Successfully Installed 60 KLD Effluent Treatment Plant for Textile Industry at Vamani Overseas, Faridabad
Industrial garment and textile operations generate wastewater that requires controlled collection and treatment before the water can be discharged or considered for reuse. For a manufacturing facility, an effluent treatment system needs to match the expected wastewater load while maintaining a treatment process that operators can manage on a regular basis. This requirement formed the basis of the 60 KLD MBR Effluent Treatment Plant project completed at Vamani Overseas in Faridabad, Haryana.
Vamani Overseas operates in the garment and apparel manufacturing sector and has its facility in Sector 24, Faridabad. The company has manufacturing capabilities covering apparel production and garment washing. Its operating activities create a need for systematic wastewater management at the facility.
The project involved the engineering and installation of a 60 KLD Effluent Treatment Plant based on Membrane Bioreactor technology. Netsol Water handled the process design, engineering, supply, installation and commissioning of the treatment system. The selected MBR configuration combines biological treatment with membrane filtration. This arrangement allows the plant to retain biomass inside the biological system while producing treated water through membrane separation.
As a leading effluent treatment plant manufacturer in Faridabad, Netsol Water developed the project around the client’s identified treatment requirement and installed the system at the operating facility.
Project Snapshot
| Parameter | Details |
| Client | Vamani Overseas Pvt. Ltd. |
| Location | Sector 24, Faridabad, Haryana |
| Plant Capacity | 60 KLD |
| Technology | Membrane Bioreactor (MBR) |
| Industry Served | Textile & Garment / Apparel Manufacturing |
| Scope of Work | Process design, engineering, equipment supply, installation, testing and commissioning |
| Executed By | Netsol Water |
Project Overview
A properly planned industrial wastewater treatment project begins with a clear understanding of the wastewater source, expected flow and operational conditions. The 60 KLD installation at Vamani Overseas was developed to provide a dedicated treatment system for the wastewater generated by the client’s garment and apparel manufacturing operations. The project records identify the installation as a 60 KLD MBR ETP Plant designed for industrial wastewater treatment.
The client’s main requirement was to establish a treatment plant capable of handling the identified daily wastewater load. The design also needed to address practical requirements associated with an operating industrial facility. The project identifies three important considerations behind the selected configuration: biological treatment of biodegradable organic matter, consistent treated-water quality through membrane filtration and a relatively compact treatment footprint.
The scope covered more than simply supplying treatment equipment. Netsol Water was responsible for process design and engineering followed by equipment supply, installation and commissioning. The project therefore covered the major stages required to move from an identified wastewater treatment requirement to an operating treatment system.
The selection of Membrane Bioreactor technology gave the project a treatment arrangement in which biological treatment and membrane separation work together. This is particularly useful where a facility requires consistent solids separation and wants to make effective use of the available treatment area. With the basic project requirement established, the next aspect to consider is the client and the industrial setting in which the plant operates.
Client Details
Vamani Overseas Pvt. Ltd. is a garment and apparel manufacturing company based in the National Capital Region. It was established in 2008 and specializes in soft woven products for women, men and children. The company is an Indian manufacturer serving apparel markets and reports manufacturing and supply operations supported by multiple production facilities.
The company’s published capabilities also include garment washing along with apparel manufacturing and embroidery. It has manufacturing capacity of more than 1.4 million pieces and a garment washing capacity of 1.2 million pieces per month.
For an apparel manufacturing facility, wastewater management forms an important part of daily plant operations. The company’s sustainability reporting also states that it monitors wastewater parameters including pH, hardness, TDS and other ZDHC parameters through third-party laboratory testing. Its published sustainability information further states that wastewater treated through its ETP is considered for reuse, recycling in applications such as washing or irrigation, or discharge subject to the relevant requirements.
The 60 KLD ETP project fits into this wider requirement for systematic wastewater management. Instead of allowing treatment to remain a general operational concern, the project provides a defined treatment capacity and a dedicated MBR-based process. This gives the facility a structured system for handling the wastewater stream associated with the project.
