IJISET - International Journal of Innovative Science, Engineering & Technology, Vol. 2 Issue 6, June 2015.

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ISSN 2348 – 7968

Water and Wastewater Quantification in a Cotton Textile

Industry
Dr. D.K. Sharma
Senior Environmental Engineer, HP State Pollution Control Board, Shimla

ABSTARCT- Textile manufacturing industry uses substantial amount of water not only in the production processes but also
in manufacturing the raw materials. Water is used successively in almost every process of production. In textile
manufacturing use of water is essentially in conjunction with several chemicals and the water used in numerous washing
cycles of cotton fabric or yarn carry along these chemicals in the waste water. Consumptive use of water is a very small
proportion of the total quantity of water used and most of the water is discharged in the form of wastewater. Similar is the
fate of chemicals used in the manufacturing of textiles. Ingredients of chemicals used in textile production ultimately
discharged as wastewater have considerable environmental significance and exert pollution load in the recipient water bodies
where such effluents ultimately get disposed. This study aims at assessment of quantity of water consumed and wastewater
discharged from every process of production in a cotton textile industry. Study has been conducted in an actual industrial set
up over a period of one year. Primary data was collected during the study of each process operation for water consumption
and wastewater discharged. Secondary data was collected from all the tube wells used for abstraction of water in the
industry. Data of water consumption and wastewater in a cotton textile is an immensely useful benchmark in planning and
prioritizing the pollution prevention and wastewater treatment strategies. Study also presents opportunity to the textile
industry in general to plan conservation of water.
KEYWORDS: Textile, Water, Wastewater, Chemicals, Effluent, Pollution, Production Process.

1. INTRODUCTION
The textile industry carries out numerous processes ranging from the manufacture of cotton
fibers and fabric production. The first step in the production of a cotton textile product is the
preparation of cotton fibers for further processing. Cotton fibers are turned into yarn by
spinning or texturing and preparation. Dyeing and finishing can be done on yarn or on woven
fabric. The last step is the fabrication of a finished product. The preparation, dyeing and
finishing of cotton textile products consume large amounts of energy, chemicals and water
[1]. The wet-processing operations require the use of several chemical baths at high
temperature to give the desired characteristics to the yam or fabric. According to the
sequence of production; processes may be classified as: (i) Pre-treatment; (ii) Dyeing and;
(iii) Finishing. Figure-1.1 depicts the sequence of production processes in a typical textile
industry.
Figure-1.1 Flow of Production Processes in Cotton Textile Industry

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Depending upon the use of the water; the processes are classified as (i) Wet; (ii)
Intermediate and (iii) Dry. Wet processes are those operations in textile manufacturing
which consume water and most of the water used is discharged as wastewater. Intermediate
processes use water but the incidence of waste water discharge is insignificant. Dry process
operations neither consume water nor discharge any wastewater. The classification of textile
manufacturing processes according to use of water is summarized in Table-1.1.

Table-1.1 Wet, Intermediate and Dry Processes [1]

WET INTERMEDIATE DRY
Scouring of wool Sizing Picking, carding and
combing
Scouring of cotton Felting (Non-woven fabrics) Spinning
Desizing Adhesive processes (including Weaving
carpet backing)
Bleaching Functional finishing (e.g. flame Knitting
retardancy, moth proofing etc)
Mercerising Printing Tufting
Carbonising Mechanical Finishing
Milling Stentering
Dyeing Heat setting
Washing Singeing

According to United States Environmental Protection Agency [2], the textile production
processes can usually be performed in batch, continuous or semi-continuous systems. In
batch systems, the machine is loaded with a fixed amount of fabric, chemical solutions are
added, and the process is conducted. After processing, the chemical bath is discharged and
the fabric is washed. Subsequent processing is usually done in the same machine. In
continuous systems, the chemical mix is placed in pans, and the fabric runs through the
machine continuously for a predetermined period. Process wastewater is a major source of
pollutants in Textile production [3]. It is reported [4] that widespread contamination of
water may occur in rivers, drainage canals and coastal waters due to discharge from textile
industry. Neşe Tüfekci et al [5] have reported that in practice, the amount of water used
and wastewater discharged and level of pollutants from different industries vary
considerably. One essential and often difficult step in water pollution prevention is to
accurately and realistically assess the current status of industry and its potential for
improvement. Schedule-VI (Part-B) of the Environment (Protection) Rules-1986 [6] states

