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Description
MJ Dairies Ltd., a prominent dairy producer established in 2003, seeks to bolster its market position and environmental sustainability through the Business Development Programme in Bulgaria, funded by the EEA and Norway Grants 2014-2021. Specializing in a diverse range of dairy products, MJ Dairies processes 20 million liters of raw milk annually, generating significant whey by-products and wastewater. To address environmental concerns and increase production capacity, the company aims to invest in an innovative installation for full-scale treatment of biological waste and wastewater, coupled with secondary processing to produce biogas, replacing 80% of the current natural gas consumption. This strategic initiative aligns with the company''s goal of reducing its carbon footprint, enhancing environmental impact, and meeting green technology standards. The project''s comprehensive environmental benefits include effective wastewater treatment, waste reuse, and a substantial reduction in CO2 emissions, contributing to the company''s commitment to sustainability and efficiency. The innovative investment, supported by calculations and good business practices, is expected to elevate MJ Dairies'' competitiveness, fostering economic growth and environmental responsibility.
The ongoing project plays a crucial role in fostering bilateral ties between Bulgaria and Norway by facilitating international collaboration and knowledge exchange. In collaboration with the University of Stavanger from Norway, this initiative aims to introduce resource-efficient wastewater treatment technologies to MJ Dairies Ltd. The Norwegian partner will play a significant role in providing support and expertise, contributing to the company''s competitiveness, sustainable growth, and the application of best practices. This collaboration underscores the commitment to shared learning and technological advancements between the two nations.
Summary of project results
The project aimed to address several critical challenges faced by MJ Dairies Ltd. in its production process. One of the primary issues was the extensive generation of wastewater and by-products, particularly whey, during dairy processing. The company processed approximately 20 million liters of raw milk annually, resulting in the production of around 16 million liters of whey. Due to its high organic content, whey could not be directly disposed of into the environment, necessitating costly transportation and secondary treatment at external facilities.
Additionally, MJ Dairies Ltd. produced 4,000 tonnes of dairy products each year, consuming 100,000 cubic meters of water and generating significant amounts of wastewater. Although the company had an existing wastewater treatment facility, it was technologically outdated and lacked the capacity to efficiently process the increasing waste load. This posed an environmental risk and an operational bottleneck, particularly as the company sought to expand its production capacity.
The project successfully addressed the challenges related to wastewater and whey management by implementing an innovative full-scale treatment system. To achieve this, the company secured financial support and invested in advanced equipment designed to process biological waste and wastewater more efficiently.
As part of the project, MJ Dairies Ltd. introduced two new treatment processes: one for wastewater containing high organic content and another specifically for whey, a by-product of cheese production. The core technology involved processing the mixed wastewater and whey through a Dissolved Air Flotation (DAF) facility. Initially, both waste streams were directed into collection pools, where they were blended to form a homogenized substrate. This substrate was then separated using a floatator, which divided it into two distinct streams:
- A fat-free liquid fraction, which was treated in an External Circulation Sludge Bed (ECSB) reactor
- A fat-containing stream, which was processed in a Solid Waste Digestion (SWD) reactor
Within these reactors, biological purification occurred through the decomposition of biomass present in the wastewater and whey. The project ensured that the treated water met environmental standards before being discharged into the city sewage system. Additionally, the biomass decomposition process generated biogas as a by-product, which was then utilized to produce steam for heating the ECSB and SWD reactors.
The project’s implementation resulted in significant improvements, including more efficient wastewater treatment, reduced environmental impact, and the conversion of organic waste into renewable energy. The biogas produced replaced 80% of the company’s natural gas consumption, enhancing energy efficiency and reducing operational costs.
The project achieved significant environmental and operational improvements, benefiting both MJ Dairies Ltd. and the broader community.
Outcomes and Impacts
Enhanced Wastewater Treatment
- The project led to the effective treatment of wastewater, ensuring that only purified water was discharged into the city sewerage system. This reduced pollution and minimized the company’s environmental footprint.
Sustainable Waste Reuse
- By implementing advanced processing technologies, the company successfully converted whey and organic waste into biomass, creating a valuable resource from previously discarded by-products.
Reduction in CO₂ Emissions and Environmental Impact
- A major achievement of the project was the 80% reduction in the company’s reliance on natural gas through the use of biogas generated from waste processing.
- As a result, MJ Dairies Ltd. achieved an 80% decrease in CO₂ emissions associated with natural gas consumption.
- Overall, the company reduced its total carbon footprint by 48%, which translated into a drop from 2,118 tonnes of CO₂ in 2019 to 1,101 tonnes in 2022.
- The project also contributed to lower electricity and water consumption, further enhancing sustainability.
Greener Technologies and Business Operations
- The company successfully modernized its production processes by incorporating eco-friendly technologies, making its operations more sustainable and energy-efficient.
Beneficiaries
MJ Dairies Ltd.: The company directly benefited from lower operational costs, reduced waste disposal expenses, and increased energy efficiency.
- The Environment: The project contributed to a cleaner ecosystem by reducing wastewater pollution and lowering greenhouse gas emissions.
- Local Community and Authorities: Improved wastewater treatment ensured better water quality in the municipal sewer system, benefiting residents and regulatory agencies.
- Energy Sector: The shift from natural gas to biogas reduced dependency on fossil fuels, promoting renewable energy use at the industrial level.
Overall, the project significantly improved the sustainability of MJ Dairies Ltd.’s operations while demonstrating a successful model for integrating environmental responsibility with business growth.
Summary of bilateral results
The bilateral collaboration between MJ Dairies Ltd. and the University of Stavanger yielded valuable results. Several online meetings facilitated productive discussions on the project’s parameters, benefits, and the potential of the proposed installation. Leveraging its expertise, the university conducted in-depth research on similar high-tech installations in Norway and neighboring countries.As part of its role, the University of Stavanger analyzed MJ Dairies Ltd.''s innovative green technology and prepared a comprehensive report. The company provided the university with technical specifications, enabling a detailed assessment. The final report was delivered, and a follow-up meeting was held, where critical project parameters were reviewed and key issues were discussed.This collaboration resulted in significant knowledge exchange, helping MJ Dairies Ltd. refine its approach based on international best practices. The partnership contributed to a deeper understanding of advanced wastewater treatment technologies, enhancing the project’s overall effectiveness and sustainability.