Client Profile at a Glance
| Attribute | Details |
| Company | Vamani Overseas Pvt. Ltd. |
| Sector | Garment & Apparel Manufacturing |
| Established | 2008 |
| Specialization | Soft woven products for women, men and children |
| Manufacturing Capacity | 1.4+ million pieces per month |
| Garment Washing Capacity | 1.2 million pieces per month |
| Facility Location | Sector 24, Faridabad |
| Monitored Parameters | pH, hardness, TDS and other ZDHC parameters |
Project Location
Project location plays an important role in industrial water treatment because the treatment plant must operate within the physical and operational conditions of the facility. Space availability, wastewater collection points, access for equipment installation and connection with existing services all influence how a treatment plant can be integrated into an industrial site.
The 60 KLD plant was installed at Vamani Overseas in Faridabad, Haryana. The company’s official contact information places its Faridabad facility in Sector 24. The industrial setting made it necessary to consider the treatment system as part of an active manufacturing facility rather than as an isolated installation. The project therefore required a suitable process configuration along with practical installation and connection work. The MBR arrangement also offered a treatment configuration that could provide membrane-based solids separation without depending on a conventional secondary clarifier.
Plant Capacity
Plant capacity determines the quantity of wastewater that the treatment system is designed to handle within a daily operating cycle. Selecting the correct capacity helps the treatment process remain aligned with the expected wastewater flow. A capacity that does not correspond to the intended requirement can create operational pressure or leave treatment infrastructure underused.
For the Vamani Overseas project, the confirmed installed capacity was 60 KLD, meaning 60 kilolitres per day. The capacity provides a defined treatment basis for the wastewater stream covered by the project. It also allows the biological and membrane stages to be designed around a specific hydraulic load. Equipment such as pumps, blowers, biological tanks and membrane systems must work together around this design capacity so that water moves through the treatment sequence at the required rate.
The 60 KLD figure should be understood as the plant’s design capacity. Industrial wastewater generation can vary with production schedules and operating activities. This makes process buffering and controlled flow management important parts of an ETP arrangement.
Treatment Technology
Technology selection determines how wastewater moves from the incoming effluent condition toward the required treated-water quality. Different industrial applications require different combinations of biological, physical and chemical treatment. In this project, the documented treatment technology was Membrane Bioreactor (MBR) technology.
The MBR system combines biological treatment with membrane filtration. A conventional biological treatment system generally uses a secondary clarifier to separate treated water from biological solids. An MBR system performs this separation with membrane modules. The membrane retains suspended solids and biomass while allowing treated water to pass through as permeate.
1. Biological Treatment
The biological stage forms the core treatment function for biodegradable organic matter. Microorganisms use the biodegradable material present in the wastewater as part of their biological activity. The treatment environment needs appropriate operating conditions so that the microbial population can process the organic load entering the reactor.
The MBR approach allows the biological biomass to remain inside the treatment system while the membrane performs the separation. This distinction allows the biological process and solids separation process to operate together without depending on the settling characteristics required by a conventional clarifier.
2. Membrane Filtration
The membrane stage provides a physical separation barrier. Water passes through the membrane while suspended solids and biological biomass remain within the biological system. This produces treated permeate with low suspended solids and low turbidity under suitable operating conditions.
The project source identifies the MBR system as an important part of achieving consistent treated-water quality. It also notes that the system can provide a more compact footprint than a conventional clarifier-based treatment arrangement of similar capacity.
3. Air Supply and Membrane Operation
The membrane system requires controlled air supply around the membrane surface. Fine-bubble air helps support the biological process and provides membrane scouring that limits the accumulation of material on the membrane surface. This makes the blower system an important part of MBR operation.
Together, biological treatment and membrane filtration provide the main treatment basis for the installed plant. The process can then deliver treated water to the collection stage for further handling according to the intended application.
Influent Characteristics
Understanding influent quality helps an engineering team establish the treatment conditions required for an industrial wastewater system. Flow alone does not define the treatment requirement. Parameters such as organic load, suspended solids, pH, dissolved substances and other contaminants can influence process selection and operating conditions.
For textile and garment-related wastewater, engineers normally review parameters relevant to the actual wastewater source before finalizing the treatment arrangement. Depending on the operations involved, these may include pH, BOD, COD, TSS, colour, oil and grease, hardness, TDS and other parameters that the client or regulatory framework may require.