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the wastewater generation as 120 m /tonne for nylon & polyester and 150 m /tonne for
P P P P

viscose rayon. No specific wastewater generation has been mentioned in the said
Schedule-VI for cotton fiber/fabric production. Report on Accounting for Water, June,
2007 [7] by the Waterfalls Institute of Technology Transfer, New Delhi, states that the
Principle of “Tragedy of Commons” is more relevant to the water as a commodity. As the
water is held in common ownership by all hence there is a dire need for socially equitable
and ecosystem based approach to water management.

2. MATERIALS & METHODS

Study was conducted in two cotton based textile industrial units. One of the units
manufactures yarn and the second unit manufactures fabric. For the purpose of the study,
these industries have been named as Unit-I and Unit-II. Production data of both the units
was obtained from the registers maintained as per mandatory requirement of excise &
sales tax. Both the units use groundwater to meet their requirements of water from the
underground sources. The data of all the tube wells was collected and inventory of water
sources was prepared. The quantitative data of all the water abstraction points was
measured using the capacities of the storage reservoirs and daily yield of all the pumps in
each industry. Monthly data of the total water abstracted from the ground water was
prepared for one year. Concurrently the quantity of wastewater was measured at the inlet
of the equalization tank of effluent treatment plant of each unit. On the basis of this
realtime data, quantity of water consumption and effluent generation per tonne of the
product is determined. Average values of the above items were also determined on the
compiled data. Thus the specific water consumption and specific wastewater generation
were then determined as a function of production expressed as m3/tonne of yarn or fabric. P P

Simultaneously, water balance was also studied for each unit operation of the production
process of fibre/yarn for one year. Random trials were conducted during different months
and seasons of study period to account for variations in product profile and water
consumption patterns. The studies were carried out for all types of products namely full
white yarn, yarn dyed with vat dyes and yarn dyed with reactive dyes. Water input into
each process was measured by assessing the flow rate by bucket-fill method using the stop
watch. Flow rate was multiplied by the time for which the valves were kept open in the
complete process cycle. Similarly the quantity of effluent being released from each process
was also measured. Weighted Mean values according to the proportion of types of
products for Water consumption and effluent generated from each process were

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determined as a function of production expressed as m /tonne of product. The proportion
P P

of each type of product was determined and was observed as 17% for full bleach white
yarn, 2% for vat dyed yarn and 81% for reactive dyed yarn in Unit-I. The proportion of
each type of product was observed as 37% for full white or yarn dyed fabric, 18% for vat
dyed and 45% for reactive dyed fabric. Same methodology was adopted for determining
the water balance of in both the units
Two values for water consumption and wastewater determined according to two
independent methodologies are than compared for checking the extent of variation,
precision and revalidation of the study results.

3. RESULTS & DISCUSSIONS

Details of total water abstraction from all sources were collected and effluents were measured
at the inlet of ETP. Data of production of fiber and yarn in Unit-I was collected for the
registers maintained by the management for purpose of excise & taxation. The results have
been presented in Table-3.1
TABLE-3.1
Data of Annual Water Use and Effluent Discharged in Unit-I
(Based on Tube Wells Abstraction & Flow in ETP)
Production Water &
Water Consumed &
of Yarn Effluent in Effluent as %
Effluent Generated 3
Month (tonnes) m /Tonne of
P P

of Water
in m3 P

product Consumed
Use Waste Use Waste

Apr 525 85760 79213 135.91 125.54 92.37

May 544 88641 81257 133.09 122.01 91.67
Jun 542 78851 72595 136.89 126.03 92.07
Jul 503 67136 64756 122.73 118.38 96.45
Aug 487 73142 68236 129.45 120.77 93.29
Sep 6755 73770 65906 125.46 112.09 89.34
Oct 563 81540 74201 140.34 127.71 91.00
Nov 525 73992 70884 140.94 135.02 95.80
Dec 544 75866 71739 139.46 131.87 94.56
Jan 542 72699 66331 134.13 122.38 91.24

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Production Water &

Water Consumed &
of Yarn Effluent in Effluent as %
Effluent Generated 3
Month (tonnes) m /Tonne of
P P

of Water
in m3
P

product Consumed
Use Waste Use Waste

Feb 503 72375 66028 143.89 131.27 91.23

Mar 487 76736 72569 157.57 149.01 94.57
Total 6755 920508 853715 NA NA 92.80
Average 563 76709 71143 136.66 126.84 92.80

The average values for water balance in respect of each process of the production observed
during the trials are given in Table-3.2. The weighted average values shown in Table represent
the values balanced according to the proportion of all types of products i.e. white, vat or
reactive dyed yarn/fiber.

