How One Water Treatment System Transformed Asia's Largest Dairy in Just 30 Days

Banas Dairy, a subsidiary of Amul and one of Asia's largest milk producer cooperatives, faced critical water quality challenges while establishing their new 30 LLPD (expandable to 60 LLPD) dairy and potato processing facility in Sanadar, Gujarat. Panda Water Tech delivered a comprehensive 7.2 MLD water treatment solution that revolutionized their operations by providing consistent, high-quality water for all processing needs.

• Capacity: 7.2 MLD (Million Liters per Day) fully automatic water treatment plant
• Timeline: Project completed and commissioned in July 2023
• Solution: Complete turnkey system including filtration, softening, ultra-filtration, and reverse osmosis

Client Background

Banas Dairy operates as a division of Gujarat Cooperative Milk Marketing Federation and stands as Asia's largest milk producer cooperative. Based in Banaskantha district, Gujarat, the cooperative collects an average of 8.3 million liters of milk daily, reaching up to 10 million liters during winter months. With 200,000 shareholders spread across 1,750 cooperative societies, Banas Dairy serves as the largest member union of the Gujarat Cooperative Milk Marketing Federation.

The company was establishing a new green field project for dairy and potato processing operations at Village Sanadar, requiring sophisticated water treatment infrastructure to support their expanding operations.

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The Challenge

Banas Dairy encountered several critical water treatment challenges that threatened their operational efficiency and product quality:

Variable Feed Water Quality

The facility faced inconsistent raw water quality, creating uncertainty in treatment outcomes and product standards. This variability posed significant risks to dairy processing operations where water quality directly impacts product safety and taste.

High Hardness and Chloride Content

The feed water contained exceptionally high levels of hardness and chloride, which can cause scaling in equipment, affect taste profiles, and reduce operational efficiency. In dairy processing, water with high mineral content can interfere with pasteurization processes and cleaning protocols.

Regulatory Compliance Requirements

The dairy needed to meet stringent water quality standards for different applications - from process water to drinking water - while maintaining compliance with food safety regulations.

COVID-19 Operational Challenges

The project timeline coincided with the pandemic, requiring innovative solutions to maintain project momentum while ensuring safety protocols.

Remote Monitoring Needs

The facility required comprehensive process parameter reporting and real-time monitoring capabilities accessible from anywhere globally, enabling proactive management of water quality.

The Solution

Panda Water Tech designed and implemented a state-of-the-art 7.2 MLD fully automatic water treatment plant tailored specifically for dairy industry requirements. The comprehensive solution included:

Multi-Stage Filtration System

• Raw water pumping and filtration with chlorination and de-chlorination
• Multi-grade pressure sand media filters for suspended solids removal
• Activated carbon filters for taste, odor, and chlorine removal
• Advanced membrane separation technology

Water Softening and Storage

• Automatic water softening system with regeneration capability
• Soft water storage and hydro-pneumatic pressure booster systems
• Capacity to handle high hardness levels effectively

Ultra-Filtration and Reverse Osmosis

• High-end ultra-filtration system for particle and microorganism removal
• Two-stage reverse osmosis system for comprehensive water purification
• De-gasifier system for enhanced water quality

Specialized Systems

• Fire water pumping system for entire facility safety
• Dedicated drinking water RO system (2000 LPH capacity)
• Comprehensive distribution piping network

Automation and Control

• PLC/HMI/SCADA operated control panels for complete automation
• Real-time monitoring and data logging capabilities
• Remote access functionality for global monitoring

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Implementation

The implementation process demonstrated Panda Water Tech's expertise in complex industrial water treatment projects:

Design Phase

Panda's engineering team conducted comprehensive water analysis and designed a customized solution addressing the specific challenges of variable feed water quality and high mineral content.

Manufacturing and Testing

All components were manufactured at Panda's 50,000 square foot facility in Ahmedabad, with rigorous pre-dispatch testing ensuring optimal performance.

Installation and Commissioning

The complete system was installed, commissioned, and thoroughly tested to ensure all parameters met dairy industry standards. The project included comprehensive training for operational staff.

Overcoming Challenges

Despite COVID-19 restrictions, the project team successfully maintained schedule through careful planning and safety protocols, demonstrating resilience and adaptability.

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Results & Impact

The implementation of Panda Water Tech's advanced water treatment system delivered transformative results for Banas Dairy:

Operational Excellence

• Consistent Water Quality: The facility now processes dairy products with reliable, high-quality water meeting all industry standards
• 7.2 MLD Daily Capacity: Complete water treatment capacity supporting current operations with expansion capability
• Multiple Water Types: Simultaneous production of filtered water, soft water, RO water, and drinking water

Quality Improvements

• Variable Feed Water Management: Successfully treating inconsistent raw water to consistent high-quality output
• Hardness and Chloride Reduction: Effective removal of problematic minerals ensuring equipment longevity and product quality
• Microbiological Safety: Ultra-filtration and RO systems ensuring pathogen-free water for all applications

Economic Benefits

Based on industry standards, dairy processing facilities typically achieve significant cost savings through advanced water treatment systems:

• Reduced chemical usage by up to 60%
• Lower maintenance costs through scale prevention
• Enhanced equipment lifespan
• Improved energy efficiency in heating and cooling systems

Environmental Impact

• Water Recovery: Advanced treatment enabling water reuse and recycling
• Waste Reduction: Minimized water waste through efficient treatment processes
• Regulatory Compliance: Meeting all environmental discharge standards

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Key Takeaways

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• Customized Solutions Drive Success: Panda Water Tech's ability to design systems specifically for dairy industry requirements, addressing unique challenges like variable feed water quality and high mineral content, proved essential for project success.
• Comprehensive Automation Enhances Operations: The fully automated PLC/HMI/SCADA system enables remote monitoring and consistent operation, critical for maintaining dairy processing standards.
• Multi-Stage Treatment Ensures Quality: The combination of filtration, softening, ultra-filtration, and reverse osmosis provides robust water quality assurance for diverse dairy applications.
• Turnkey Approach Minimizes Risk: Panda's end-to-end responsibility from design through commissioning ensures seamless project delivery and optimal performance.

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