This distinction is important because actual wastewater characteristics can vary according to production activity and operating conditions. The wastewater profile identified during site assessment and laboratory testing normally provides the basis for process design. Vamani’s sustainability reporting confirms that the company monitors wastewater parameters including pH, hardness and TDS through third-party laboratory testing.
Treatment Process
An industrial ETP works effectively when every treatment stage prepares the wastewater for the stage that follows. The process starts with controlled wastewater collection and continues through physical preparation, biological treatment, membrane filtration and treated-water collection. Each stage addresses a different part of the wastewater treatment requirement.
1. Effluent Collection
Wastewater from the facility first enters the collection arrangement. This stage brings the wastewater generated by the relevant operations together so that it can move toward the treatment plant in a controlled manner. Controlled collection also helps prevent untreated wastewater from entering downstream systems without passing through the intended treatment sequence.
2. Preliminary Treatment
The incoming wastewater undergoes preliminary treatment before it reaches the biological and membrane stages. Screening can remove coarse solids and textile-related fibres that could otherwise affect pumps and membrane equipment. This initial separation protects downstream components and prepares the wastewater for further treatment.
Preliminary treatment has an important role in an MBR system because membrane modules require suitable feed conditions. Large fibres and coarse materials must not enter the membrane section without appropriate removal.
3. Equalization
Wastewater flow and characteristics can change during daily manufacturing activities. Equalization provides a buffer between wastewater collection and biological treatment. The wastewater remains in the equalization stage so that the downstream biological process receives a more controlled flow.
This step also reduces the effect of sudden changes in hydraulic or organic loading. A controlled feed helps maintain more stable treatment conditions and allows the biological system to respond to the wastewater in a planned manner.
4. Biological Treatment
After equalization, the wastewater enters biological treatment. Microorganisms present in the reactor break down biodegradable organic matter under controlled conditions. The biological stage forms the main treatment mechanism for reducing the biodegradable component of the wastewater.
The MBR configuration allows the system to maintain biological solids within the reactor. This provides the basis for the membrane separation stage that follows.
5. MBR Membrane Separation
The biologically treated mixed liquor moves into the MBR membrane section. Submerged membrane modules separate treated water from the retained biomass. The membrane allows permeate to pass while retaining suspended solids and microorganisms within the treatment system.
Air supplied around the membrane modules supports biological activity and helps reduce fouling on the membrane surface. The resulting permeate then moves toward the treated-water collection stage.
6. Treated Water Collection
The filtered water is collected in a treated-water tank. The final use or discharge route depends on the facility’s requirements and applicable conditions. Vamani’s ETP wastewater can be used for reuse or recycling in applications such as washing or irrigation or may be discharged subject to applicable requirements.
7. Sludge Management
Biological treatment produces excess biomass. Operators need to remove this excess sludge from time to time so that the biological process remains within its intended operating conditions. Sludge handling therefore forms part of routine ETP management even though the primary treatment objective remains the production of treated water.
The completed treatment sequence creates a controlled path from raw industrial wastewater to treated water. It also ensures that the membrane system receives wastewater that has already passed through the stages designed to protect its operation.
Treatment Process at a Glance
| Stage | Function |
| Effluent Collection | Brings facility wastewater together in a controlled manner before treatment |
| Preliminary Treatment | Screens coarse solids and fibres to protect pumps and membranes |
| Equalization | Buffers flow and load variations before biological treatment |
| Biological Treatment | Microorganisms break down biodegradable organic matter |
| MBR Membrane Separation | Membrane modules separate treated permeate from biomass |
| Treated Water Collection | Filtered water collected for reuse, recycling or discharge |
| Sludge Management | Excess biomass removed to maintain biological process conditions |
Major Equipment
Equipment selection has a direct influence on how a treatment plant operates. Every pump, tank, blower, membrane module and control component performs a particular function in the process sequence. For an MBR ETP, the equipment must also work together because biological treatment and membrane filtration form an integrated system.
1. Equalization System
The equalization arrangement provides temporary storage and flow balancing before biological treatment. It helps manage variations in wastewater generation and reduces sudden changes in the hydraulic load sent toward the treatment process.
2. Biological Reactor
The biological reactor provides the environment in which microorganisms treat biodegradable organic matter. Its operation depends on controlled wastewater flow and suitable aeration conditions. The biological reactor works directly with the membrane section because the treated biomass remains within the MBR process rather than being separated through a conventional secondary clarifier.
