FG Glass's manufacturing processes edging and arising rely heavily on water for equipment cooling and glass fine removal. While the existing effluent treatment plant (ETP) maintained regulatory compliance, treated water was being discharged rather than recovered for reuse.

Challenge

A comprehensive analysis of the facility's water lifecycle revealed opportunities to reduce consumption and operational costs through advanced water reclamation technology.

Approach

A systematic evaluation of filtration technologies was conducted, assessing each option against critical parameters:

• Maintenance requirements and operational complexity
• Facility footprint and space utilization
• System reliability and uptime performance
• Treated water quality and reuse potential

The recommended solution—a high-performance filtration system—was selected for its ability to consistently produce water quality suitable for both production reintegration and secondary applications including landscape irrigation.

Results

• 8% reduction in monthly water consumption
• 13% decrease in water-related operational costs
• Sub-four-year return on investment
• Technology successfully scaled to new facility based on proven performance

The project established a replicable framework for sustainable water management, subsequently adopted as the standard for the organization's expansion projects.

Project executed by: Rohit Chavan, Taher Kachwala and Rahul Rathod