Jiangsu Hengfeng Fine Chemical Co., Ltd.

In the food industry, caramel is more than just a basic ingredient; it is a product that requires precise control over formulation and processing. From the high-temperature reaction of sugar or glucose to the final stabilization of color and flavor, caramel manufacturing involves complex chemical and physical changes. Alongside product quality, manufacturers are increasingly challenged by environmental management issues, particularly the treatment of high-strength wastewater generated during production. Caramel manufacturing wastewater is typically characterized by deep color, high organic content, and finely dispersed suspended solids. Unreacted sugars, caramel pigments, and colloidal substances remain highly stable in water, making natural sedimentation ineffective. Traditional physical separation methods often struggle to achieve consistent results, leading to high turbidity in treated water, excessive sludge volumes, and unstable operation of downstream treatment systems. Under these conditions, polyacrylamide (PAM) has proven to be an effective and reliable solution in caramel manufacturing wastewater treatment. As a high-molecular-weight polymer flocculant, PAM works by extending its molecular chains in water and binding dispersed particles together through adsorption and bridging mechanisms. This transforms fine, stable particles into larger and denser flocs, significantly improving solid–liquid separation efficiency.   A food manufacturer specializing in liquid caramel color once faced persistent challenges with unstable clarification performance and fluctuating effluent quality. Even with increased dosages of inorganic coagulants, the sedimentation process remained inefficient, while operating costs and sludge disposal volumes continued to rise. After introducing a properly selected polyacrylamide product into the clarification stage, floc formation became faster and more uniform. Suspended caramel particles settled more rapidly, effluent clarity improved noticeably, and the overall system became easier to control and maintain. Beyond immediate improvements in turbidity and color removal, the application of PAM delivered broader operational benefits. By stabilizing the pretreatment process, the treated wastewater entering downstream biological or advanced treatment units became more consistent in quality. This reduction in hydraulic and organic load fluctuations helped protect the entire treatment system, reduced operational risks, and improved long-term reliability. As environmental regulations continue to tighten, caramel manufacturers can no longer rely on short-term or reactive wastewater treatment strategies. Achieving stable compliance while maintaining economic efficiency has become a core operational objective. In this context, polyacrylamide is not merely an auxiliary chemical but a functional component that actively supports process optimization. With proper product selection, controlled dosing, and standardized operation, PAM can deliver sustained value in caramel manufacturing applications. Its contribution goes beyond meeting discharge standards; it enables a more stable, efficient, and manageable production environment. This is why polyacrylamide has become an increasingly important and widely adopted solution within the caramel manufacturing industry.

Indonesia is one of the important producers of alumina in Southeast Asia. With the continuous expansion of alumina refining capacity, alumina plants are facing increasing challenges in solid–liquid separation efficiency, red mud settling performance, and overall operating stability.   An alumina refinery in Indonesia was seeking a more efficient flocculant solution for its clarification and mud settling process. The existing flocculant system showed unstable performance, high dosage consumption, and insufficient settling and overflow clarity, which affected production efficiency and operating costs.   Challenges Faced   During on-site communication and technical evaluation, the customer mainly encountered the following issues:   Slow settling rate of red mud, limiting the throughput of thickeners   Poor overflow clarity, causing higher suspended solids in the clarified liquor   High flocculant consumption, resulting in increased chemical costs   Unstable floc formation, sensitive to changes in slurry concentration and operating conditions   The customer required a flocculant with strong adaptability to high-alkalinity alumina slurry and stable performance under continuous operation.   Hengfeng Solution   Based on the customer’s process conditions and slurry characteristics, Jiangsu Hengfeng Fine Chemical Co., Ltd. recommended a polyacrylamide emulsion specially designed for alumina (aluminum oxide) applications.   Key features of Hengfeng’s alumina-grade PAM emulsion include:   Optimized molecular structure for high-alkalinity alumina systems   Rapid dissolution and activation, suitable for on-site continuous dosing   Strong flocculation ability to promote fast red mud settling   Formation of large, dense, and stable flocs, improving solid–liquid separation   Our technical team provided dosage guidance, preparation instructions, and on-site optimization support during the trial phase.   Implementation Process   The product was tested in the clarification and thickening stage of the alumina production process. After adjusting the dilution ratio and dosing point, the system quickly reached stable operation.   Trial parameters were optimized step by step based on:   Settling rate observation   Overflow turbidity   Mud bed stability   Chemical consumption comparison   Results and Achievements   After using Hengfeng’s polyacrylamide emulsion, the alumina plant achieved significant improvements:   Settling rate increased noticeably, allowing higher thickener efficiency   Overflow clarity improved, with reduced suspended solids   Flocculant dosage reduced, lowering overall chemical costs   More stable operation, less sensitivity to process fluctuations   The customer reported that the product performance was consistent and reliable, meeting the requirements of long-term continuous operation.   Customer Feedback   The alumina plant expressed high satisfaction with both the product performance and Hengfeng’s technical support. Based on the successful trial results, the customer moved forward with regular use of Hengfeng’s alumina-specific polyacrylamide emulsion.

Testing the effectiveness of polyacrylamide emulsion on treating grain oil production wastewater involves several steps, from sample collection to analysis. Here is a general procedure you can follow: Materials Needed Grain oil wastewater sample Polyacrylamide powder (prepared as per the previous guideline) Beakers or containers Magnetic stirrer pH meter Lime water Flocculation testing apparatus (e.g., jar test apparatus) Filtration apparatus Chemical dosing equipment Spectrophotometer (for further analysis of contaminants if needed) Testing Procedure 1. Sample Collection: Collect samples of grain oil production wastewater in clean containers. Ensure that the samples are representative of the wastewater being treated. 2. Initial Characterization: Adjust pH: Use a Lime water to adjust the initial pH of the wastewater. Visual Assessment: Examine the color and clarity of the wastewater. Note any visible contaminants. 3. Preparation of Polyacrylamide powder: Ensure that you have a prepared solution of polyacrylamide, as discussed in the previous procedure. This can be used for the flocculation process. 4. Flocculation Test (Jar Test): Setup: Prepare a series of beakers for different doses of polyacrylamide(e.g., 0, 5, 10, 15, 20 mg/L). Add Wastewater: Add equal volumes of the wastewater sample to each beaker (e.g., 500 mL). Add Polyacrylamide: Add the specified amount of polyacrylamide emulsion to corresponding beakers. Mixing: Stir the solutions at a rapid speed (e.g., 200 rpm) for about 1-2 minutes, then slow down to a lower speed (e.g., 30 rpm) for an additional 5 minutes to allow floc formation.     5. Settling Time: Stop stirring and allow the flocs to settle for a predetermined time. 6. Post-Treatment Analysis: Visual Assessment: Observe and note the clarity and color of the treated water. pH Measurement: Measure the final pH of the treated samples. Filtration: Filter the supernatant from each beaker to evaluate the effectiveness of the flocculating agent further. 7. Additional Testing (if needed): Use additional tests such as COD (Chemical Oxygen Demand), BOD (Biochemical Oxygen Demand), or specific contaminant analysis (e.g., heavy metals, dyes) using a spectrophotometer to assess the effectiveness of the treatment further and compare results with the initial values. Safety Precautions Wear appropriate PPE (gloves, goggles, lab coat) while handling wastewater samples and chemical agents. Handle all chemicals and equipment according to safety guidelines. Conclusion This procedure provides a systematic approach to assessing the effectiveness of polyacrylamide on treating grain oil production wastewater. It's important to optimize the concentration of polyacrylamide based on the characteristics of the specific wastewater being treated for best results.