THE STORY OF

SALT & WATER

IN MAKING
A T-SHIRT
 T-SHIRT MAKING PROCESS

PRODUCT PROCESS

CULTIVATION &
COTTON
GINNING

YARN SPINNING

GREY FABRIC KNITTING

USE OF
DYED & FINISHED DYEING &
SALT &
FABRIC FINISHING WATER

CUTTING , STITCHING
T-SHIRT
& FINISHING
 INPUT OUTPUT OVERVIEW FOR
DYEING
CHEMICAL INPUTS WATER ENERGY OTHERS ITEMS
ü Dyestuffs ü Electricity ü Packing
ü Boiler Fuel ü Lub oil-grease
ü SALT ü Genset Fuel ü Accessories
ü Basic Chemicals
ü Auxiliaries

RAW MATERIALS
DYEING & FINISHING PRODUCTS
ü Grey Fabric ü Dyed &
Finished
Fabric

WASTE WATER GAS EMISSIONS SOLIDWASTE WASTE HEAT

üConcentrated Waste Water ü Boiler ü Packing ü Boiler

with Salt ü Genset ü Containers ü Genset
ü Raw Materials ü Dryers
üWash Water
ü Sludge ü Effluent
ü Ash
 THE SCENARIO OF
SALT & WATER USAGE
n The Whole of Europe is discharging about
200 Million Kilogram of Salt every year in
Textile Dyeing
n The Whole of Tirupur is discharging about
80 Million Kilograms of Salt every year in
Textile Dyeing
 SALT & WATER USED IN MAKING
ONE T-SHIRT

T-Shirt Salt Used Water Used

To make To make
One T-Shirt One T-Shirt
White Nil 15 litres
T-Shirt
Coloured 200 grams 35 litres
T-Shirt
 Objectives of
Salt & Water Recovery Plant
at PREM , Tirupur, India

n To recover 95% of Water for reuse

from Textile Dyeing Waste Water
= 111 Million litres / annum
n To recover 90% of Salt for reuse from
Textile Dyeing Waste Water
= 4,50,000 Kgs / annum
 The Need

SWITCHER-PREM
SUSTAINABLE DEVELOPMENT
PROGRAMME
AS PART OF
THEIR CORPORATE SOCIAL
RESPONSIBILITY
Nature of Waste Water
n Concentrated Dye Bath Effluent
having high amount of Salt
10% of the total volume
n Wash Effluent
90% of the total volume

The above two types of Effluent are

segregated at source and collected
separately and treated separately
 Treatment Scheme
Segregation at Source

Dye Effluent Wash Effluent

Pre Treatment Primary, Secondary &

Tertiary Treatment

Multiple Evaporator Reverse Osmosis

Plant
2 stage water recovery
Salt Crystallizer
Concentrated
Recovered Water Reject
Recovered Salt
For Reuse for Reuse
 Technology of Salt Recovery
n During the Dyeing Process, Glauber’s Salt will be used
instead of Common Salt because it is purer and easier
to recover for Reuse
n The concentrated Dye Effluent with Glauber’s Salt is
pre treated to remove colour
n It is passed through Multiple Evaporators and gets
concentrated
n The concentrated solution is chilled in Vacuum
Crystallizer and the Glauber’s Salt is crystallized
n The crystallized Glauber’s Salt is centrifuged and taken
for Reuse in the Dyeing Process
 Technology of Water Recovery
n The Wash Effluent is given Primary Treatment to remove
colour
n Then it is given Biological Treatment in Fluidized Bed Bio
Reactors to reduce BOD and COD loads
n The treated Effluent goes through Tertiary Treatment to
further improve its quality and made suitable for Reverse
Osmosis Recycling
n The clear Effluent is passed through Reverse Osmosis
Membranes in two stages and the clean water is
Recovered and sent to Dyeing Process for Reuse
n The concentrated Reject from the RO is sent to Multiple
Evaporator for evaporation along with the Dye Effluent to
recover Water and Salt
 Capital Cost of the Project
Glauber’s Salt Recovery Plant Rs. 158 lakhs
With
Multiple Evaporators, Crystallizer
Centrifuge, Structure etc.
Water Recycling Plant Rs. 200 lakhs
With
Primary Treatment Plant,
Secondary Bio Reactor,
Tertiary Treatment Plant,
Two Stage Reverse Osmosis Recycling Plant
TOTAL PROJECT COST Rs. 358 lakhs
USD 8,00,000
 The Cost & The Benefits

Inputs Required for Operation

ü Electrical Power
ü Steam Energy
ü Chemicals & Consumables
ü Man power
ü Cost of Funds
Benefits
ü Value Recovered Salt
ü Value of Recovered Water
 COST OF OPERATION
FOR SALT RECOVERY
n Every Kilogram of Recovered Salt Costs
Rs. 8 more than the cost of buying the Salt
u This means Every T-Shirt cost goes up
by Rs. 2.00
u Therefore for 2.50 Million Coloured
T-Shirt / annum, it will cost the Company
by Rs 5.00 Million = USD 1,13,600
 COST OF OPERATION
FOR WATER RECOVERY
n Every Kilo litre of Recovered Water costs Rs. 30
more than the cost of procuring Water
u Every White T-Shirt cost goes up by Rs. 0.45
costing the Company annually for
2 Million T-Shirts = Rs 0.90 Million = USD 20,400
u Every Coloured T-Shirt cost goes up by Rs. 1.05
costing the Company annually for
2.5 Million T-Shirts = Rs 2.62 Million = USD 59,500
 THE FINAL COST OF
SALT & WATER RECOVERY
n The Total annual Additional Cost of
Salt & Water Recovery
= Rs. 8.00 Million = USD 1,80,000
n This means finally every T-Shirt costs more
by Rs. 1.77 = USD 0.04
 Benefits of this Project
for the Company
n Meeting the statutory requirements
n Using Glauber’s Salt gives better Dyeing Results
n Using Recovered Water gives enhanced Dyeing
Performance in terms of Fastness, Uniformity,
Reproducibility and less rejection
n Tackles the Water Shortage problem
n A major step in achieving Zero Liquid Effluent
Discharge
n Satisfying the requirements of SWITCHER &
PREM GROUP’S Corporate Social Responsibilities
 Benefits of this Project
for the Environment
n Stops discharging several thousand tons Salt on the
land and water receivers and hence the increase in
the salinity is prevented
n Several thousand tons of salt is Recovered and
Reused
n Stops discharging several million litres of Effluent
n Stops drawing and using several million litres of
water from the nature
n A major step in implementing Sustainable
Development Concept
 Importance of this Project
ØSo far Waste Water Recycling in a Textile Dye House
is incomplete, because of the handling of the
RO Reject with high level of Salt Content
ØSalt Recovery and Reuse in a Textile Dye House is a
Technological Breakthrough
ØThis Project for the combined Recovery & Reuse of Salt
and Water will be a milestone in the Textile Dye
House Effluent Treatment globally
ØThis Project will be an eye opener even for the Developed
Countries in the European & American Continents