How Bioculture Enhances COD & BOD Reduction in Adhesive Manufacturing Wastewater

Bioculture introduces specially selected microorganisms that can degrade complex organic compounds, resins, and toxic chemicals that are present in adhesive wastewater to enhance the reduction of COD and BOD in adhesive manufacturing wastewater. These bacteria are actively digesting organic matter, thereby leading to a faster and more efficient reduction in COD and BOD compared to regular biological treatment.

Industrial wastewater from adhesive manufacturers is one of the most difficult types of wastewater to treat. 

In addition to this, they usually have very high organic loads, and they may contain toxic contaminants like formaldehyde and other substances that cannot be degraded by biological methods. As a result, traditional treatment systems often do not meet their required discharge standards because of the continuous presence of high levels of COD (Chemical Oxygen Demand) and BOD (Biochemical Oxygen Demand), even after multi-stage treatment has been applied. This is where bioculture technology becomes a game changer for difficult industrial wastewater streams.

In these cases where the conventional methods fail, the introduction of Bioculture for COD and BOD reduction leads to drastic performance improvements, as it not only increases the amount of organic matter degraded biologically but also stabilizes the microbial population and thus, the overall efficiency of the treatment plant is increased manifold.

In this blog we have discussed a case study from a major adhesive manufacturing facility in Malaysia to explain how biocultures significantly improve performance in both aerobic and anaerobic systems.

The Challenge: High COD & BOD in Adhesive Wastewater

The Malaysian case study revealed an impressive 168 m³/day of highly organic wastewater processed by the plant coming from a chemical-intensive adhesive production line. 

The wastewater was very complex and contained various compounds which further increased the amount of COD and BOD, One of these compounds was formaldehyde which is well known for its resistance to biodegradation. 

Even a very strong strategy consisting of two-stage anaerobic treatment followed by two-stage aerobic treatment with very long retention times was not able to reach the target removal rates. The aeration tanks had very low MLVSS (Mixed Liquor Volatile Suspended Solids) accumulation, which is a very important indicator of active biomass, and the whole system had a hard time keeping up with the biodegradation process.

Adhesive wastewater often contains VOCs (volatile organic compounds) that are toxic to microbial communities, further complicating treatment. Without the right biological support, treatment plants can face persistent COD/BOD discharge levels that risk non-compliance, unpleasant odours, and ecosystem harm. These issues are part of the common wastewater treatment challenges faced by many industries dealing with high organic and toxic loads.

Bioculture: A Strategic Solution

The treatment team implemented a mixed aerobic and anaerobic bioculture dosing strategy with BactaServe-Aerobic and BactaServe-Anaerobic microbial blends specifically designed for the characteristics of the wastewater, in order to deal with these problems.

This approach is similar to how BactaServe aerobic bioculture is used to strengthen microbial activity and improve overall effluent treatment efficiency in challenging environments.

Why Bioculture Works

Unlike general activated sludge, specialized bioculture for COD and BOD reduction introduces selected microbial strains that supported by the science behind aerobic bioculture, which explains how selected microorganisms naturally purify complex wastewater streams.

• Efficiently metabolize complex organics, including recalcitrant compounds derived from adhesives and formaldehyde,

• Adapt quickly to harsh influent conditions,

• Thrive in both oxygen-rich and oxygen-limited environments, and

• Multiply rapidly to build robust biomass capable of sustained biodegradation.

  
  

This tailored microbiological boost is essential in challenging industrial streams where conventional microbial communities struggle to survive or perform consistently.

Case Study Implementation: Strategy & Dosing

Stage 1: Initial High-Dose Bioculture Boost

To start with, bioculture with high concentration was given for the first two months. This strategy of jump-starting allowed microorganisms to get rid of the inhibitors, develop a strong presence and start the process of transforming the complex organics into the biodegradable intermediates.

Main objectives during the initial stage were:

• Fast increase of performance biomass (improvement of MLSS & MLVSS in ETP), 

• Deescalation of toxic organics,and

• Bioculture stability through aerobic and anaerobic conditions.

  
  

Stage 2: Maintenance Dosing for Operational Stability

Having attained a stable microbial ecosystem, the dosage of bioculture was slowly lowered to a maintenance level. This allowed for operational efficiency while still drastically reducing the bioculture input. Amazingly, after achieving stability, the system kept up with high removal rates of COD and BOD with the use of bioculture that was a fraction of what it had been before.

Outcomes: Dramatic COD & BOD Improvement

The bioculture-enhanced treatment delivered significant performance gains compared to the pre-bioculture baseline:

Improved Organic Load Reduction

The treatment system, with the aid of bioculture, achieved a remarkable reduction of COD in the adhesive wastewater and a huge reduction of BOD in the industrial effluent that had before been resistant to conventional biological treatment. This, in turn, resulted in better compliance with effluent standards and lower environmental risk.

Enhanced MLSS & MLVSS

One of the primary successes was the growth of active biomass which was indicated by the improved MLSS & MLVSS metrics that are crucial for the biological degradation process. The increased biomass led to the maintenance of an active metabolism and thus un-interrupted process of organic pollutants breaking down by microorganisms even during the changes in the influent loads. This is a key indicator of sustainable bioculture-driven wastewater management where microbial stability ensures long-term treatment performance.

Bio Stability and Efficiency

The bioculture was already well-settled when the system started to run really steadily. The reduction of bioculture dosing did not affect the chemical industries' wastewater treatment that much as the process could still remove a great deal of pollutants the reason being the application of suitable microbial communities as seeds was very effective.

