Case Study: 30 KLD ETP Plant with UF System Installed at Dimple Creations, Udyog Vihar, Gurugram

Efficient wastewater treatment is essential for textile and garment manufacturing facilities, where production processes generate wastewater containing dyes, detergents, suspended solids and organic contaminants. Treating this effluent before discharge or reuse is critical for environmental protection, regulatory compliance and responsible water management.

In this project, V Aqua Water successfully installed and commissioned a 30 KLD Effluent Treatment Plant (ETP) with an integrated Ultrafiltration (UF) System at Dimple Creations, located in Udyog Vihar, Gurugram, Haryana.

The project was designed to address the wastewater treatment requirements of a garment manufacturing facility while providing a reliable solution for reducing organic pollution, removing suspended particles and improving treated water quality.

By combining biological treatment, multi-stage filtration and advanced UF membrane technology, V Aqua Water delivered an integrated wastewater treatment solution designed to support regulatory compliance and future water recycling requirements.

This case study covers the project requirements, treatment challenges, engineering approach, plant configuration, treatment process and expected operational benefits.

Project Snapshot

About the Client – Dimple Creations

Dimple Creations is a garment manufacturing unit located in Udyog Vihar, Gurugram, one of Haryana’s established industrial and commercial areas.

Garment manufacturing involves several water-consuming activities, including fabric washing, rinsing, finishing and other production-related operations. These processes generate wastewater containing detergents, organic matter, suspended particles and, depending on the production process, colour-bearing substances.

Such wastewater cannot be discharged directly into the environment without appropriate treatment.

To manage its industrial wastewater responsibly, Dimple Creations required a properly designed Effluent Treatment Plant capable of handling daily wastewater generation and maintaining consistent treatment performance.

V Aqua Water was selected to provide a customised 30 KLD ETP solution with an additional Ultrafiltration stage to improve the quality of treated water.

Project Background: Industrial Wastewater Treatment Requirements

The textile and garment industry is associated with considerable water consumption and wastewater generation. Water used during washing, rinsing and finishing processes often contains organic pollutants, detergents, suspended solids and other contaminants.

The wastewater characteristics can change throughout the production cycle. Variations in flow rate, pH, COD, BOD and suspended solids make industrial wastewater treatment more challenging than treating a consistent domestic sewage stream.

For Dimple Creations, the primary requirement was to establish a treatment system that could:

• Handle approximately 30,000 litres of wastewater per day.
• Manage variations in wastewater flow and pollutant concentration.
• Reduce organic contaminants and suspended solids.
• Improve treated water clarity through advanced filtration.
• Support compliance with applicable pollution control requirements.
• Provide a foundation for treated water recycling and reuse.

V Aqua Water approached the project with a focus on treatment efficiency, practical plant operation and long-term reliability.

Client Requirements

During the initial project assessment and engineering stage, the treatment requirements were defined around the following objectives.

1. Treatment Capacity of 30 KLD

The plant needed to handle approximately 30 kilolitres of industrial wastewater per day, with suitable provisions for managing variations in daily wastewater generation.

2. Improved Treated Water Quality

The client required treated water with reduced organic pollution, suspended solids and turbidity.

An Ultrafiltration system was incorporated to provide an additional treatment barrier and improve the consistency of the final water quality.

3. Pollution Control Compliance

The treatment system was designed to support compliance with the applicable Haryana State Pollution Control Board (HSPCB) and Central Pollution Control Board (CPCB) requirements.

Actual compliance depends on the site’s consent conditions and the applicable discharge or reuse standards.

4. Easy Operation and Maintenance

The plant needed to be practical for industrial use, with dependable equipment, an integrated treatment arrangement and manageable maintenance requirements.

5. Water Conservation and Sustainability

The project also aimed to create opportunities for treated wastewater reuse, helping reduce dependence on freshwater resources and supporting more sustainable manufacturing operations.

Challenges Identified Before Installation

Before finalising the treatment configuration, the engineering requirements associated with garment manufacturing wastewater were considered.

The major challenges included:

Variable wastewater characteristics: Different production activities can generate wastewater with varying organic loads, pH levels and flow rates. Without proper equalisation, these fluctuations can affect treatment performance.

Organic contamination: Washing and finishing processes contribute biodegradable and dissolved organic matter, increasing BOD and COD levels.

Suspended solids and textile fibres: Lint, fabric particles and other suspended materials can cause blockages and affect downstream treatment equipment.

