Pharmaceutical Wastewater Treatment Plant – Process, Design & Key Features
Client: Global Pharma
Industry: Pharmaceutical Manufacturing
Scope: Integrated Wastewater Treatment & Sustainability Initiative
Project Overview
Global Pharma approached HECS at a decisive moment. Their API manufacturing facility was producing large volumes of wastewater with complex chemical loads, and their existing systems were no longer sufficient to support their environmental commitments. They needed a treatment setup that could do more than meet basic standards — they required a system that aligned with their long-term sustainability vision while ensuring uninterrupted production.
Our objective was to build a wastewater management model that turned compliance into a strategic advantage. The solution had to treat diverse wastewater streams, enable maximum reuse, lower operational costs, and reinforce their environmental leadership in the pharmaceutical sector.
Understanding the Challenge
Global Pharma generated two distinct wastewater streams every day:
1. Sewage from regular operations
- This required biological treatment and safe reuse for non-potable applications.
2. Industrial effluent from API processes
- This stream carried pharmaceutical residues, solvents, and chemical contaminants that demanded advanced treatment systems.
- The existing infrastructure couldn’t handle the complexity. Limitations in treatment capacity, inconsistent performance, and rising disposal costs threatened both regulatory compliance and sustainability reporting. Global Pharma sought a reliable, intelligent, and future-ready solution that would safeguard their operations and brand image.
Engineering the HECS Solution
To address this dual challenge, HECS engineered a fully integrated wastewater treatment package, built within durable FRP-prefabricated modules designed to last in corrosive pharmaceutical environments.
1. 6 KLD Sewage Treatment System
The STP is built on a hybrid MBBR (Moving Bed Biofilm Reactor) process, chosen for its strength in handling variable loads while maintaining stability.
Key features include:
- High biological degradation efficiency
- Compact structure ideal for industrial space constraints
- Treated water suitable for irrigation, cooling towers, and other utility uses
- Automated functioning with minimal operator input
This system enabled Global Pharma to utilize reclaimed water every day instead of relying on fresh municipal supply.
2. 20 KLD Industrial Effluent Treatment Plant
The ETP is the core of the transformation. It uses a combination of:
- Chemical treatment to neutralize pharma contaminants
- Biological treatment to break down biodegradable components
- Advanced filtration to ensure near-zero residue in the final output
The treated water is now compliant with stringent pharmaceutical discharge norms and can be reused or safely discharged depending on operational requirements.
Smart Design & Energy Efficiency
Every element of the solution focuses on long-term performance:
- Variable Frequency Drives for optimized energy use
- High-efficiency aeration systems
- Automated sensors and controls for stable operation
- FRP construction for corrosion resistance and faster installation
The design ensured long-lasting, low-maintenance, and reliable treatment performance.
Project Outcomes
Reduced Operational Effort
- Automation significantly cut down manual checks and labor dependency, allowing staff to stay focused on guest service operations.
Sustainable Water Reuse
- High-quality treated water now supports landscaping and cleaning activities, reducing freshwater consumption at the resort.
Assured Environmental Compliance
- Automated monitoring ensures discharge quality meets Kerala Pollution Control Board standards consistently.
Remote System Accessibility
- The HECS SMART HUB App enables the resort’s maintenance team to supervise plant performance from any location and take proactive action when required.
Client Testimonial
The 20 KLD ETP and 6 KLD STP installed at our pharmaceutical facility have made a remarkable difference in our daily operations. The system runs smoothly with minimal intervention, and the automated controls ensure consistent treatment quality around the clock. We’ve seen a clear improvement in water reuse, reduced disposal issues, and far better compliance stability. This setup has truly enhanced our efficiency and strengthened our environmental performance.
— General Manager
Global Pharma
Delivering Real, Measurable Impact
✔ Strengthened Water Security
Global Pharma now reuses a significant portion of treated water, reducing dependency on municipal sources and supporting long-term water conservation.
✔ Stable Regulatory Compliance
The upgraded system consistently meets environmental discharge norms, eliminating compliance-related risks and ensuring uninterrupted operations.
✔ Reduced Operational Costs
Savings come from:
- Lower freshwater procurement
- Reduced effluent disposal charges
- Optimized energy usage
The system continues to reduce expenses month after month.
✔ Elevated Sustainability Reputation
Global Pharma’s commitment to environmental responsibility is now visible in measurable outcomes. Their sustainability reports now highlight real-world achievements, improving trust among clients, partners, and the community.
The Larger Impact
This project illustrates how pharmaceutical manufacturing units can integrate meaningful environmental solutions without compromising efficiency. HECS has demonstrated that wastewater treatment is more than a compliance requirement — it is a strategic investment in resource optimization, brand value, and operational resilience.
For Global Pharma, wastewater management has evolved from a cost center into a strategic asset that supports their goal of producing life-saving pharmaceuticals responsibly and sustainably.
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