Table-3.2 Water Balance on the Basis of Process Study Trials in Unit-I

Sr. Process Operation Water (m3/tonne of fabric)
P P

No. White Vat Dyed Reactive Weighted

Dyed Average
Use Waste Use Waste Use Waste Use Waste
1. Pre- Scouring & 21.44 20.34 22.87 20.34 23.56 22.00 22.62 20.89
treatment Bleaching
H2O2
R R R R 6.88 5.88 7.90 6.34 7.25 6.56 7.34 6.26
Neutralization
Washing 0 0 21.34 21.34 20.64 17.88 20.99 19.61
2. Dyeing Dyeing 0 0 41.94 36.38 39.5 34.66 40.72 35.52
Washing 0 0 15.76 14.68 13.42 11.82 14.59 13.25
3. Finishing Softening & 15.40 12.34 25.92 23.34 22.78 18.69 21.37 18.12
Neutralization
Total 43.72 38.56 135.73 122.42 127.15 111.61 127.63 113.65

Similarly for Unit-II which manufactures cotton fabrics, the monthly details of production,
water abstraction and effluent generation have been shown in Table-3.3

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Table-3.3 Data of Annual Water Use and Effluent Discharged in Unit-II

(Based on Tube Wells Abstraction & Flow in ETP)

Water Consumed & Water & Effluent

Effluent as % of
Production Effluent Generated in m3/Tonne of
P P

Month Water
(Tonnes) in m3 P product
Consumed
Use Waste Use Waste
Apr 792.5 107730 102164 135.94 128.91 94.83
May 841.93 109750 106703 130.36 126.74 97.22
Jun 962.05 118590 116458 123.27 121.05 98.20
Jul 775.08 120033 109010 154.87 140.64 90.82
Aug 899.17 121604 117730 135.24 130.93 96.81
Sep 1005.61 124960 115783 124.26 111.50 92.66
Oct 1006.96 120030 115354 119.20 114.56 96.10
Nov 918.61 105610 102228 114.97 111.29 96.80
Dec 1127.01 121410 115064 107.73 102.10 94.77
Jan 1045.56 117670 112860 112.54 107.94 95.91
Feb 982.32 115913 111961 118.00 113.98 96.59
Mar 1007.15 138060 125933 137.08 115.11 91.22
Total 11363.95 1421360 1351248 125.08 118.91 95.07
Average 947.00 118446.67 112604 125.08 118.91 95.07

Corresponding values for water balance in respect of each process of the production observed
during the trials are given in Table-3.4. The weighted average values shown in Table
represent the values balanced according to the proportion of each type of product i.e. white,
vat or reactive dyed fabric.

Table-3.4 Water Balance on the Basis of Process Study Trials in-II:

Sr. Process Operation Water (m3/Tonne of fabric)
P P

No. White Vat Dyes Reactive Weighted

Dyes Average

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Use Waste Use Waste Use Waste Use Waste

1. Pre- Desizing &
12.35 10.54 14.34 12.56 11.94 9.89 12.88 11.00
treatment Bleaching
Mercerizing 27.64 24.32 31.54 25.76 29.84 27.42 26.38 27.85

Washing 12.60 13.98 13.02 16.58 14.02 14.36 16.51 12.96

2. Dyeing Perble Range 0.00 0.00 14.26 10.68 13.55 9.12 11.53 9.42
Pad Steam 0.00 0.00 11.86 9.26 10.58 8.56 11.22 8.91
Washing 0.00 0.00 24.52 24.88 23.00 25.56 26.14 25.70
3. Finishing Softening &
10.84 8.55 15.34 13.54 14.56 12.48 13.58 11.52
Neutralization
Total 63.42 57.39 124.88 113.26 117.49 107.39 118.24 107.36

