.webp)
FISH PROCESSING ETP CASE STUDY
How a 600 MT/day Fish Processing ETP Achieved 90% Odour Control
Industry: Marine Products / Fishmeal & Fish Oil Processing (Animal Feed)
Facility Scale: 600 MT/day Raw Fish Capacity (West Coast, India)
Primary Solution: NutriServe Rapid Oxidizer Liquid Additive
90%
Condensate Odour Reduction
30%
Treatment Cost Reduction
Up to 65°C
Effective Water Temperature
This fish processing ETP case study shows how a 600 MT/day marine processing plant controlled obnoxious odours from hot condensate water using NutriServe Rapid Oxidizer. Field trials achieved 90% odour reduction at 200 ml per 100 L, with treatment remaining effective at temperatures up to 65°C. The solution also reduced treatment costs by 30% without increasing TDS or adding load to the existing ETP.
Background & Technical Challenge
Plant Overview
A leading marine products facility processes approximately 600 MT of raw fish per day to produce fishmeal and fish oil for animal feed. The production area operates across three processing lines equipped with cookers, press machines, tri-canters, evaporators, and dryers.
During processing, approximately 0.55 MT of condensate water is generated per MT of raw fish. Stick-water from the tri-canter passes through evaporators, where steam is condensed and collected in a 20 m³ condensate tank at temperatures ranging from 35°C to 65°C before being transferred to the ETP.
The hot condensate generated a severe obnoxious odour, while vapours from the blowers produced a strong ammoniacal smell. Previous treatments using lemon fragrance, UV, ozone, and hypochlorites were unsuccessful, leading the facility to evaluate NutriServe Rapid Oxidizer for condensate odour control.
The Technical Challenge & Risk
High Condensate Generation: The plant generated 0.55 MT of condensate water per 1 MT of raw fish processed, equivalent to approximately 330 MT/day at the 600 MT/day production capacity. The condensate carried a strong obnoxious odour requiring treatment before ETP transfer.
Hot, Odorous Condensate: Condensate water was collected in a 20 m³ tank and treated at temperatures ranging from 35°C to 65°C, creating strong odour and uncomfortable conditions for employees and nearby residents.
Ammoniacal Vapour Emissions: Vapours from the cooker, press machine, and dryer lines were routed towards the scrubber using blowers with a 30 kW electrical load. The plant reported a strong ammoniacal smell with high pH from the blower vapours.
Multiple Odour Hotspots: Strong putrefying odours occurred in the fish unloading area, while the production lines, condensate water, and blower vapours created additional odour sources across the facility.
Failed Previous Treatments: The plant dosed 3 litres/day of lemon fragrance into the condensate tank, but this only masked the odour. Trials with UV treatment, ozone, and hypochlorites were also unsuccessful.
Treatment Process Flow Diagram
Treatment process flow diagram of the fish processing facility showing the production process, condensate generation, odour treatment, and transfer of treated condensate water to the ETP.
The integrated process converts raw fish into fishmeal and fish oil while generating condensate water during evaporation. NutriServe Rapid Oxidizer is dosed into the condensate treatment stream before the water is transferred to the existing ETP.
Process units mapped based on actual plant flow:
Raw Fish → Cooker → Press Machine → Tri-Canter → Evaporator → Condenser → Condensate Water Tank → NutriServe Rapid Oxidizer Treatment → ETP
Process Overview
Cooking & Pressing: Raw fish is cooked using indirect steam and pressed to separate water and oil from the processed fish.
Tri-Canter Separation: Oil, water, and sludge are separated, with fish oil collected separately and process water transferred to the evaporator.
Evaporation & Condensation: Approximately 80% of the water is evaporated, while the resulting steam is cooled in a condenser and collected as condensate water.
Odour Treatment: NutriServe Rapid Oxidizer is applied to the condensate water to reduce the obnoxious odour generated during fish processing.
ETP Transfer: Treated condensate water is subsequently released to the existing ETP for further treatment.
Bio-Augmentation Strategy & Dosing
Why NutriServe™ Rapid Oxidizer Was Selected
To control the obnoxious odour generated from hot fish processing condensate, Amalgam Biotech implemented NutriServe Rapid Oxidizer as a direct condensate water treatment. The solution was selected after existing treatments, including lemon fragrance, UV, ozone, and hypochlorites, failed to provide effective odour control.
Field trials demonstrated effective odour reduction across condensate temperatures ranging from 35°C to 65°C, with 90% efficiency at a 200 ml dose per 100 L and up to 100% efficiency at 300 ml per 100 L under trial conditions.