3. MBR Membrane Modules
The membrane modules form the central filtration component of the system. They separate treated water from the biological mixed liquor. Their physical barrier retains suspended solids and biomass while treated permeate passes through.
4. Air Blowers and Diffusers
Air blowers provide the required air supply to the biological process and membrane zone. Fine-bubble diffusers distribute air into the system. The air supply also supports membrane surface scouring as part of routine membrane operation.
5. Pumps
Pumps move wastewater, treated water and other process streams between different stages of the treatment plant. Proper pump selection supports controlled movement through the process sequence and helps maintain the intended plant flow.
6. Treated Water Tank
The treated-water tank receives permeate produced by the membrane system. It provides a controlled collection point before the water moves toward its intended reuse, recycling or discharge route.
7. Control and Monitoring System
An ETP also requires operational controls that allow operators to monitor the treatment process and manage equipment according to operating requirements. The control arrangement provides a central point for running pumps, blowers and related equipment while supporting routine plant operation.
The equipment therefore works as an integrated treatment system rather than as separate components. This relationship becomes especially important during installation and commissioning.
Major Equipment Summary
| Equipment | Function |
| Equalization System | Temporary storage and flow balancing before biological treatment |
| Biological Reactor | Environment for microorganisms to treat organic matter |
| MBR Membrane Modules | Separate treated water from biological mixed liquor |
| Air Blowers & Diffusers | Supply air for biological activity and membrane scouring |
| Pumps | Move wastewater and treated water between treatment stages |
| Treated Water Tank | Collects permeate before reuse, recycling or discharge |
| Control & Monitoring System | Central point for operating and monitoring the plant |
Installation Process
Installation requires careful planning because an ETP must fit into the available site while connecting correctly with wastewater collection, power, piping and other services. A planned installation also reduces the risk of connection errors and helps the commissioning team begin testing without unnecessary delays.
The project began with site assessment and planning at the Vamani Overseas facility in Faridabad. The installation team considered the available space and the practical requirements associated with connecting the new plant with the site’s wastewater collection system.
After the site requirements were established, Netsol Water developed the 60 KLD MBR process configuration. The design brought together equalization, biological treatment, membrane filtration, air supply and treated-water collection in a coordinated treatment sequence.
The next stage involved equipment engineering and supply. The major process components were prepared for installation according to the defined 60 KLD treatment requirement. Equipment delivery then supported the physical installation at the operating facility.
Mechanical installation connected the treatment units with the required piping and process lines. Pumps and associated equipment were positioned so that wastewater could move from one treatment stage to the next. The electrical installation connected the operating equipment with the plant controls and power supply.
Special attention was required around the membrane system because the MBR process depends on correct hydraulic and air connections. The blower system also needed connection with the membrane and biological stages so that the required aeration and membrane scouring could take place.
Once the mechanical, piping and electrical work was completed, the system moved toward testing and commissioning. This created a controlled transition from physical installation to active wastewater treatment.
Plant Commissioning
Commissioning verifies that a treatment plant is ready for regular operation. Commissioning brings the separate components together and provides an opportunity to check the complete process sequence.
After installation, the Netsol Water team carried out testing and commissioning of the 60 KLD MBR ETP Plant. The documented project information states that commissioning included establishing the biological process, bringing the membrane system into operation and verifying the treatment sequence before handover.
The commissioning stage required the team to check equipment operation and ensure that water could move through the process as designed. Pumps needed to operate at the required stages. The blowers had to provide air to the biological and membrane sections. The membrane system needed to produce permeate while retaining the biological solids.
The team also checked the interaction between the different process units. A treatment plant can only perform as intended when individual components work together. For this reason, commissioning covered more than equipment startup.
Operator guidance formed another part of the project handover. The client operating personnel received guidance on routine monitoring and basic upkeep required for the MBR system.
Once these checks were completed, the plant could enter regular operation under the client’s operating procedures. The commissioning stage therefore marked the completion of the installation process and the transition to day-to-day treatment.
Treated Water Reuse
Treated water has greater practical value when a facility can manage it effectively after treatment. Reuse can reduce the need for fresh water in suitable applications while recycling can support better management of the site’s overall water use. The exact reuse application should always depend on treated-water quality and the requirements of the intended use.
The MBR process produces treated permeate with low suspended solids and low turbidity because the membrane physically retains biological solids. This quality makes MBR–treated water suitable for further polishing or disinfection when required for a reuse application.
Vamani Overseas‘ sustainability reporting states that treated wastewater from its ETP can be reused or recycled for activities such as washing or irrigation or managed for discharge as applicable. The report also states that the company monitors wastewater parameters through third-party laboratory testing.
This creates an important connection between treatment performance and water management. The purpose of the ETP is not limited to treating wastewater. Properly managed treated water can also become part of a more organized approach to industrial water use.
Results and Performance
Project results provide a practical indication of whether the installed system has achieved its intended purpose. For an industrial ETP, performance should be evaluated through treatment capacity, equipment operation, treated-water quality and the ability of the system to operate within the client’s daily requirements.
The completed project provided Vamani Overseas with a 60 KLD MBR-based wastewater treatment system for its Faridabad facility. The documented installation involved process design, engineering, equipment supply, installation, testing and commissioning by Netsol Water.
The MBR configuration provides physical membrane separation in addition to biological treatment. This allows the system to retain biomass inside the biological process and produce treated permeate with low suspended solids. The project documentation also identifies the compact treatment footprint as an important characteristic of the selected configuration.
The project record identifies typical treated-water assessment parameters associated with the system, including pH, BOD, COD, TSS and oil and grease. The published project material gives reference values of pH 5.5–9.0, BOD 30 mg/L, COD 250 mg/L, TSS 100 mg/L and oil and grease 10 mg/L.
Another documented result is the completion of the system through commissioning and operator guidance. The plant moved beyond equipment installation into an operational treatment arrangement that the client could manage as part of its facility activities.
The project therefore addressed the confirmed requirement for a dedicated 60 KLD industrial wastewater treatment system while introducing MBR technology for biological treatment and membrane-based separation. It also created a treated-water stream that can support reuse or discharge management according to the client’s operating and regulatory requirements.
Treated Water Quality Parameters (Reference Values)
| Parameter | Reference Value |
| pH | 5.5 – 9.0 |
| BOD | 30 mg/L |
| COD | 250 mg/L |
| TSS | 100 mg/L |
| Oil & Grease | 10 mg/L |
Customer Feedback/Testimonial
Having a dedicated 60 KLD MBR ETP gives our Faridabad facility a defined system for managing the wastewater covered by the project. The installation combines biological treatment with membrane filtration and provides a clear treatment sequence from effluent collection to treated-water production. The completion of installation and commissioning has also given our operating team a structured system that can be monitored and maintained as part of our regular facility activities.
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Conclusion
The successful installation of the 60 KLD MBR ETP at Vamani Overseas demonstrates how an industrial wastewater treatment project can be planned around a defined treatment capacity and a specific process requirement. The project combined biological treatment with membrane filtration to provide a controlled wastewater treatment arrangement for the Faridabad facility. Netsol Water managed the project from process design and engineering through equipment supply, installation, testing and commissioning.
The selected MBR technology provides a clear treatment pathway while retaining biological solids within the process and separating treated water through membrane filtration. The system also supports the production of treated water that can be considered for reuse or recycling where the required quality and application conditions are met. Vamani Overseas‘ own sustainability reporting reflects the company’s ongoing approach to monitoring wastewater quality and managing treated wastewater through reuse, recycling or discharge.
For industrial facilities in Faridabad and other manufacturing locations, wastewater treatment requirements can differ according to production activities, wastewater characteristics, daily flow and available plant space. A suitable system therefore begins with proper wastewater assessment and process planning rather than selecting equipment based only on plant capacity.
Netsol Water brings process engineering, manufacturing, installation and commissioning experience to industrial wastewater projects. As an effluent treatment plant manufacturer in Faridabad, Netsol Water can help industries assess their wastewater treatment requirements and identify a suitable ETP configuration based on the actual application.
For information about industrial ETP solutions or to discuss a similar wastewater treatment requirement, contact Netsol Water for a project-specific consultation and treatment solution.
Contact Netsol Water
| Contact Mode | Details |
| Phone | +91-9650608473 |
| enquiry@netsolwater.com |