Water balance studies conducted in Unit-I as per Table-3.1 show that the overall consumption
of water during April, 2010 to March, 2011 was 920.51 million litres and the corresponding
quantity of waste water was 853.72 million litres. Annual Average water consumption was
observed 136.66 m3/Tonne of the processed yarn/fibre whereas the resultant waste water was
P P

observed 126.84 m3/Tonne of the processed yarn/fibre. Highest value for water consumption
P P

was observed as 157.57 m3/Tonne and lowest value was observed as 122.73 m3/Tonne.
P P P P

Corresponding highest and lowest values for waste water were observed as 149.01 kl/tonne
and 118.38 m3/Tonne respectively. It is seen that 92.80% of the water consumed is discharged
P P

as effluent as per month wise data. Water balance studies conducted in Unit-II as per Table-
3.3 showed that the overall consumption of water during April, 2010 to March, 2011 was
1421.36 million litres and the corresponding quantity of waste water was 1351.25 million
litres. Annual Average water consumption was observed 125.08 m3 /tonne of the finished P P

fabric whereas the resultant waste water was observed 118.91 m3 /tonne of the finished fabric. P P

Highest value for water consumption was observed as 154.87 m3 /tonne and lowest value was P P

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observed as 107.73 m /tonne. Corresponding highest and lowest values for waste water were
P P

observed as 140.64 m3 /tonne and 102.10 m3 /tonne respectively. It is seen that 95.07% of the
P P P P

water consumed is discharged as effluent as per month wise data.

Further trial studies of individual process operations were also conducted during the same
period to correlate and compare the mean values with those obtained from the month wise
data of water and waste water. The mean values as per Table-3.2 for water consumption and
resultant effluent on the basis of trial studies in unit-I were observed as 127.63 m3/Tonne of P P

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yarn/fibre and resultant value for effluent was observed as 113.66 m /Tonne of yarn/fibre. It isP P

observed from the data of Table-3.2 that 89.05% of water consumed results in effluent. The
mean values as per Table-3.4 for water consumption and resultant effluent on the basis of trial
studies in unit-II were observed as 118.24 m3 per tonne of fabric and resultant average value
P P

for effluent was observed as 107.36 m3 per tonne of fabric. It is observed from the data of
P P

Table-3.4 that 92.02% of water consumed results in effluent. The water consumption and
wastewater generation in Unit-I and Unit-II are figuratively represented in Figure-3.1 and
Figure-3.2.
Figure-3.1 Actual & Average Monthly Water Consumption in Unit-I & II
180
160
140
120 Water Use m3/tonne
100 Unit-I
80 Water Use m3/tonne
Unit-II
60 Average Water Use
40 m3/tonne Unit-I
20 Average Water Use
m3/tonne Unit-II
0
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

Figure-3.2 Actual & Average Monthly Wastewater Generation in Unit-I & II

160
140
120
Wastewater m3/tonne
100 Unit-I
80 Wastewater m3/tonne
Unit-II
60
Average Wastewater
40 m3/tonne Unit-I
20 Average Wastewater
m3/tonne Unit-II
0
Apr May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar

According to the study trials, it is also observed that 40% water consumption is in pre
treatment section, 43% in dyeing section and 17% in finishing section in Unit-I.
Corresponding share of effluent contribution by these three sections of production in Unit-I is
observed as 41%, 43% and 16% respectively. In Unit-II, 47% water consumption is observed

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in pre-treatment process, 41% in dyeing and 12% in finishing process. Proportion of

wastewater generation form pre-treatment, dyeing and finishing processes has been observed
as 48%, 41% and 11% respectively. According to studies by Aysegul PALA, July, 2001 [8]
waste water is generated from mainly from three sources in cotton textile industry with
average proportion as 45% from cotton pre-treatment, 35 to 40% from dyeing, and 5 to10%
from finishing operations during full capacity operation. These values are comparable with
those observed during the study of process. Processwise proportion in percentage terms for
water consumption and generation of wastewater in both Unit-I and Unit-II is depicted in
Figure-3.3 and Figure-3.4.