Colour and chemical residues: Depending on the processes involved, textile wastewater may contain residual dyes, detergents and other chemical compounds.

Space utilisation: Industrial facilities often need to accommodate treatment equipment within an existing operational area. An efficient plant layout is therefore important.

Consistent treated water quality: Conventional biological treatment alone may not deliver the clarity required for certain reuse applications. Additional filtration is necessary to improve final water quality.

Wastewater Characteristics

Understanding the incoming wastewater is an important part of designing an effective ETP system.

Wastewater generated by textile and garment manufacturing facilities can contain:

• BOD (Biochemical Oxygen Demand): Represents biodegradable organic pollution.
• COD (Chemical Oxygen Demand): Indicates the overall concentration of chemically oxidisable substances.
• TSS (Total Suspended Solids): Includes fibres, lint and other suspended particles.
• TDS (Total Dissolved Solids): Represents dissolved salts and minerals.
• Colour: May result from residual dyes and processing chemicals.
• Detergents and surfactants: Commonly introduced during washing and cleaning operations.
• Oil and grease: May be present in certain industrial wastewater streams.
• Variable pH: Can fluctuate depending on the chemicals used during manufacturing.

Representative Raw Wastewater Parameters

The following values are indicative examples of textile and garment industry wastewater. They are not verified laboratory results from the Dimple Creations project.

Actual influent characteristics should always be established through laboratory wastewater analysis before finalising plant design and performance guarantees.

V Aqua Water’s Proposed Solution: 30 KLD ETP with UF System

After evaluating the treatment requirements and the nature of industrial wastewater, V Aqua Water proposed a customised 30 KLD Effluent Treatment Plant with an integrated Ultrafiltration System.

The treatment configuration combines conventional wastewater treatment processes with membrane-based polishing technology.

The ETP handles the primary treatment requirements, including the reduction of organic pollution and suspended solids. The subsequent filtration stages improve water clarity, while UF membranes provide an additional barrier against fine suspended particles, colloidal matter and microorganisms.

The system incorporates:

• Screening and raw effluent collection.
• Equalisation tank.
• Biological aeration treatment.
• Secondary clarification.
• Pressure Sand Filter (PSF).
• Activated Carbon Filter (ACF).
• Ultrafiltration (UF) System.
• Sludge collection and handling.

This arrangement provides a structured treatment process, with each stage performing a specific function to improve the quality of wastewater.

Plant Design and Major Components

The 30 KLD ETP plant was designed as an integrated treatment system. Each treatment unit contributes to the overall performance of the plant.

1. Screening and Raw Effluent Collection

The first stage involves collecting incoming industrial wastewater and removing larger suspended materials.

Screening helps remove:

• Fabric fibres.
• Lint and textile particles.
• Coarse suspended solids.
• Other unwanted materials.

The screened wastewater is then transferred to the raw effluent collection system.

2. Equalisation Tank

Industrial wastewater generation is rarely uniform throughout the day. The equalisation tank helps balance variations in flow and pollutant concentration.

It provides a more consistent feed to the downstream treatment stages.

Air mixing can be used to maintain uniform wastewater conditions, prevent solids from settling and minimise septic conditions. pH correction may also be carried out at this stage, depending on the wastewater characteristics.

3. Aeration Tank – Biological Treatment

The aeration tank is one of the most important components of the ETP.

It uses aerobic microorganisms to break down biodegradable organic matter present in wastewater.

Air is supplied through an aeration arrangement to maintain the dissolved oxygen required for biological activity.

This process helps reduce:

• Biochemical Oxygen Demand (BOD).
• A significant portion of biodegradable COD.
• Organic pollution in the wastewater.

Maintaining appropriate dissolved oxygen, biomass concentration and retention time is essential for stable biological treatment.

4. Secondary Clarifier

After biological treatment, wastewater enters the secondary clarifier.

The tank allows biological sludge to settle under gravity, separating it from the treated water.

The clarified water moves to the next treatment stage, while settled sludge can be returned to maintain the biological population. Excess sludge is transferred to the sludge handling system.

5. Pressure Sand Filter (PSF)

The Pressure Sand Filter removes residual suspended solids and reduces turbidity.

Water passes through graded filtration media, which captures fine particles that may remain after clarification.

This stage also helps protect downstream filtration equipment and UF membranes.

6. Activated Carbon Filter (ACF)

The Activated Carbon Filter provides additional polishing through adsorption.

Activated carbon can help reduce:

• Residual colour-causing organic compounds.
• Dissolved organic contaminants.
• Unwanted odour.
• Certain chemical residues.

