the large volumes of

water involved.

• Environmental Impact of Excessive Water Usage and Inefficient Wastewater Management

a) Water Scarcity and Stress: The food processing industry's substantial water demand can

strain local water resources, leading to water scarcity and stress in regions facing water scarcity

issues.

b) Ecological Impact: Discharging untreated or inadequately treated wastewater into water

bodies can degrade water quality, disrupt aquatic ecosystems, and harm aquatic life due to the

release of nutrients and pollutants.

c) Energy Consumption: Water extraction, treatment, and wastewater management require

significant energy input. Excessive water usage contributes to increased energy consumption

and associated greenhouse gas emissions.

d) Chemical and Nutrient Pollution: Wastewater from food processing often contains

chemicals and nutrients that, if not properly treated, can contaminate water sources, leading to

eutrophication and algal blooms.

e) Compliance and Reputation Risks: Poor wastewater management can result in non-

compliance with environmental regulations, leading to penalties and damage to the company's

reputation.

21
➢ Impact of TADOX Technology on Water Recycling

Water recycling is a critical aspect of sustainable water management in the food processing

industry. TADOX technology plays a significant role in enabling effective water recycling and

reuse, contributing to reduced water consumption and environmental conservation.

• Analyzing the Effectiveness of TADOX Technology in Water Recycling

TADOX technology is designed to treat industrial and municipal sewage wastewater, with the

primary goal of achieving zero liquid discharge (ZLD). The advanced oxidative treatment

process employed by TADOX effectively breaks down pollutants, organic compounds, and

colorants present in wastewater. This treated effluent can be recycled and reused for various

non-potable applications within the food processing plant, reducing the demand for freshwater.

Ca studie of food proce ng pFliga-n2.t2 Etfhfeactt hofaTvAeDiOm

XponleSm
eweangeteW
daTter technology demonstrate

the successful recycling and reuse of treated wastewater. The technology's high efficiency in

pollutant degradation and pathogen removal ensures that the recycled water

22
meets quality standards suitable for specific industrial processes, such as cleaning, irrigation,

or cooling purposes.

• Implementing Closed-Loop Water Systems with TADOX

Closed-loop water systems, also known as water recycling loops, involve treating and reusing

wastewater within the same process, thus minimizing water intake from external sources.

TADOX technology facilitates the establishment of closed-loop water systems, offering a

sustainable solution for water management in food processing operations.

In a closed-loop water system, the treated effluent from the TADOX process is collected and

channeled back into the production processes. By integrating TADOX technology into closed-

loop systems, food processing plants can significantly reduce their freshwater intake and

minimize the discharge of wastewater into the environment. This closed-loop approach helps

achieve higher water use efficiency and reduces the strain on freshwater resources.

• Examining the Economic and Environmental Benefits of Water Recycling through TADOX

Water recycling through TADOX technology offers both economic and environmental benefits

to food processing plants:

Economic Benefits: a. Reduced Water Costs: Recycling and reusing treated wastewater help

reduce the need for freshwater intake, resulting in lower water utility costs for the food

processing plant. b. Lower Disposal Costs: By recycling and reusing treated effluent, the

volume of wastewater requiring off-site disposal decreases, leading to cost savings on

wastewater treatment and disposal.

Environmental Benefits: a. Water Conservation: Water recycling contributes to the

conservation of freshwater resources, promoting sustainable water use in regions facing water

scarcity. b. Reduced Environmental Impact: By recycling wastewater and minimizing the

23
 discharge of effluents, TADOX technology helps prevent water pollution and its adverse effects

on ecosystems.

Overall, the implementation of TADOX technology in water recycling initiatives can lead to

more sustainable water management practices in the food processing industry. It offers a viable

solution to address water scarcity, reduce operational costs, and mitigate the environmental

impact associated with water consumption and wastewater discharge.

➢ Water Savings and Environmental Benefits of Optimized CIP Systems

Clean-in-Place (CIP) systems play a crucial role in maintaining hygiene and process efficiency

in the food processing industry. Optimizing CIP processes can lead to significant water savings,

reduced chemical usage, and lower energy consumption, resulting in positive environmental

benefits.

Fig-2.3 CIP Representation

• Quantifying Water Savings Achieved through Optimized CIP Systems

Implementing optimized CIP systems in food processing plants can result in substantial water

savings. By fine-tuning the CIP process parameters, such as flow rates, cleaning duration, and

temperature control, water consumption during cleaning cycles can be minimized.