Key Benefits
Achieved 90% odour reduction at 200 ml/100 L during trials
Effective across 35°C to 65°C condensate temperatures
Reduced obnoxious condensate odour within less than 20 minutes
Reduced treatment costs by approximately 30%
Added no additional load to the existing ETP
Improved condensate water clarity with no increase in TDS
Simple dosing without complex treatment chemistry
4-Step Condensate Odour Control Process
NutriServe Rapid Oxidizer was applied directly to the fish processing condensate stream to provide rapid odour treatment before transfer to the ETP. The treatment was tested at different temperatures and dosing concentrations to establish effective operating conditions.
1. Condensate Collection
Hot, odorous condensate is collected in the 20 m³ tank.
2. Rapid Oxidizer Dosing
NutriServe Rapid Oxidizer is added directly to the condensate water.
3. Rapid Odour Reduction
Obnoxious odour is reduced with a contact time of less than 20 minutes.
4. ETP Transfer
Treated condensate is transferred to the existing ETP without adding additional treatment load.
Field Trial & Dosing Matrix
To neutralize volatile amine and sulfur molecules rapidly without raising effluent TDS, Amalgam Biotech deployed directly into condensate recirculation lines.
Test Run | Water Volume | Water Temp | Product Dosage Rate | Odor Removal (%) | Field Observation |
Run 1 | 100 Liters | 35 – 40°C | 200 mL (2 mL/L) | 90% Reduction | Very faint residual odor detected |
Run 2 | 100 Liters | 35 – 40°C | 300 mL (3 mL/L) | 100% Removal | Faint clean chemical product scent |
Run 3 | 100 Liters | 50 – 65°C | 200 mL (2 mL/L) | 90% Reduction | Faint odor immediately; gone upon cooling |
Run 4 | 100 Liters | 50 – 65°C | 300 mL (3 mL/L) | 100% Removal | Total odor removal across hot condensate |
*Full-scale operating ratio: 1 kg NutriServe per 1,000 Liters of fish processing condensate water (100 L prepared solution dosed continuously at 4 L/hour).
*Dosing schedule is based on this plant case study and may vary depending on plant operating conditions and site-specific factors.
Performance Results & Analytics
Key Metrics Achieved
90% Odour Reduction: NutriServe Rapid Oxidizer achieved 90% treatment efficiency at 200 ml per 100 L of condensate water during trials at both 35 to 40°C and 50 to 65°C.
Rapid Odour Control: The treatment removed 80% of bad odour within less than 20 minutes of contact time, enabling rapid treatment of obnoxious fish processing condensate.
30% Treatment Cost Reduction: The treatment delivered an approximately 30% cost reduction, providing a techno-commercially viable alternative to the previous odour treatment approach.
No Additional ETP Load: Condensate treatment added no additional load to the existing ETP, while improving water clarity without increasing TDS.
High-Temperature Performance: Effective odour reduction was demonstrated across condensate temperatures ranging from 35°C to 65°C, addressing odour from both hot and cooled condensate streams.
Operational Achievements
Performance Metric | Pre-Treatment Baseline | NutriServe State |
Condensate Odor Level | Obnoxious Amine / Decay | 85–100% Total Reduction |
Treatment Cost | High / Inefficient Trials | 30% Net Cost Savings |
Effect on Effluent TDS | High (hypochlorite risk) | Zero TDS Increase |
Impact on Downstream ETP | Bio-inhibition / Load | Zero Extra Hydraulic Load |
Reaction / Contact Time | Hours (Ineffective) | < 20 Minutes Contact Time |
600 MT/day fish processing facility where NutriServe Rapid Oxidizer was used to control obnoxious odours from hot condensate water before ETP treatment.
Client Feedback: Condensate Odour Removal & 30% Cost Savings
“Evaporator condensate from our 600 MT/day fishmeal processing line was producing strong amine odours that UV and ozone treatment could not control. NutriServe Rapid Oxidizer completely eliminated the odour within 20 minutes without increasing TDS. It also reduced our overall treatment costs by 30%.”
General Manager of Marine Operations
Fishmeal Facility, West Coast India
⭐⭐⭐⭐⭐
Facing Severe Fishmeal Odor Complaints or ETP Pretreatment Issues?
Let our marine waste specialists analyze your stick-water condensate parameters and design a custom NutriServe Rapid Oxidizer dosing protocol.
Step 1: Share your process details and treatment objectives.
Step 2: Our engineers assess your system and operating conditions.
Step 3: Receive a tailored solution and implementation plan.
Frequently Asked Questions
Q1: How did NutriServe Rapid Oxidizer eliminate 100% of condensate odour in a 600 MT/day fish processing plant?