Figure-3.3 Processwise Percent Water Consumption in Unit-I & II

50
45
40
35
30
25 Unit-I

20 Unit-II
15
10
5
0
Pretreatment Dyeing Finishing

Figure-3.4 Processwise Percent Wastewater Generation in Unit-I & II

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60

50

40

30 Unit-I
Unit-II
20

10

0
Pretreatment Dyeing Finishing

Variation is observed in assessment of water consumption and effluent generation determined

on the basis of month wise data and process study trials. In Unit-I, the values determined
according to month wise data are higher by 6.60% and 10.40% for water consumption and
effluent generation respectively as per values in Table-3.1 and Table-3.2 respectively. In Unit-
II values determined according to month wise data are higher by 5.47% and 9.71% for water
consumption and effluent generation as per Tables-3.3 and Table-3.4 respectively.
Comparatively the consumption of water and generation of effluent as per month wise data is
more in Unit-I than in Unit-II by a margin of 8.4% and 6.27% respectively. Similarly
comparative water consumption and effluent generation determined as per study of process
show that water use and effluent generation in Unit-I is more than Unit-II by a margin of
7.00% and 5.53% respectively. Overall variation between the effluent generation as a function
of water consumption determined on the basis of the month wise data and actual process
studies was observed as 3.75% for unit-I and 4.27% for Unit-II respectively. The comparative
analysis based on secondary data and primary data determined on the basis of process study
trials is depicted in Figure-3.5

FIGURE-3.5 Comparative Analysis of Water Balance of Unit-I&II

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160
140
120
100
80 Unit-I
60
40 Unit-II
20
0
Water Use Water Use as per Eff Secondary Eff as per Trials
Secondary data Study data

4. CONCLUSIONS
It is established from the study that mean values of water consumption determined by
averaging the values of primary & secondary data for manufacturing of cotton yarn and cotton
fabric have been assessed at 132.15 m3/tonne and 121.66 m3/tonne respectively.
P P P P

Corresponding values of wastewater generation have been observed as 120.25 m3/tonne and P P

3
113.14 m /tonne. The consumption of water and generation of waste water are proportional to
P P

quantity of production. Scale of operation has direct link with the consumption of water and
effluent generation. Specific water consumption and wastewater generation in small plants is
likely to be higher than the larger plants. Pre-treatment and dyeing processes consume
maximum water and hence result in maximum effluent. These processes account for 83% of
water consumption and 84% of effluent in Unit-I and 88% of water consumption and 89% of
effluent in Unit-II. It is concluded that the water consumption and effluent generation in m3 P

per tonne of the product observed during the study trials is less than the quantities arrived at
P

by analyzing the secondary data. This can be explained due to the fact that the study trials
focussed on the process unit operations and did not account for waste generated from non-
point sources such as water losses in distribution, floor washings and utilities. The process
analysis of water consumption and waste water generation provides the baseline benchmarks
for a comprehensive pollution prevention and water conservation in the cotton textile
manufacturing.

5. REFERENCES:
1. Guidelines by Scottish Environmental Protection Agency 2001 “Sectoral Guidance
Note IPPC S6.05”, pp-1, 8
2. United States Environmental Protection Agency, 1996 “ Pollution Prevention in the
Textile Industry” pp-9, 15, 21, 31, 46-87

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3. Guidelines by Multilateral Investment Guarantee Agency, January,1996,

“Environmental Guidelines for Pollution Prevention and Abatement in Textile
Industry”, pp505-506
4. World Bank Technical Paper No. 93, Vol.1, 1989, “The Safe Disposal of Hazardous
Wastes: The Special Needs and Problems of Developing Countries”, pp-43
5. Neşe Tüfekci, Nüket Sivri, İsmail Toroz, June 2007, “Pollutants of Textile Industry
Wastewater and Assessment of its Discharge Limits by Water Quality Standards”,
Turkish Journal of Fisheries and Aquatic Sciences 7, pp- 97-103
6. Schedule-I of Environment (Protection) Rules, 1986, Pollution Control Law Series:
PCLS/02/2006, CPCB, pp-345
7. Report on Accounting for Water, June, 2007, “Information on Science & Technology
Applications”, Waterfalls Institute of Technology Transfer, New Delhi Vol. 13, pp-6
8. Aysegul PALA, July, 2001, “Chemical Treatment of Textile Wastewaters: Statistical
Characterization, Colour and Sulfide Removal”, Indian Journal of Environmental
Health Vol.43, No.3, pp-128-129

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