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Daniel Fashion Processors in Vapi succeed in improving their ETP operations

Figure 1: Dosing of FeSo4 at Daniel Fashion Processors

Summary of the success

Daniel Fashion Processors is a small-scale company in the Gujarat Industrial Development Corporation’s (GIDC) Industrial Estate in Vapi employing approx 55 workers in the textile processing sector. Since its establishment in 1974, Daniel Fashion Processors has been concerned about their environmental performance. The company was facing problems with pigmentation in wastewater even after treatment through the ETP – a situation which the company’s management and the employees running the ETP were eager to improve.

The German consultancy, GOPA Infra visited Daniel Fashion Processors several times in the course of 2017, to assess and audit the company’s ETP operations, and in order to subsequently develop and suggest improvement measures. With support, encouragement & handholding from GOPA Infra and GIZ, Daniel Fashion Processors learned how to fine tune the coagulation and flocculation processes of the ETP by properly dosing the application of Lime and Ferrous Sulphate (FeSO4), and by adding polyelectrolyte to the process. The intervention led to a significant improvement of the quality of wastewater and even resulted in cost savings for the company.

About the problem

There are more than 1,500 industries from various sectors, such as chemical, paper, dye, drug and pharmaceutical, pesticide, fertilizer, electroplating, etc., located in GIDC Vapi industrial estate. Most of these companies are members of the CETP Society of Vapi having a capacity of 55 MLD. Due to the large volume and diversity of wastewater, the treatment of the effluent at the CETP, however, is very challenging. Hence, pre-treated and more homogenous wastewater streams from discharging companies would reduce inlet pollution values at the CETP and lead to its improved operation.

The CETP is experiencing difficulties in treating effluent parameters, such as Colour, COD, BOD, TDS, TSS, Ammonical Nitrogen, Phenol, etc. and is considered to be on the borderline of pollution board compliance. The CETP treated effluent is directly discharged into the Daman Ganga River.

Daniel Fashion Processors came forward with the wish to improve the outlet quality of its ETP’s wastewater. In particular, they faced operational problems during primary treatment of the ETP leading to high levels of colour and pigmentation.

Actions initiated

To systematically improve the situation, the Industrial Estate Vapi of the Gujarat Industrial Development Corporation (GIDC) was included as a project site under the “Sustainable and Environment-friendly Industrial Production (SEIP)” project under Indo-German technical cooperation. Jointly with GIDC, Deutsche Gesellschaft für Internationale Zusammenarbeit (GIZ) GmbH has been implementing the SEIP Project in Vapi since 2016.

Under SEIP, a German consultancy was hired to assess the operations of 10 ETPs installed at various companies. In February, May and July 2017, national and international experts visited the selected companies to collect data and samples in order to do preliminary assessments. Subsequently, a detailed assessment of improvements was undertaken and improvement measures were detailed out.

Efficiency improvement

After evaluating the issues of the ETP, the team of international consultants suggested to adjust the dosing of Lime and Ferrous Sulphate (FeSO4)  to acceptable levels which would improve the coagulation and flocculation process in the ETP. Further, the experts suggested changing the location from the screen chamber to the dosing tank to add the chemicals. To enhance the settling of colour particles, it was further advised to add polyelectrolyte. The expert team also noticed a lack of agitation in the wastewater. Hence, an airline form a nearby compressor was installed to improve agitation.

Figure 3 Improper dosing location at the screen chamber

Figure 4: Change of dosing location approved by management

Figure 5: Addition of Lime

Figure 6: Airline mixing arrangement 

Problems identified




Problems in the coagulation and flocculation process in the primary treatment section of the ETP

- Adjust dosing of Lime     and Ferrous Sulphate (FeSO4)

No cost

Improvement of Colour by 38.14%.

Improper settling of colour particles

- Addition of     polyelectrolyte

INR 3,590

Savings of 3,650 kg of Lime which translating into cost savings of INR 36,500/year

Improper mixing of wastewater due to lack in agitation

- An airline from a nearby compressor now provides better agitation

INR 2,500

Savings of 1,000 kg of FeSo4/year translating in to savings of INR 11,000/year

Total costs:

INR 6,090

Total savings: 

INR 53,500/year

Payback time:

~1 ½ months

Environmental benefits

Economic benefits

Reduction of Colour by 38%

Reduction of Sludge by 18%

INR 36,500/year saving through reduction of Lime

INR 11,000/year saving through reduction of FeSO4

INR 6,000 savings through decreased sludge handling and disposal cost

Figure 7: Colour reduction after treatment prior to intervention

Figure 8: Colour reduction of the discharge after the intervention

The success – The benefits!!!

What is most striking about this intervention are the annual savings of INR 53,500 achieved with very little investment. Equally important is the fact that implemented suggestions has enhanced the quality of wastewater discharged after ETP treatment significantly thereby contributing to the reduction of environmental pollution.

Before the intervention, there was a general lack of knowledge and awareness regarding saving potentials through more efficient wastewater treatment processes. Knowledge and techniques to properly dose chemicals for wastewater treatment were not available to the company. The fact that improved wastewater management is not merely a good deed for the environment, but also leads to cost savings is being vividly demonstrated by this case example. Cost savings are often a trigger for companies to change their perception regarding environmentally-friendly production, paving the way for further, more large-scale, interventions.

In the case of Daniel Fashion Processors, the company invested INR 40,000 into a treatability study of their wastewater exploring the suitability of adding a secondary treatment processor their ETP. This step was also recommended by the consultant. The positive results of the study have motivated the management of Daniel Fashion Processors to also act on this recommendation.

Figure 9: Laboratory study of the impact of secondary treatment

Figure 10: Results after treatment in the laboratory

Mr. Oommen Varghese, Manager, Daniel Fashion Processors

“GIZ approached us as suggested by GPCB. We are very glad with the interaction and improvements seen in our ETP. Lab scale tests have shown remarkable results which we would like to implement and we have already implemented 1st portion and achieved nearly 40 % reduction in colour. Way to go for sustainable development. Thank you, GIZ, for everything.”



Mr. Awasthi, ETP Manager, Daniel Fashion Processors

“Effluent improvement with savings was untouched in our plant. GIZ came to us and guided us to achieve improvements that even led to savings. We have achieved 18% reduction in sludge which results in great saving and a much-needed improvement regarding our solid waste management concerns. We are thankful to GIZ for their suggestion of dosing point change, polyelectrolyte addition and temporary air arrangement and also his constant care for our ETP. GIZ also suggested more techno-economically viable practical solutions which we would like to incorporate in our treatment in the future.”



Mr. Sushil, ETP Operator, Daniel Fashion Processors

“Operating an improved process increases confidence in operations. GIZ suggested changes in the dosing location from screen chamber to dosing tank which improved the process greatly. I am very happy with the improved results which have motivated me to also operate more efficiently.”