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M/s Kwality Polythreads Pvt. achieve major energy and cost savings in Haridwar

Summary of the success

M/s Kwality Polythreads Pvt. Ltd. is a producer of poly threads located within the Integrated Industrial Estate (IIE) of the State Infrastructure and Industrial Development Corporation of Uttarakhand Ltd. (SIIDCUL) in Haridwar. M/s Kwality Polythreads Pvt. Ltd. was able to further improve the performance of its Effluent Treatment Plant (ETP), reduce its consumption of water, decrease the input of chemicals and the production of sludge and simultaneously make cost savings.

Assigned by GIZ, the German consultancy adelphi visited 50 companies to undertake rapid assessments of their production facilities. The companies interested in increasing their resource efficiency and reducing the pollution caused by their production were selected for a more detailed assessment. With handholding support from adelphi and GIZ, M/s Kwality Polythreads Pvt. Ltd. was enabled to successfully implement multiple measures. Besides direct tangible environmental and economic benefits, the measures also created a better awareness, openness and eagerness to invest in new technologies and to apply better techniques for wastewater treatment.

About the problem

The Ganga provides livelihood to more than 500 million people. It is the main water source for many economic and agricultural activities. The river and its surroundings are habitat for many plant and animal species. Ganga is well known for its tremendous cultural and religious significance. Despite numerous rejuvenation efforts over the past 30 years, environmental pressure on Ganga has rather increased than decreased.

As stated on the homepage of SIIDCUL, IIE Haridwar is an industrial estate located in the catchment area of River Ganga spreading over an area of 2,034 acres. It comprises of 15 sectors of which 12 are occupied by more than 550 industrial units, mainly pharma, electrical and electronics, packaging, food production, metal processing, plastic and rubber moulding, and cosmetics. In total, there are 473 operational units in the estate generating industrial and domestic wastewater. The effluent streams are collected and are treated at the industrial estate’s Common Effluent Treatment Plant (CETP).

GIZ closely looked into removing difficulties faced by industries in meeting the inlet norms of the CETP by improving the operations of ETPs so that all the pollutant parameters such as COD, and the wastewater volume discharged is well within the permissible ceiling. In addition, resource efficiency is constantly looked at and if energy and water savings can be realised, this is being suggested and implemented for further cost and environmental benefits.

Actions initiated

To systematically improve the situation, IIE Haridwar was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” and “Support to Ganga Rejuvenation” (SGR) projects within the Indo-German Development Cooperation. In cooperation with SIIDCUL, a public agency owning the industrial estate, both projects are being implemented by the Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH to find solutions to improve the efficiency and efficacy of wastewater treatment plants and reduce pollution.

The SEIP Project is aiming at mitigating environmental problems caused by industrial production focusing on industrial wastewater and solid waste management. Since the project’s initiation in 2015, technical solutions as well as business and management models to reduce acute environmental pollution and to improve resource efficiency in industrial production are piloted in a total of five Indian industrial estates. Implemented since 2015, one of the aims of the SGR project in the state of Uttarakhand is to demonstrate that the pollution caused by municipal wastewater and industrial effluent can be reduced by efficient management of wastewater and functionality of treatment plants.

A German consultancy adelphi was hired to identify resource inefficiencies and cost-saving opportunities. Regulatory pressure, economic motivations as well as the wish to act more responsibly and sustainably were drivers for the companies to invite the consultants to undertake the assessments and to subsequently implement the solutions.

Whilst the detailed assessments are still ongoing, some suggestions on improvements were already given by the experts during initial site visits that were successfully implemented. Further measures were recommended and are documented in this success story as major cost savings have been realised while sustainability factors were improved as well.

ETP improvement

M/s Kwality Polythreads Pvt. Ltd. is operating on an 8,000m² industrial plot in IIE Haridwar and employs 150 people. The annual turnover of M/s Kwality Polythreads Pvt. Ltd. ranges between 60 and 70 crore INR.

Before the initial interventions, the wastewater generated by M/s Kwality Polythreads Pvt. Ltd. occasionally surpassed the ceiling value of the CETP inlet. The implemented measures led to the reduction of sludge by half and realisation of water savings of about 20 per cent. Also, these improvements were achieved with zero cost investment.

As two measures concerning resource efficiency have been suggested by the consultancies from adelphi the following benefits can be presented: