Lotte India Corporation
The Challenge
Undersized ETP Unable to Keep Pace with Expansion
Lotte India Corporation operates a state-of-the-art confectionery manufacturing facility in Rohtak, Haryana, producing high-quality chocolates, candies, and sweet products for the Indian market. As part of their aggressive expansion strategy, Lotte planned to add two additional production lines to their existing facility, tripling their manufacturing capacity.
This expansion would significantly increase wastewater generation from process cleaning, ingredient handling, and utility operations—creating complex treatment challenges with high organic loads, fats, oils, and sugars typical of confectionery manufacturing. Beyond handling increased volumes, Lotte faced mounting regulatory pressure for greater wastewater reuse and a strategic mandate to work toward eventual zero liquid discharge (ZLD) as part of their corporate sustainability commitments.
Key Issues:
- !Expansion with two new production lines significantly increased wastewater generation
- !Existing 200 KLD ETP was treating only 125 KLD due to very high COD (~6,000 mg/L) versus original design assumptions
- !Tightening pollution norms and internal sustainability goals required higher reuse and a pathway toward Zero Liquid Discharge (ZLD)
The Solution
Multi-Barrier Treatment System Designed for Real Operating Conditions
Spans Envirotech conducted a detailed review of influent quantity and quality to redesign the plant based on actual operating conditions rather than theoretical assumptions. This ground-up approach ensured the new system would reliably handle the facility's real wastewater characteristics, including the high-strength organic loads that had overwhelmed the original ETP.
We installed a multi-barrier treatment system combining anaerobic and aerobic biological treatment with advanced physical separation and polishing stages, expanding the system to treat 300 KLD reliably. The solution was designed reuse-ready to enable internal water recycling and built on a modular foundation aligned with Lotte's future ZLD ambitions.
Technologies Deployed:
Implementation Timeline:
Phase 1: Influent Assessment & System Redesign
Conducted a detailed review of actual influent quantity and quality. Identified the mismatch between original design assumptions and real operating conditions, and developed a comprehensive redesign plan based on factual data.
Phase 2: Multi-Barrier System Installation
Installed parallel DAF units, high-rate anaerobic E2E reactor, and two-stage aerobic biological treatment. Engineered the system to handle high organic loads reliably at 300 KLD capacity.
Phase 3: Polishing & Reuse Integration
Commissioned ultrafiltration and UV disinfection for treated water polishing. Integrated reuse-ready infrastructure enabling treated water to be recycled for cooling towers and horticulture.
The Results
Tripled Capacity, Superior Treatment & Reuse Enabled
125 → 300 KLD
Treatment Capacity
Capacity increased from 125 KLD to 300 KLD to support full production expansion
>95%
COD Reduction
COD reduced from ~6,000 mg/L to below 250 mg/L consistently
50%
Wastewater Reuse
Treated water recycled for cooling towers and horticulture
Enabled
ZLD Readiness
Modular foundation created for future Zero Liquid Discharge implementation
“Spans has been a trusted partner in the successful expansion of our effluent treatment plant at our Rohtak confectionery facility. With the addition of new production lines, our wastewater loads increased significantly and the existing ETP could no longer cope. SPANS redesigned the complete treatment system to handle high-strength wastewater, expanding capacity to 300 KLD while achieving over 95% COD reduction. Their solution has enabled 50% reuse of treated water and created a strong foundation toward Zero Liquid Discharge, improving both compliance and sustainability.”
Arvind Sikarwar
Factory Head, Lotte India Corporation
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