Hyfun Foods
Hyfun Foods, a leading producer of frozen French fries and potato specialties, needed a robust wastewater treatment system to support water reuse and sustainable operations.
The Challenge
High COD Concentration
Wastewater contained COD levels as high as 10,000 mg/L, requiring specialized anaerobic treatment (IC Reactor) and biological polishing processes to reduce organic load efficiently.
Oil & Grease Contamination
Food processing operations generated significant oil and grease that could coat membranes and inhibit downstream biological systems if not efficiently separated during primary treatment.
Variable pH Conditions
Fluctuating wastewater characteristics required robust equalization, continuous pH management, and process stability to protect biological cultures and ensure stable plant operations.
Water Reuse & Circularity
The client needed high-quality treated water suitable for reuse within manufacturing operations. Shubham implemented Zero Liquid Discharge (ZLD) using ultrafiltration and reverse osmosis to achieve this.
Strict Treated Water Quality
Food manufacturing demands high-purity water with zero quality variations. Our system was designed with dual-stage membrane filtration to meet strict reusable process water specifications reliably.
Process Flow Diagram
Engineering Solution
Shubham designed a customized treatment solution combining physicochemical, biological, and advanced membrane technologies.
Primary Treatment
Components: Screening, Oil & Grease Removal System, Collection Tank
Purpose: Remove floating impurities, separate oil and grease, equalize fluctuating hydraulic loads
Secondary Treatment
Components: Chemical Dosing, pH Adjustment, Holding Tank, IC Reactor, Aeration System, Secondary Clarifier, Flash Mixing Tank, Filter Press
Purpose: Reduce high organic load, lower COD concentrations, remove suspended solids, stabilize treatment process
Tertiary Treatment
Components: Filtration System, Treated Water Storage Tank, Ultrafiltration (UF), Reverse Osmosis (RO)
Purpose: Remove residual turbidity and odor, produce high-quality reusable water, support Zero Liquid Discharge objectives
Results & Performance
ETP INLET
ETP OUTLET
| Parameter | Inlet Value | Outlet Value |
| pH | 4.5–8.5 | 6.8 |
| BOD | 300–350 mg/L | 20 mg/L |
| COD | 7000–10000 mg/L | 39 mg/L |
| TSS | 150–250 mg/L | 7 mg/L |
| Oil & Grease | 15 mg/L | NIL |
Performance Highlights
99.6%
COD Reduction
94%+
BOD Reduction
Near-Zero
Oil & Grease
300 m³/day
Water Reuse Capacity
Sustainability Impact
By implementing advanced treatment technologies and water reuse infrastructure, the project contributes to:
Reduced freshwater consumption
Circular water management
Lower environmental discharge
Improved ESG performance
Water-secure manufacturing operations