Industry Background: Why Water Treatment Is Critical in Textiles
The textile industry is one of the largest consumers and polluters of water in industrial sectors. Processes like dyeing, printing, and finishing generate highly colored, turbid wastewater containing:
Suspended solids
Color pigments
BOD & COD
Residual chemicals
Microplastics
Without effective pre-treatment and filtration, these contaminants can clog RO membranes, cause regulatory violations, and affect water reuse.
Project Overview
Client: 100 KLD textile processing plant in Tirupur, Tamil Nadu
System Type: ETP + RO + Reuse setup
Problem:
High turbidity (>12 NTU)
TSS above 100 ppm
Colored water with dye traces
Frequent RO fouling (every 45 days)
Objective
To implement cost-effective filter media solutions to:
Reduce turbidity to <1 NTU
Lower TSS to <10 ppm
Eliminate residual color
Prolong RO membrane life
Solution Implemented by Starke
After a site visit and water sample testing, Starke’s technical team recommended a multi-media filter bed upgrade with the following layer configuration:
| Layer | Media Type | Thickness |
|---|---|---|
| Top | Anthracite Coal (0.8–1.4 mm) | 300 mm |
| Middle | Purozite® Zeolite (0.6–1.2 mm) | 300 mm |
| Lower | Quartz Silica Sand (0.6–1.0 mm) | 250 mm |
| Bottom | Coarse Garnet (0.3–0.6 mm) | 150 mm |
| Base | Graded Gravel Support (2–6 mm) | 100 mm |
Additionally, Starke Coconut Shell Activated Carbon was added as a separate polishing unit to remove residual color and odor.
Media Highlights
Purozite®
Enhanced zeolite-based media
High surface area for TSS and turbidity removal
Better backwash flow, lower clogging
Anthracite Coal
Coarse top layer to trap larger particles
Extends filter cycle before backwash
Coconut Shell Activated Carbon
High iodine value (>1000 mg/g)
Removes dye residue, smell, and organics
Results After 4 Weeks of Operation
| Parameter | Before Treatment | After Starke Media |
|---|---|---|
| Turbidity (NTU) | 12.5 | 0.6 |
| TSS (ppm) | 112 | 6.8 |
| Color (Visual) | Yellow-brown | Clear |
| RO Cleaning Cycle | 45 days | 120+ days |
| Water Reuse % | 50% | >85% |
Cost Savings Achieved
Reduced membrane cleaning frequency (saved ₹80,000/year)
Improved water reuse (reduced freshwater intake by 35%)
Less chemical consumption in RO
Longer media life (estimated 2.5–3 years before change)
Client Feedback
“We were struggling with poor filter performance and frequent downtime. After switching to Starke Filter Media, our turbidity dropped instantly, and RO maintenance was cut by half. Very satisfied with the product and support.”
— Plant Head, KM Textiles Pvt. Ltd.
Why Starke Was Chosen
✅ Technical evaluation
✅ Customized multi-layer media recommendation
✅ Fast dispatch and installation support
✅ Proven track record in industrial effluent treatment
Frequently Asked Questions
Q1. Can this setup be used in dyeing units with high color load?
Yes. Pairing activated carbon with Purozite works well for color-heavy wastewater.
Q2. How often is backwash required?
Every 7–10 days depending on load and pressure drop.
Q3. Are these media reusable?
Yes. Most of the media used are reusable for 2–5 years with proper backwash.
Q4. Can I retrofit these in existing sand filters?
Yes. Starke offers layered refill kits to convert single-layer filters into high-efficiency multi-media systems.
Facing turbidity, color, or TSS problems in your textile ETP or RO plant?
Let Starke help you achieve regulatory compliance and long-term savings.
Email: info@starkefiltermedia.com
Website: www.starkefiltermedia.com