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Quantifying the water savings achieved through optimization involves comparing water

consumption data before and after the implementation of optimized CIP systems.

Case studies from various food processing plants can be analyzed to showcase the magnitude

of water savings achieved through CIP optimization. These studies can demonstrate how proper

optimization and automation of CIP processes lead to more efficient use of water during

cleaning procedures.

• Evaluating Reduction in Chemical Usage and Energy Consumption with Efficient CIP
Processes

Optimized CIP systems not only save water but also result in reduced chemical usage and

energy consumption. By employing the correct concentration and type of cleaning agents and

adopting best practices, CIP systems can achieve through cleaning with minimal chemical

usage.

Evaluation of chemical consumption data before and after CIP optimization can provide

insights into the reduction achieved. Additionally, assessing the energy consumption during

CIP cycles, such as water heating and pump operation, can highlight the energy-saving

potential of efficient CIP processes.

• Showcasing Case Studies and Data Illustrating the Positive Environmental Impact of CIP
Optimization

Several food processing plants have implemented optimized CIP systems to enhance cleaning

efficiency while conserving resources. Case studies and data from these plants can demonstrate

the positive environmental impact of CIP optimization.

Environmental benefits includes:

a) Reduced Water Footprint: Water savings achieved through CIP optimization contribute to a

reduced water footprint for the food processing industry, supporting sustainable water

management.

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 b) Lower Chemical Discharge: With minimized chemical usage, the discharge of cleaning

agents and their potential environmental impacts are reduced.

c) Energy Conservation: Efficient CIP processes lower energy consumption, leading to

reduced greenhouse gas emissions and promoting energy conservation.

d) Environmental Compliance: Optimized CIP systems help food processing plants comply

with environmental regulations related to water usage and chemical discharge.

➢ Economic Analysis and Cost-Benefit Evaluation

Implementing TADOX technology and optimized CIP systems in the food processing industry

requires a thorough economic analysis to determine their financial viability and potential return

on investment (ROI). This analysis involves comparing the initial investment costs with the

long-term savings in water, energy, and operational expenses.

• Economic Analysis of Adopting TADOX Technology and Optimized CIP Systems

To conduct the economic analysis, data on the initial capital costs of installing TADOX

technology and optimizing CIP systems must be gathered. This includes the cost of purchasing

and installing the required equipment, such as UV/n–TiO2 photocatalytic reactors, RO units,

evaporators, CIP system components, sensors, and automation technology.

Additionally, operational costs, such as maintenance, energy consumption, and chemical usage,

must be considered. These costs should be compared to the expenses incurred by using

conventional treatment methods and non-optimized CIP systems.

Furthermore, economic analysis should factor in the potential cost savings resulting from

reduced water consumption, lower chemical usage, and energy-efficient processes. This

analysis will help provide a comprehensive understanding of the financial implications of

adopting TADOX technology and optimized CIP systems.

• Comparing Initial Investment Costs with Long-Term Savings

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The next step is to compare the initial investment costs with the long-term savings over a

specified period. Long-term savings include reductions in water usage, energy consumption,

chemical expenses, and potential savings from reduced downtime and improved equipment

lifespan due to optimized processes.

Case studies and real-world data from food processing plants that have already implemented

TADOX technology and optimized CIP systems can serve as valuable references for this

comparison. The analysis should also consider the potential financial benefits resulting from

meeting environmental compliance requirements and avoiding penalties.

• Performing a Cost-Benefit Evaluation to Assess Financial Viability and ROI

The cost-benefit evaluation involves comparing the total costs associated with adopting

TADOX technology and optimized CIP systems to the potential benefits and savings accrued

over a specified period. The ROI is a key metric to assess the financial viability of these

technologies.

The cost-benefit analysis should account for:

a) Water Savings: Quantify the water savings achieved through TADOX technology and CIP

optimization, considering the cost per unit of water.

b) Chemical Savings: Evaluate the cost savings resulting from reduced chemical consumption

due to TADOX technology and optimized CIP processes.

c) Energy Savings: Assess the reduction in energy consumption and associated cost savings

from using energy-efficient technologies.

d) Operational Efficiency: Factor in potential savings from increased operational efficiency,

reduced downtime, and improved production output.

e) Environmental Compliance: Consider the financial benefits of meeting environmental

regulations and avoiding penalties.

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 By conducting a robust cost-benefit evaluation, decision-makers can make informed choices

regarding the adoption of TADOX technology and optimized CIP systems, weighing both the

short-term costs and long-term benefits to achieve sustainable and economically viable

solutions.

