Hosur is one of India's most important automobile and engineering clusters. Two-wheeler, truck and component manufacturers, electroplating and surface finishing units, paint shops, electronics assembly, precision machining, forging and foundry units fill the SIPCOT estates and surrounding areas. Each produces process wastewater with its own chemistry — oils, coolants, metals, paint residues and cleaning chemicals. Intellect Aqua designs, builds, upgrades and operates effluent treatment plants (ETPs) for Hosur industries.
Every plant starts with a study of your actual effluent, so treatment matches your process and consent conditions rather than a standard catalogue design.
Industries We Serve in Hosur
Automobile and Auto Component Plants
Paint shops, pre-treatment lines (degreasing, phosphating), component washing and machining generate oily, metal-bearing and paint-laden wastewater. See automobile industry solutions.
Electroplating and Surface Finishing
Chrome, nickel, zinc and other plating lines produce rinses with dissolved metals and, in some cases, cyanide or hexavalent chromium. These streams need segregated treatment — chrome reduction, cyanide destruction, metal precipitation — before any combined treatment.
Electronics and Precision Engineering
Cleaning and etching processes produce smaller but chemically varied effluents that need careful pH control and treatment.
Forging, Foundry and Heat Treatment
Quench water, scale and oily wastewater need oil separation, settling and filtration.
Food and Beverage
High-organic effluent treated with biological stages.
Our ETP Design Process
- Map every wastewater stream, including concentrated baths and rinses
- Measure daily and peak flow
- Test pH, COD, BOD, TSS, oil, metals, cyanide and TDS as relevant
- Review your consent conditions and customer requirements
- Design segregated and combined treatment with margin
- Share capital cost, running cost and an operating plan
Typical ETP Stages
- Oil and grease separation and skimming
- Segregated chrome reduction and cyanide destruction for plating streams
- Equalisation and neutralisation
- Coagulation, flocculation, metal precipitation and clarification
- Biological treatment for organic streams
- Sand and carbon filtration
- UF and RO for water recovery
- Filter press for sludge
- ZLD where required
Segregation Is the Key to Plating ETPs
Mixing chrome, cyanide and general rinses in one tank makes treatment dangerous and ineffective. We design separate collection and treatment for each hazardous stream, then combine them only after the hazard is removed. This is safer, cheaper on chemicals and far more reliable for compliance.
Water Recovery in Hosur
Water is expensive and scarce in Hosur. Treated effluent can be recovered through UF and RO for reuse in rinsing, washing, cooling towers and paint shop pre-treatment, cutting fresh-water purchase. Many plants combine recovered water with a water treatment plant for fresh water.
Supporting Customer and Compliance Audits
Global OEMs audit their suppliers' environmental performance. We design ETPs with flow meters, sampling points, log sheets and clear operating procedures, so your plant can show consistent performance at any audit or pollution control inspection.
Upgrading Existing ETPs
Production growth, new paint or plating lines and tighter customer requirements often leave existing ETPs overloaded. We audit, test and upgrade the limiting stages — far cheaper than building new.
Sludge Management
Metal-bearing sludge is hazardous waste. We size clarifiers and filter presses for your load, minimise sludge volume through correct dosing and advise on safe storage and authorised disposal.
Separate Domestic Sewage
Staff toilets, canteens and hostels generate sewage best treated in a separate STP.
Paint Shop and Pre-Treatment Effluent
Automobile paint shops use degreasing, phosphating or modern zirconium pre-treatment, followed by painting booths with water curtains. These steps create oily, phosphate-bearing and paint-sludge-laden wastewater. We design treatment with oil separation, chemical precipitation of phosphates and metals, paint sludge coagulation and clarification, followed by filtration. Where possible, we recommend rinse water recovery so the pre-treatment line uses less fresh water. The right design keeps your paint quality consistent and your ETP stable.
Operation and Maintenance
Our AMC service provides trained operators, chemicals, spares, sludge handling, testing and audit-ready records.
Why Hosur Industries Choose Intellect Aqua
- Experience with automobile, plating and engineering effluents
- ETP, RO, ZLD and O&M from one team
- ETP capacities from 10 KLD to 2 MLD
- 15+ years of industry experience and 700+ projects
Areas We Serve
We build ETPs across Hosur and Krishnagiri district — SIPCOT Phase I and II, Mathigiri, Zuzuvadi, Bagalur, Alasanatham, Shoolagiri, Kelamangalam, Krishnagiri and Bargur.
We also build ETPs in Chennai, Ranipet, Salem and Coimbatore.
Get a Free ETP Assessment
Share your processes, daily effluent volume and current setup. We will visit and recommend a solution.