Rapid Biological Stabilization of a Low-Load STP at Chakan MIDC Using CleanMaxx Technology

Background and Problem Statement

A multinational company operating from its Chakan MIDC facility in India was struggling to stabilize the biological performance of its 140 KLD Sewage Treatment Plant (STP).

Despite the large design capacity, the plant received only about 3 KLD of wastewater daily, primarily originating from canteen dishwashing activities and washrooms.

This resulted in an extremely low and unbalanced organic load, coupled with nutrient deficiencies and elevated pH levels, which severely hindered microbial development.

Consequently, the biological system failed to maintain healthy biomass, leading to operational challenges, including persistent foaming, poor biomass growth, and severe odour emissions.

The effluent, characterized by a yellowish-orange colour and pungent smell due to high urine content, further complicated treatment.

Additionally, the presence of detergents and surfactants from dishwashing activities contributed to continuous foaming in the aeration tank, making consistent treatment performance difficult to achieve.

Key Issues

• Poor MLSS due to very low and inconsistent organic load in the STP.
• Persistent foul odour and yellowish colour in the treated water caused by nitrogen-rich sewage from washrooms.
• Excessive foaming in the aeration tank was triggered by detergents and surfactants from canteen wastewater.
• Difficulty in meeting PCB discharge norms under unstable treatment conditions.
• Operational instability due to highly fluctuating sewage inflows.

Key Objectives

• Rapid development of MLSS
• Eliminate foul odour and colour
• Control and prevent foaming
• Achieve PCB norms
• Improve overall plant efficiency

Plan of Action

Organica Biotech team of experts visited the STP to understand the current operations. Based on the on-site analysis, they found two major problems affecting the overall system performance: Nutrient scarcity and high pH (around 9).

Based on the analysis and findings, Organica Biotech introduced the CleanMaxx technology — CleanMaxx and CleanMaxx NT.

CleanMaxx, a consortium of beneficial microbes, has superior strains of non-genetically engineered and robust microbes rather than a single strain, thereby making it more suitable for surviving under varied temperature, pH, and fluctuating organic load. This helps in the faster commissioning of biological systems. The microbes are microencapsulated to provide better shelf life.

CleanMaxx NT is a source of micro- and macronutrients, combined with biostimulants, to accelerate microbial growth and activity in biological wastewater systems. Formulated for stringent conditions, it replenishes nutrient deficiencies, boosts biomass development, and enhances overall biodegradation efficiency.

Organica Biotech recommended a dosage plan for CleanMaxx and CleanMaxx NT in the aeration tank. Continuous aeration was ensured, and the R&D team conducted periodic BioCheck microscopic analyses to monitor microbial activity and system health.

Results

Following the addition of CleanMaxx technology, Organica Biotech’s R&D team conducted BioCheck studies to evaluate the health and performance of the biological system at regular intervals (Days 5, 10, and 15).

BioCheck is a comprehensive diagnostic study designed to assess the current health of the biological wastewater treatment process.

1. BioCheck Lab Report After the Addition of CleanMaxx and CleanMaxx NT

2. MLSS Development

MLSS analysis was carried out on a regular basis along with COD and BOD analysis to monitor biomass development and system health.

The implementation team observed significant microbial growth within 15 days from commissioning, with progressive improvements throughout the study period.

Day 1: 150 mg/L (initial inoculation)
Day 15: 1000–1200 mg/L (rapid biomass growth)
Day 30: 2000–3000 mg/L with an MLVSS: MLSS ratio of 0.75 (ideal range for stable operation)

Significant MLSS Development	Good Biomass Settling in Aeration Tank

Odour, Colour, and Foaming Control

• Noticeable odour reduction within 7 days; complete elimination by Day 15
• Persistent foaming was reduced to negligible levels, ensuring clear treated water at the outlet

Before Treatment (Excessive foaming)	After Treatment (Complete reduction in foaming)

Conclusion

Organica Biotech successfully transformed the client’s underperforming STP into a stable and compliant system within 30 days using CleanMaxx and CleanMaxx NT. The intervention:

• Achieved rapid biomass growth under low organic load conditions
• Achieved good biological growth at a pH of 9 (higher than optimal)
• Completely eliminated odour, colour, and foaming issues
• Ensured treated effluent met stringent PCB norms consistently