Textile manufacturing is one of the most water-intensive industrial sectors, with fiber processing, dyeing, and finishing operations generating large volumes of wastewater containing high Total Dissolved Solids (TDS). For Garg Acrylics Limited, a leading textile manufacturer in Ludhiana, managing this complex effluent stream became a critical operational challenge, as well as an environmental responsibility. Increasingly stringent discharge norms, rising pressure on freshwater resources, and the need to reduce environmental impact made conventional wastewater management practices insufficient and cost heavy.
In response, they adopted Zero Liquid Discharge (ZLD) as a core element of its sustainability strategy, with objectives extending beyond regulatory compliance to include reduced freshwater dependence, improved resource efficiency, and long-term operational resilience. To achieve this, the company implemented a next-generation ZLD system engineered by Spray Engineering Devices Limited (SED), featuring MVR-based low-temperature evaporation technology. This advanced solution enables efficient, cost effective, reliable, and energy-conscious wastewater treatment, demonstrating how progressive textile manufacturers can align regulatory compliance with sustainable and circular production practices.
Engineering Reliability, Efficiency & Sustainability
Traditional ZLD systems, especially steam-dependent conventional technologies, often struggle with high operating costs, scaling issues, and inconsistent water recovery. Garg Acrylics partnered with SED with a clear goal: deliver dependable ZLD performance with reduced energy consumption, lower operating cost, and maximum water recovery.
At the core of the system is SED’s Mechanical Vapor Recompression (MVR) based low-temperature evaporator – a breakthrough technology designed for efficiency and sustainability.
What sets SED’s ZLD solution apart:
- Reduced Steam Consumption & Operation Cost
The boiler-free system reduces steam demand to a negligible level, significantly lowering operating costs while simplifying plant design, capital investment, and auxiliary utility requirements. - Fully Automatic & Electric-Driven
A fully automatic, VFD-driven and electric system ensures smooth, precise, and energy-efficient operation. With centralized DCS control, the entire plant is continuously monitored and managed, delivering safe, reliable, and uninterrupted performance with minimal manual intervention. - 100% Clean Water Recovery
High-purity condensate is recovered and reused within plant operations, cutting freshwater intake and enhancing circularity. - Near-Zero Carbon Emissions
This boiler-free system functions with near zero carbon emissions, fully supporting today’s sustainability objectives.
A Model for Responsible Textile Production
The system has earned appreciation from regulatory stakeholders, including the Punjab Pollution Control Board (PPCB) Chairman, who recognized the installation as a benchmark for sustainable industrial practice.
Engineering a Cleaner Future
Today, sustainability and ZLD are necessities, not trends. SED enables industries to adopt these practices without the burden of high operating costs or complex steam-driven systems. Through innovation and commitment to environmental responsibility, SED is helping industries move toward cleaner and more resilient tomorrow.
Inlet Parameters
| Sr. No. | Particulars’ | UOM | Operating Range |
| Feed Flow | M3/hr. | 2.5 | |
| TDS | PPM | 30,000 – 50,000 | |
| TSS | PPM | 4100 | |
| pH | – | 7-8 | |
| Calcium Hardness | PPM | 830 | |
| Total Hardness | PPM | 1200 |
Outlet Parameters
| Sr. No. | Particulars’ | UOM | Operating Range |
| Condensate Recovery | % | ~ 90 | |
| Condensate TDS | PPM | < 25 | |
| pH | – | 8-9 |
Utility Requirement
| Power | kW/day | 1160 |
| Steam | Kg/day | ~ 250 |
Client’s Words
( Mr. Ujjwal Garg – Director – Garg Acrylics) said “Due to recent Pollution Control Board guidelines on zero discharge, we opted for a ZLD plant. Compared to conventional evaporators, MVR technology is most suitable for high-TDS streams and offers low operating costs, making it a necessary step toward sustainability. The Punjab Pollution Control Board authorities visited our plant to review the technology in use and appreciated the system. This is a proven technology for high-TDS wastewater, which has been in operation at our site for more than six months, and we are satisfied with both its performance and SED’s support.”