➢ Regulatory Compliance and Sustainability

• Compliance with Water Conservation Regulations

a) TADOX technology facilitates compliance with water conservation regulations in the food

processing industry. By achieving Zero Liquid Discharge (ZLD), it ensures that no liquid

effluents are discharged, meeting stringent wastewater discharge limits set by regulatory

authorities.

b) TADOX helps food processing companies adhere to specific parameters such as maximum

allowable levels of pollutants, Biochemical Oxygen Demand (BOD), Chemical Oxygen

Demand (COD), and color in the treated effluent.

• Meeting Environmental Protection Standards

a) Optimized CIP systems play a crucial role in maintaining hygienic and contaminant-free

processing environments, ensuring compliance with health and safety regulations.

b) Efficient CIP systems reduce the risk of cross-contamination and help food processing

plants meet food safety standards and environmental protection requirements.

• Resource Management and Sustainability

a) The adoption of TADOX technology and optimized CIP systems promotes sustainable

water management practices in the food processing industry.

b) Water recycling through TADOX technology reduces water consumption, preserving

precious water resources and contributing to environmental sustainability.

c) TADOX's reduced chemical usage and resource-efficient approach help in minimizing the

environmental footprint of wastewater treatment processes.

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 • Waste Reduction and Circular Economy

a) TADOX technology converts wastewater into treated water, reducing the need for liquid

effluent discharge and minimizing waste generation.

b) Optimized CIP systems contribute to a circular economy by reducing the generation of

wastewater and cleaning agents, leading to a more sustainable production process.

• Energy Efficiency and Carbon Footprint

a) Both TADOX technology and optimized CIP systems contribute to energy efficiency,

reducing greenhouse gas emissions and the overall carbon footprint of food processing

operations.

b) The use of energy-efficient components, automation, and process optimization further

enhances sustainability efforts.

• Corporate Social Responsibility (CSR) and Stakeholder Perception

a) Implementing environmentally friendly technologies like TADOX and optimized CIP

systems aligns with corporate social responsibility initiatives.

b) Sustainable practices in the food processing industry positively impact the reputation and

perception of companies among stakeholders, consumers, and investors.

➢ Future Prospects and Recommendations

• Advancements in TADOX Technology

a) The future of TADOX technology looks promising, with ongoing research and

development focusing on enhancing its efficiency and cost-effectiveness.

b) Further advancements may lead to improved nanomaterials and photocatalysts, enhancing

the oxidative treatment process and reducing energy consumption.

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• Integration of Industry 4.0 and Automation

a) The integration of TADOX technology and optimized CIP systems with Industry 4.0

concepts can revolutionize wastewater treatment and process optimization in the food

processing industry.

b) Smart sensors, data analytics, and automation can optimize treatment processes, leading to

more resource-efficient and sustainable operations.

• Policy Support and Incentives:

a) Governments and regulatory bodies should incentivize the adoption of TADOX

technology and optimized CIP systems through tax benefits, grants, and subsidies.

b) Policy frameworks should encourage industries to implement sustainable water

management practices to achieve water conservation targets.

• Knowledge Sharing and Training:

a) Knowledge sharing platforms, workshops, and training programs should be organized to

create awareness about the benefits of TADOX and optimized CIP systems.

b) Skilled workforce and operators should be trained to handle and maintain these

technologies effectively.

• Collaborative Research and Development:

a) Collaborative efforts between research institutions, technology developers, and food

processing companies can accelerate the innovation and development of water-efficient

technologies.

b) Joint research projects can address specific challenges and gaps in the adoption of TADOX

and optimized CIP systems.

• Adoption in Small and Medium Enterprises (SMEs):

a) Efforts should be made to promote the adoption of TADOX and optimized CIP systems in

small and medium-sized food processing enterprises.

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b) SMEs play a significant role in the food industry, and their sustainable practices can

collectively lead to substantial water savings.

• Environmental Certifications and Labels:

a) Implementing TADOX and optimized CIP systems can qualify food processing companies

for various environmental certifications and labels, enhancing their reputation as

environmentally responsible organizations.

b) Certifications like ISO 14001 and eco-labels can provide a competitive advantage in the

market.

• Public-Private Partnerships:

a) Public-private partnerships can foster collaboration between governments, private

companies, and non-governmental organizations to promote sustainable practices in the food

processing industry.

b) Joint initiatives can facilitate the implementation of TADOX technology and optimized CIP

systems across the sector.