Its performance depends on the wastewater composition, carbon quality and operating conditions.

7. Ultrafiltration (UF) System

Ultrafiltration is the advanced membrane treatment stage integrated into this project.

UF membranes contain very fine pores that act as a physical barrier against suspended particles, colloidal matter and many microorganisms.

The process helps produce treated water with:

• Low turbidity.
• Reduced suspended solids.
• Improved visual clarity.
• More consistent filtration quality.

Unlike Reverse Osmosis, Ultrafiltration does not significantly remove dissolved salts. Therefore, it is particularly useful when the primary requirement is removing fine particles and improving water clarity.

8. Sludge Handling System

The treatment process generates sludge containing settled suspended solids and biological biomass.

The sludge handling system collects and manages this material through appropriate thickening and dewatering arrangements.

Reducing sludge volume makes handling, transportation and disposal more manageable.

30 KLD ETP Treatment Process Flow

The complete treatment sequence is designed to progressively remove contaminants from industrial wastewater.

Treatment Process:

1. Raw Effluent Collection – Incoming wastewater is collected.
2. Screening – Large particles, lint and coarse solids are removed.
3. Equalisation – Flow and wastewater characteristics are balanced.
4. Biological Aeration – Microorganisms break down biodegradable organic matter.
5. Secondary Clarification – Biological sludge is separated from treated water.
6. Pressure Sand Filtration – Remaining suspended solids and turbidity are reduced.
7. Activated Carbon Filtration – Residual colour, odour and certain organic compounds are reduced.
8. Ultrafiltration – Fine suspended particles, colloids and microorganisms are removed through membrane filtration.
9. Treated Water Collection – The treated water is collected for suitable discharge or reuse applications.
10. Sludge Management – Separated sludge is collected and handled appropriately.

This multi-stage treatment arrangement helps improve wastewater quality while maintaining a practical operating process.

Project Execution: From Design to Commissioning

V Aqua Water handled the project through the major stages of engineering, manufacturing, installation and commissioning.

1. Engineering and Plant Design

The engineering team assessed the project requirements and developed the treatment configuration around the required 30 KLD capacity.

Equipment selection, tank sizing, process arrangement and plant layout were considered during the design stage.

2. Manufacturing and Fabrication

The treatment equipment, tanks and associated structural components were manufactured and prepared according to the approved engineering requirements.

Quality checks were incorporated to ensure proper equipment assembly and readiness for installation.

3. Installation at Udyog Vihar, Gurugram

The ETP system was installed at Dimple Creations’ facility in Udyog Vihar, Gurugram.

Mechanical equipment, interconnecting pipelines, electrical connections and associated treatment components were integrated into the complete system.

4. Testing and Inspection

After installation, the equipment and individual treatment stages were checked to verify their operating condition.

Functional testing helped confirm that the system was ready for integrated operation.

5. Commissioning and Handover

The plant was commissioned and prepared for operational use.

The commissioning process involved checking the treatment sequence, equipment operation and overall system functionality.

The project was successfully installed and commissioned, providing Dimple Creations with a dedicated industrial wastewater treatment facility.

Technologies Used in the 30 KLD ETP Plant

Results and Treatment Performance

The installed 30 KLD ETP with UF System combines biological treatment, conventional filtration and membrane polishing to improve industrial wastewater quality.

The following table presents indicative treatment performance values for a similar ETP configuration. These figures are illustrative and should not be presented as measured Dimple Creations project results without supporting laboratory and commissioning reports.

Indicative Raw and Treated Water Parameters

Important Note About TDS Reduction

Ultrafiltration removes suspended particles, colloidal matter and microorganisms. However, it does not remove dissolved salts to any significant extent.

This means TDS generally remains similar before and after UF treatment.

If a facility requires lower TDS levels or higher-quality recycled water, a Reverse Osmosis (RO) system can be considered as an additional treatment stage after UF.

Key Treatment Benefits

The ETP with UF configuration offers several important treatment advantages:

• Improved clarity of treated wastewater.
• Reduction in BOD and COD through biological treatment.
• Removal of suspended solids through clarification and filtration.
• Additional membrane-based polishing through UF.
• Better control over wastewater quality.
• Potential for treated water reuse in suitable non-potable applications.

Final discharge compliance and reuse suitability must be established through actual treated-water testing against the applicable regulatory and application-specific standards.

Benefits of the ETP Plant for Dimple Creations

The installation of the 30 KLD ETP with UF System provides several operational and environmental advantages.