NutriServe Rapid Oxidizer used direct liquid-phase chemical oxidation to neutralise volatile amines and nitrogenous foulants in a 20 m³ hot condensate tank operating at 35°C to 65°C. At a dosage of 300 mL/100 L, it achieved 100% odour elimination within 20 minutes.
Performance Highlights:
Target Waste Stream: Hot stick-water condensate generated at 0.55 MT per 1 MT of raw fish processed, producing 330 MT/day of condensate.
Cost Efficiency: Reduced chemical treatment costs by 30% compared with legacy advanced oxidation systems.
Zero ETP Load: Improved condensate water clarity with no increase in Total Dissolved Solids (TDS) or secondary organic COD loading.
Q2: Why do conventional lemon fragrances, ozone, and hypochlorite fail on fish processing condensate odours?
Synthetic fragrances only mask strong amine odours without changing their molecular structure. Ozone, UV cabinets, and hypochlorite are less effective because the high temperature (35°C to 65°C) and heavy organic load of stick-water condensate rapidly consume oxidants and continue to release volatile compounds.
Engineering Comparison:
Fragrances & Deodorisers: Temporarily mask unpleasant odours but do not remove amine vapours or reduce associated workplace risks.
UV/Ozone/Hypochlorite: Require higher CAPEX and power consumption and can face rapid oxidant depletion and increased TDS.
NutriServe Rapid Oxidizer: Breaks down amine and organosulphur compounds directly in the hot liquid phase without increasing effluent TDS.
Q3: What volatile malodorous compounds are generated during raw fish decay and stick-water evaporation?
Raw fish breakdown releases several nitrogenous and sulphur-based odour compounds, including Trimethylamine (TMA), Dimethylamine (DMA), Ammonia (NH₃), Methyl Mercaptan, and Hydrogen Sulfide (H₂S). These compounds have very low human odour detection thresholds and can cause strong off-gassing during evaporation.
Mass Balance Context (600 MT/day Capacity):
Raw Fish Input: 600 MT/day, producing 120 MT/day of fishmeal and 60 MT/day of fish oil.
Condensate Stick Water: 330 MT/day (330,000 litres) requiring continuous liquid-phase oxidation.
Process Wash Water: 420 MT/day routed to biological treatment.
Q4: What is the full-scale dosing protocol for NutriServe Rapid Oxidizer in fishmeal condensate tanks?
The full-scale dosing ratio uses 1 kg of NutriServe Rapid Oxidizer per 1,000 litres of hot condensate water. It is typically prepared as a 100 L concentrated working solution and continuously dosed into the recirculation tank at a controlled rate of 4 L/hour.
Dosing Matrix Summary:
35°C to 40°C Water: 200 mL/100 L achieves 90% odour reduction, while 300 mL/100 L achieves 100% odour removal.
50°C to 65°C Water: 300 mL/100 L achieves 100% odour removal in high-temperature evaporator condensate.
Q5: How does NutriServe Rapid Oxidizer protect downstream biological Effluent Treatment Plants (ETP)?
NutriServe Rapid Oxidizer breaks down complex amine foulants into non-odorous, biodegradable intermediates without adding secondary chemical toxicity, non-biodegradable surfactants, or dissolved mineral salts. This allows treated condensate to enter biological aeration tanks without disrupting MLSS or causing shock load problems.
Effluent Impact:
Zero TDS Elevation: Prevents additional salt build-up, supporting water recycling or safe discharge.
No Secondary COD: Unlike organic masking agents, it does not increase chemical oxygen demand (COD) in ETP aeration tanks.
Q6: Where are the primary odour emission sources located in a marine products and fish oil facility?
The main odour sources include Raw Fish Unloading Bays, where fish can begin to decay before processing; Cooker Press & Tri-Canter Units; Evaporator Stick-Water Condensate Tanks, which release hot amine vapours; and Scrubber Vapour Blowers, which discharge ammoniacal exhaust into the surrounding air.
Facility Integration: Treating the condensate directly at the liquid interface helps prevent foul vapours from reaching the scrubber blowers, reducing odour exposure for plant personnel and nearby communities.
Written by Ashutosh Vadanagekar
Technical Director, Amalgam Biotech
Ashutosh Vadanagekar has over 22 years of experience in water and wastewater treatment, with expertise in process design and bioculture technology. He develops and implements eco-friendly biological treatment solutions for ETPs and STPs across industries, addressing challenges such as high COD and BOD, ammonia, FOG, odour and biological process instability. He also contributes technical expertise and practical insights to Amalgam Biotech’s wastewater treatment case studies. Connect on LinkedIn