Case Study
GSK Consumer Healthcare India (merged with Hindustan Unilever in 2020) operated major manufacturing facilities producing nutrition and health food drink brands including Horlicks, Boost, Maltova, and Viva across plants in Nabha, Rajahmundry, and Sonepat. As a prominent FMCG player in the health and wellness category, the company’s food processing and malt-based manufacturing operations generated substantial organic wastewater from production processes, equipment cleaning, and utility systems. Facing stringent Environmental Protection Act standards, corporate sustainability commitments from both GSK and Unilever parent organizations, and the need for enhanced supply chain resilience, the company required an ETP expansion solution that would deliver long-term compliance, optimize lifecycle treatment costs, and reduce operational burdens while supporting continued manufacturing growth.
01.
Challenge
- GSK required enhanced resilience and sustainability across its supply chain operations
- The existing ETP facility needed significant upgrades to meet evolving corporate standards
- Faced an incremental investment requirement of ₹5+ Crores with uncertainty around future scalability
02.
Solution
- We designed a comprehensive ETP expansion strategy aligned with GSK’s long-term growth trajectory and sustainability goals
- Engineered a robust, scalable solution that eliminated the need for repeated capacity upgrades
- Optimized the system for both 100% regulatory compliance and minimal operational complexity
03.
Results
1. Reduced Total Wastewater Treatment Costs by 19%+ on a Lifecycle Basis
Our comprehensive ETP redesign for GSK Healthcare delivered substantial cost savings by optimizing both capital expenditure and ongoing operational expenses. Unlike traditional approaches that focus solely on minimizing initial investment, we engineered the system for total lifecycle cost efficiency—reducing chemical consumption, energy usage, maintenance requirements, and labor intensity. This holistic approach achieved a 19%+ reduction in total cost of ownership (capex + opex) over the system's operational lifespan, demonstrating that properly engineered wastewater treatment solutions generate significant ROI through lower day-to-day running costs, extended equipment life, and reduced replacement cycles.
2. Secured Long-Term Regulatory Compliance with Zero Violations
The expanded ETP system ensures GSK Healthcare maintains 100% compliance with Environmental Protection Act standards, State Pollution Control Board regulations, and corporate sustainability requirements. Our robust, multi-barrier treatment approach consistently meets all discharge parameters—BOD, COD, TSS, heavy metals, and pH—eliminating the risk of regulatory penalties, potential production shutdowns, and environmental violations. Since commissioning, the facility has recorded zero compliance incidents, providing complete peace of mind and protecting GSK's reputation as a responsible corporate citizen. The system's design buffer accommodates future regulatory changes, ensuring long-term compliance without requiring major infrastructure upgrades.
3. Eliminated Frequent Capacity Bottlenecks and Minimized Day-to-Day Operational Challenges
By engineering the ETP for scalability and real-world operating conditions, we eliminated the chronic capacity constraints and operational disruptions that previously hampered production. The system handles peak flows and variable load conditions seamlessly, removing production bottlenecks that forced manufacturing slowdowns during high-demand periods. Automated controls, intelligent process design, and reduced manual intervention points have simplified daily operations—plant operators now focus on production optimization rather than constantly troubleshooting wastewater treatment failures. This operational reliability translates to higher manufacturing uptime, predictable maintenance schedules, reduced emergency repairs, and lower dependency on specialized external technical support.
We needed an ETP expansion that wouldn't require frequent upgrades while ensuring 100% compliance. Spans designed a scalable system that reduced our total lifecycle treatment costs by 19%+, achieved long-term regulatory compliance, and minimized operational complexity. They focused on sustainable engineering rather than just meeting immediate capacity needs—exactly what our supply chain resilience strategy required.
(erswhile GSK Consumer Healthcare India)