1. Improved Wastewater Management

The plant provides a dedicated facility for treating wastewater generated during garment manufacturing activities.

2. Better Treated Water Quality

The combination of biological treatment, sand filtration, activated carbon and UF membrane technology improves the overall quality and clarity of treated water.

3. Support for Environmental Compliance

Appropriate wastewater treatment helps industrial facilities meet applicable pollution control requirements and minimise the environmental impact of their operations.

4. Water Recycling Opportunities

Treated water can potentially be reused in suitable applications, subject to the required water quality and process-specific conditions.

This can reduce freshwater consumption and improve overall water management.

5. Improved Operational Control

An integrated treatment arrangement helps streamline wastewater management and makes the treatment process easier to monitor.

6. Long-Term Sustainability

Industrial wastewater treatment supports responsible resource management and helps businesses move towards more sustainable manufacturing practices.

Project Video – 30 KLD ETP Plant with UF System

The project video provides a closer look at the 30 KLD ETP Plant with UF System installed at Dimple Creations, Udyog Vihar, Gurugram.

Watch the project video to see the installed ETP system and its major treatment components.

The video can help industrial facility owners, project consultants and decision-makers understand the practical installation of an ETP system designed for garment manufacturing wastewater.

It also offers an opportunity to explore the plant arrangement and the integration of different wastewater treatment technologies.

Why Choose V Aqua Water for Industrial ETP Plants?

V Aqua Water provides industrial wastewater treatment solutions designed around the specific requirements of different manufacturing sectors.

From conventional Effluent Treatment Plants to advanced membrane-based treatment and water recycling systems, the company focuses on delivering practical solutions for industrial wastewater management.

This project highlights several important aspects of V Aqua Water’s approach.

Industry-Specific Treatment Solutions

Different industries generate different types of wastewater. V Aqua Water considers wastewater characteristics, treatment capacity and operational requirements while developing suitable treatment configurations.

Complete Project Execution

The scope can include engineering, equipment manufacturing, installation, testing and commissioning, providing customers with an integrated project solution.

Advanced Filtration Technology

The integration of Pressure Sand Filters, Activated Carbon Filters and Ultrafiltration systems helps improve treated water quality beyond conventional treatment stages.

Customised Plant Design

Treatment capacity, equipment selection and plant configuration can be tailored to the available space, wastewater characteristics and project requirements.

Focus on Compliance and Water Recovery

V Aqua Water develops wastewater treatment solutions that help industrial facilities manage effluent responsibly while exploring opportunities for water recycling.

Industrial Wastewater Treatment Experience

The company provides solutions for different industrial applications, including textile, garment manufacturing and other sectors requiring customised ETP systems.

Conclusion

The successful installation and commissioning of the 30 KLD ETP Plant with UF System at Dimple Creations, Udyog Vihar, Gurugram, demonstrates the importance of combining effective biological treatment with advanced filtration technology.

Designed and executed by V Aqua Water, the project brings together equalisation, aeration, clarification, sand filtration, activated carbon filtration and Ultrafiltration in one integrated wastewater treatment arrangement.

The system provides a dedicated solution for managing industrial wastewater, improving treated water clarity and supporting responsible water management.

For garment manufacturers and other industrial facilities, an appropriately designed Effluent Treatment Plant is an important investment in environmental compliance, operational efficiency and long-term sustainability.

Looking for a Reliable ETP Plant Manufacturer in Gurugram?

If your manufacturing facility generates industrial wastewater and requires an efficient, customised treatment solution, V Aqua Water can help.

We provide industrial wastewater treatment solutions, including:

• Industrial Effluent Treatment Plants (ETP).
• Sewage Treatment Plants (STP).
• ETP Plants with Ultrafiltration Systems.
• Industrial Water Recycling Plants.
• Reverse Osmosis (RO) Systems.
• Wastewater Treatment and Reuse Solutions.

Whether you operate a textile manufacturing unit, garment factory, pharmaceutical facility, food processing plant or another industrial operation, our team can help you identify a suitable wastewater treatment configuration.

Contact V Aqua Water today to discuss your industrial wastewater treatment requirements and get a customised ETP plant solution.

V AQUA WATER TREATMENT COMPANY

• Website: https://www.vaqua.in/
• Call: 9560654995
• Email: sales@vaqua.in
• Location: Gurugram, Haryana, India

V Aqua Water – Reliable Industrial Wastewater Treatment and Recycling Solutions.