Industrial RO plant for Textiles
A textile-grade reverse-osmosis (RO) plant removes 97-99 % of salts, heavy metals and dye residues, enabling ZLD compliance, cutting chemical costs 30 % and safeguarding consistent, fault-free colours.
Why RO Plants Are Essential for Textile Manufacturing
Textile mills consume 100-250 L water / kg fabric.
Reactive-dye salt use fell 35 % at ABC Knits after RO installation.
Removes TDS that causes shade variation and hydrolysis.
Reduces overall treatment OPEX ≈ 40 % versus conventional systems.
Meets CPCB / EPA discharge limit < 100 ppm TDS.
Critical Applications in Textile Processing
| Process | RO-Water Requirement | Quality Impact |
|---|---|---|
| Fabric Dyeing | TDS < 50 ppm • Silica < 5 ppm | Prevents dye migration & uneven shades |
| Washing/Rinsing | Chloride < 10 ppm • Hardness < 1 °dH | Eliminates mineral deposits |
| Steam Generation | Conductivity < 10 µS/cm | Prevents boiler scaling |
| Printing | Iron/Manganese-free | Avoids fabric staining |
RO Water Treatment for Dyeing Units: Color Consistency & Qua
RO water treatment for dyeing units solves:
Dye hydrolysis from high alkalinity
Metamerism (color shifts) caused by TDS fluctuations
Salt wastage in reactive dyeing (reduces NaCl usage by 35%)
System specs: 75-85% recovery rate, dual-media filtration pretreatment, pH correction to 6.5-7.5.
Solving High-TDS Challenges in Textile Effluents
Textile effluents reach 8,000-15,000 ppm TDS from dyeing auxiliaries. High TDS RO plants:
Use boron-rejecting membranes for salt-heavy streams
Operate at 150-250 psi pressure for high osmotic solutions
Integrate antiscalant dosing systems to prevent CaSO₄ fouling
Post-RO water: <500 ppm TDS – safe for reuse in dye baths.
Advanced Effluent Treatment with RO Systems
Primary Treatment
Screening → Equalization → Biological DEKO
RO Pretreatment
Activated carbon → Ultrafiltration (0.03µm)
Reverse Osmosis
99% rejection of dyes (azo, reactive) and PVA sizes
Concentrate Management
Evaporators for ZLD
Achieving Zero Liquid Discharge in Textile Mills
Zero liquid discharge for textile industry configuration:
RO role
Concentrates effluent 5-8x before evaporation
Water recovery
85-92%
Salt production
Na₂SO₄ crystals for detergent industry reuse
Solving High-TDS Challenges in Textile Effluents
Dyeing Effluent → Cooling → Sand Filter → Carbon Filter → Antiscalant → RO →
↓
Recycled Water (TDS<200ppm) → Dye Bath Makeup
↓
RO Concentrate → Electrocoagulation → Sludge Press
Reverse-Osmosis Systems for Process Water
Sanitary SS 316 housings (no Fe contamination).
Automated hot-alkaline CIP for dye fouling.
Double-pass configuration delivers < 10 ppm TDS for critical shades.
Real-time SDI monitoring protects membranes.
Benefits of RO Plants in Textile Operations
1
Dye savings: 15-20 % via improved fixation.
2
Water cost: ₹20 / m³ recycled vs. ₹95 / m³ freshwater.
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Compliance: Meets EU EcoLabel & Oeko-Tex STeP.
4
Energy: 30 % lower power than MEE-only ZLD.
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Waste: 90 % landfill diversion thanks to salt crystallisation.
Selecting Your Textile RO System – Technical Specs
| Parameter | Dyeing / Washing | Effluent Treatment |
|---|---|---|
| Capacity | 50–500 m³/day | 100–2 000 m³/day |
| Membrane | Polyamide TFC HR | Seawater RO |
| Pressure | 100–150 psi | 180–250 psi |
| Automation | PLC + SCADA | IoT cloud control |
| Certifications | CE, ISO 14001 | GOTS, ZDHC 3 |
Our Range of Products
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Frequently Asked Questions
Can RO remove reactive dyes from textile wastewater?
Yes—RO rejects > 99 % dyes > 200 Da; pair with activated carbon for low-MW dyes.
What TDS is ideal for beverage water?
• Bottled water: 10–50 ppm
• Brewing: < 100 ppm
• Soft drinks / CSD: < 10 ppm
How much wastewater can RO recycle in textile mills?
Typically 70-85 % of dye bath effluent with proper pretreatment; concentrate goes to ZLD.
Do textile RO plants need special membranes?
Use fouling-resistant, high-boron-rejection, chlorine-tolerant models for dye environments.
What’s the ROI for an RO-based ZLD system?
Payback 2-3 years—fresh-water savings ₹40 lakh/yr + avoided fines and dye savings.
How often are membranes CIPed in dye-house duty?
Every 3–4 weeks with an 80 °C alkaline wash to strip dye films and restore flux.