Leading dairy manufacturer scales up with space-smart ZLD wastewater expansion

By Staff Report May 9, 2025 6:40 pm IST

Facing the dual challenge of scaling up operations and meeting strict environmental norms, a leading private dairy manufacturer in Moga, Punjab, partnered with Veolia Water Technologies and Solutions India for a space-efficient Zero Liquid Discharge (ZLD) solution. This solution resulted in nearly 99% wastewater recycling within the facility.

One of the major challenges in scaling up a manufacturing facility is optimising limited available space, especially when sustainability and regulatory compliance are key concerns. A prominent private dairy manufacturer, currently expanding its operations at a flagship facility in Moga, Punjab, faced such a challenge during its recent growth phase.

To support the facility’s wastewater treatment and sustainability objectives, the company partnered with Veolia Water Technologies and Solutions India (VWTS India). VWTS India assessed the requirements and delivered a phased, space-efficient treatment infrastructure.

The facility, which produces a diverse portfolio of dairy, nutrition, and food products, needed to significantly boost its production capacity without expanding its physical footprint. It also had to enhance wastewater treatment capacity and introduce a crystalliser system to meet stringent environmental standards.

VWTS India had previously installed a Membrane Bioreactor (MBR) system and Reverse Osmosis (RO) plant at the site, with a capacity of 1800 m³/day and 50 m³/hr, respectively. These systems facilitated partial recycling of treated wastewater for non-potable uses such as horticulture, aligning with the client’s sustainability goals. As expansion progressed, an upgrade was essential to meet rising wastewater loads and implement a Zero Liquid Discharge (ZLD) solution.

Anticipating future growth, VWTS India had initially designed the systems to be scalable. A second phase, comprising an additional 1800 m³/day of MBR and 25 m³/hr of RO, was commissioned in 2023.

In 2024, the client entrusted VWTS India with a Phase III upgrade, valued at USD 5.0 million, to implement an additional 518 m³/day of recycling capacity and a 36 m³/day ZLD system. This expansion will result in nearly 99% of the wastewater being recycled within the facility.

“This is our largest order to date with this client and our first ZLD deployment with them globally,” said the VWTS India Projects Team. “By closing the loop on wastewater reuse, we’re helping our client take a major step toward sustainable water management.”

The Phase III expansion also features several advanced technologies to enhance efficiency and minimise the environmental impact:

• A Brackish Water RO (BWRO) system with 65% recovery
• A High Rate Solids Contact Clarifier (HRSCC) for removing silica and hardness
• ZW1500 ultrafiltration and a multi-stage Seawater RO (SWRO) setup, delivering 80% recovery and producing 36 m³/day of concentrated brine
  

 Veolia’s Mechanical Vapour Compression (MVR)- based crystallizer system better carries out the ZLD process. It is capable of handling feed TDS of 93,000 ppm. Unlike conventional multi-effect evaporators (MEE), the MVR system requires no external steam after start-up, significantly reducing carbon emissions and energy dependency.

MBR-based approach and advanced crystalliser technology helped VWTS India minimise steam requirements, optimise space, and take measurable strides toward achieving a net-zero discharge status for the manufacturer.

With this project, Veolia WTS India continues strengthening its position as a trusted sustainability partner for global manufacturers looking to expand responsibly and efficiently.