• Long-Term Vision for Water Conservation:

a) The food processing industry should develop a long-term vision for water conservation,

setting ambitious targets for reducing water consumption and wastewater generation.

b) Implementing TADOX and optimized CIP systems can be part of this vision to achieve

sustainable water management.

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 CHAPTER : II
3.1 Limitations

Limitations of TADOX Technology and CIP Systems in the Food Processing Industry:

Initial Investment Cost: The implementation of TADOX technology and optimized CIPsystems

may require significant upfront investment, which can be a barrier for some small andmedium-

sized food processing companies with limited financial resources.

Technical Expertise: The successful implementation and operation of TADOX technology and

advanced CIP systems require technical expertise and specialized knowledge, which may not

be readily available in all food processing facilities.

Compatibility: Integrating TADOX technology and optimized CIP systems with existing

wastewater treatment infrastructure and processing equipment may present challenges,

especially in older facilities with outdated systems.

Operational Complexity: TADOX technology involves a three-stage treatment process, and

optimizing CIP systems may require precise control of various parameters. Managing and

maintaining such complex systems may require additional training and resources.

Regulatory Compliance: While TADOX technology and optimized CIP systems can contribute

to regulatory compliance, meeting ever-changing environmental regulations and standards can

be challenging, and continuous monitoring and adaptation may be necessary.

Limited Data: As emerging technologies, there might be limited historical data on the long-

term performance and reliability of TADOX and advanced CIP systems, which could impact

decision-making for some companies.

Environmental Impact: While TADOX technology reduces sludge generation and chemical

usage, the environmental impact of nanomaterials used in the process requires thorough

investigation and assessment.

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Implementation Time: Installing and commissioning TADOX systems and optimizing CIP

processes may require downtime in food processing operations, impacting production

schedules and efficiency.

Adoption Rate: The adoption rate of new technologies in the food processing industry can be

slow due to resistance to change and a preference for traditional practices.

Scale and Application: TADOX technology and advanced CIP systems may be more suitable

for large-scale food processing facilities with higher water consumption. Smaller facilities may

find it challenging to justify the investment.

Despite these limitations, TADOX technology and optimized CIP systems hold great promise

in revolutionizing wastewater treatment and water management in the food processing industry.

Addressing these limitations through research, collaboration, and technological advancements

can lead to widespread adoption and contribute to a more sustainable and efficient food

processing sector.

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 3.2 Conclusions
In conclusion, this project report sheds light on the critical importance of sustainable water

management and advanced wastewater treatment technologies in the food processing industry.

The adoption of TADOX (The TERI Advanced Oxidation Technology) and Clean- in-Place

(CIP) systems offers promising solutions to the challenges faced by the industry in minimizing

water consumption, improving water reuse efficiency, and achieving zero liquid discharge.

TADOX technology presents a groundbreaking approach to wastewater treatment, facilitating

zero liquid discharge by efficiently breaking down pollutants and organic compounds. Its

advantages over conventional treatment methods, including reduced chemical usage and sludge

generation, make it an attractive option for food processing plants aiming to enhance their

environmental sustainability.

Similarly, CIP systems play a vital role in maintaining a hygienic process environment and

maximizing cleaning efficiency without the need for disassembly. Optimized CIP processes

have demonstrated substantial water savings, reduced chemical usage, and improved sanitation,

contributing significantly to environmental conservation.

Through this report, we have explored the potential of these technologies in water recycling

and closed-loop systems, further emphasizing their economic and environmental benefits.

Additionally, their role in meeting regulatory compliance and enhancing the sustainability

profile of food processing operations has been highlighted.

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Despite the significant advantages, it is essential to recognize the limitations and challenges

associated with the implementation of TADOX and CIP systems. Initial investment costs,

complexity, and potential resistance to change are among the factors that need to be carefully

addressed during the adoption process.

The project report provides valuable insights and recommendations for wider adoption of these

technologies, including incentives and policy support, to drive the industry towards a more

sustainable future. By embracing advanced wastewater treatment technologies and optimizing

water management practices, food processing companies can enhance their operational

efficiency, reduce environmental impact, and contribute to a more sustainable and responsible

industry.

In conclusion, the successful integration of TADOX and CIP systems in the food processing

industry presents a compelling opportunity to achieve water conservation goals and promote

sustainable practices, ensuring a brighter and greener future for both the industry and the planet.

35
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