Benefits Beyond COD & BOD

Beyond just lowering organic loads, bioculture dosing delivers operational advantages:

1. Enhanced Aerobic Tank Performance

By strengthening microbial populations in aerobic zones, the system achieved more efficient organic degradation, improved oxygen utilization, and lower incidences of biomass washout. Strong aerobic biomass also supports bioculture for odour control in industrial plants by preventing septic conditions inside treatment tanks.

2. Better Management of High COD Influent

High COD influent can overwhelm traditional activated sludge systems. Similar success has been seen in handling toxic industrial wastewater with bioculture across various heavy industries. Biocultures tailored for high-load environments help maintain performance even during feed spikes or batch variations, common in adhesive production.

3. Reduced Toxicity Impact

Specialized microbes can degrade toxic intermediates including formaldehyde, mitigating inhibitory effects on the biological system and reducing overall toxicity in the effluent.

4. Microbial Dosing for ETP Efficiency

Targeted dosing strategies mean the right microbes are present at the right concentrations, ensuring continued biodegradation without excessive biomass buildup or sludge handling issues.

Best Practices for Adhesive Wastewater Treatment with Bioculture

In case you are deciding to use biocultures in your ETP, take the expert suggestions below into account: 

• Analyze the characteristics of the influent to determine the proper mixture of aerobic and anaerobic bioculture strains. 

• Initially, load the system, then gradually switch over to maintenance dosing as soon as biomass resorts to its normal state.

• Monitor the key performance indicators like COD, BOD, MLSS, MLVSS, and dissolved oxygen to adjust the dosing and aeration accordingly.

• Merge with physical and chemical processes (like equalization tanks) in order to receive shocks and build up the resilience of the system.

  
  

Conclusion

The Malaysia adhesive production scenario brilliantly illustrates the application of bioculture in the reduction of COD and BOD in difficult industrial effluents. The mixing of aerobic and anaerobic bioculture techniques allows the treatment plants to get rid of poor biodegradation, low biomass levels, and toxic influent conditions thus turning the wastewater treatment process to their favor. 

For manufacturers of adhesives and the chemical sector that are always dealing with high organic loads, the bioculture-enhanced method is not only a means to meet the regulatory requirements but a way to gain a more stable operation, less toxicity, and a more efficient long-term operation. With the appropriate microbial assistance, even the most challenging wastewater streams can be handled and made sustainable in a very effective and environmentally friendly manner.

Struggling with high COD & BOD in your adhesive wastewater?

Let the experts at Amalgam Biotech design a customized bioculture dosing strategy that restores biological balance, improves biomass activity, and helps your ETP consistently meet discharge standards.

Talk to our wastewater specialists today.

Frequently Asked Question

What is bioculture for COD and BOD reduction?

Bioculture for the reduction of COD and BOD is the application of specifically picked microbial consortia to cause faster biological decomposition of organic pollutants in wastewater. These microorganisms in the manufacturing of glue break down the complicated substances like resins, solvents, and toxic intermediates, thus allowing a quicker and more consistent COD and BOD reduction than the traditional activated sludge process.

Why is COD so high in adhesive manufacturing wastewater?

The reason for the elevated chemical oxygen demand is that the effluent of glue makers is made up of synthetic polymers, formaldehyde-containing compounds, solvents, and non-biodegradable organics. These substances lead to the situation of high COD in the influent stream, which is hard to manage, and most of the time, they slow down the natural microbial activity to such an extent that normal biological treatment becomes useless without the aid of bioculture.

How does bioculture help in BOD reduction in industrial effluent?

Bioculture enhances BOD reduction in industrial effluent by increasing the population of active, pollutant-adapted microorganisms. These microbes consume biodegradable organic matter more efficiently, resulting in faster oxygen demand reduction and improved overall treatment performance, as demonstrated in the adhesive manufacturing case study.

What is the role of aerobic and anaerobic bioculture in wastewater treatment?

The anaerobic and aerobic biocultures cooperate to treat the high-strength wastewater. The anaerobic bacteria decompose even the most complex and toxic organics in the absence of oxygen, and the aerobic microorganisms continue the process of oxidation on the pollutants that are left. This combined method is crucial for the biological treatment of high-strength wastewater, for instance, adhesive effluent.

Can bioculture improve MLSS and MLVSS in an ETP?

Yes. Bioculture significantly enhances biomass development, leading to measurable MLSS & MLVSS improvement in ETP. Higher MLVSS indicates a greater concentration of active microorganisms, which directly improves organic degradation capacity and treatment stability.

How does bioculture improve aerobic tank performance?

Bioculture strengthens microbial activity and oxygen utilization, resulting in enhancing aerobic tank performance. Benefits include better floc formation, improved sludge settling, higher COD removal, and reduced biomass washout critical for maintaining compliance in adhesive wastewater treatment plants.

Is bioculture effective for COD reduction in adhesive wastewater?

Yes. COD reduction in adhesive wastewater improves significantly with bioculture because selected microbes can metabolize complex resins and refractory organics that conventional biomass cannot. In the case study, bioculture transformed a poorly performing system into a stable, high-efficiency treatment process.

How is formaldehyde wastewater treated biologically?

Formaldehyde wastewater treatment requires specialized microbial strains that can tolerate and degrade toxic aldehydes. Bioculture introduces such strains, reducing toxicity and preventing microbial inhibition, making biological treatment viable even for chemically aggressive adhesive effluents.

Why is microbial dosing important for ETP efficiency?

Targeted microbial dosing for ETP efficiency ensures that the treatment system maintains the right microbial population to handle fluctuating loads and toxic shocks. In chemical industries, this prevents process failure, stabilizes COD removal, and reduces recovery time after influent variations.