Planning and Establishing a BIS-Certified Packaged Drinking Water Plant in Delhi (IS 14543:2024 Compliant)

Sandeep Panwar
Apr 27
36 min read

Executive Summary

This report provides a comprehensive blueprint for establishing a Bureau of Indian Standards (BIS) certified packaged drinking water bottling plant in Delhi, compliant with the latest standard, IS 14543:2024. The escalating demand for safe and reliable drinking water in urban centers like Delhi necessitates stringent quality control, making BIS certification under IS 14543

Modern packaged bottling plant for drinking water, featuring advanced automated machinery within a clean, spacious facility.

mandatory for market entry and consumer trust. This plan outlines the critical stages involved, from initial site selection and regulatory navigation within the complex Delhi framework (including FSSAI, BIS, DPCC, CGWA approvals) to detailed plant layout design adhering to strict hygiene norms (IS 14543 Annex B/G). It elaborates on the essential water treatment processes, specifying technical parameters for multi-stage filtration, Reverse Osmosis (RO), UV sterilization, and Ozonation, crucial for meeting the rigorous quality standards of IS 14543:2024. The report details requirements for automated bottling and packaging lines, including material specifications for bottles and caps (PET, HDPE/PP conforming to relevant IS standards). Furthermore, it specifies the mandatory setup of an in-house quality control laboratory, listing essential equipment and outlining the Scheme of Inspection and Testing (SIT) for raw, treated, and finished water. Operational readiness aspects, including manpower planning for capacities like 2000 LPH or 5000 LPH, raw material sourcing, and crucial waste management strategies (RO reject water handling and mandatory EPR compliance for plastic waste) are addressed. Finally, a preliminary cost estimation covering major investment heads for the proposed capacities is provided, alongside key technical specifications. Successful establishment hinges on meticulous planning, adherence to regulatory and technical standards, robust quality control, and effective operational management.

Section 1: Introduction to BIS-Certified Water Bottling in Delhi

Overview The demand for packaged drinking water in major metropolitan areas like Delhi has witnessed significant growth. This trend is largely fueled by increasing consumer awareness regarding health and hygiene, coupled with concerns over the quality and reliability of municipal tap water sources. Packaged drinking water, as defined by Indian regulations, refers to water derived from various sources that undergoes specific purification treatments before being sealed in containers for direct consumption. It is distinctly different from packaged natural mineral water, which has its own set of standards (IS 13428) and typically originates from specific, protected underground sources with characteristic mineral compositions.
The Imperative of BIS Certification For any entity planning to manufacture and sell packaged drinking water in India, obtaining certification from the Bureau of Indian Standards (BIS) is not optional, but a mandatory legal requirement. The specific standard governing packaged drinking water (other than natural mineral water) is IS 14543, recently revised to IS 14543:2024. Compliance with this standard is enforced by the Food Safety and Standards Authority of India (FSSAI), which requires a valid BIS license as a prerequisite for issuing its own mandatory FSSAI license for food businesses.The BIS certification culminates in the grant of a license to use the Standard Mark, commonly known as the ISI mark, on the product packaging, along with a unique CML (Certification Mark License) number. This ISI mark serves as a powerful symbol of quality assurance and safety for consumers, indicating that the product conforms to the stringent benchmarks set by the national standards body. It is crucial for building consumer confidence, achieving market access, and ensuring legal compliance. Operating without this certification can lead to severe consequences, including product seizures, significant fines, and legal action under the Food Safety and Standards Act, 2006, effectively barring market participation.
Report Objective and Scope The objective of this report is to provide a detailed, actionable blueprint for entrepreneurs, project managers, and business planners aiming to establish a BIS-certified packaged drinking water bottling plant in Delhi, ensuring compliance with the latest standard, IS 14543:2024. The scope encompasses a comprehensive analysis of the regulatory requirements (BIS, FSSAI, Delhi-specific permits like DPCC, CGWA), technical specifications for water treatment and bottling processes, guidelines for plant layout and hygiene, requirements for the in-house quality control laboratory, essential machinery listing, operational considerations including manpower and waste management, and a preliminary financial estimation for plant capacities of 2000 Liters Per Hour (LPH) and 5000 LPH.

Section 2: Decoding BIS Standard IS 14543:2024

Transition to IS 14543:2024 The Bureau of Indian Standards periodically reviews and revises its standards to align with technological advancements, international practices (like WHO guidelines), and evolving safety considerations. The standard for packaged drinking water, previously IS 14543:2004 and subsequently IS 14543:2016, has been revised to IS 14543:2024. BIS has mandated the implementation of this revised standard, setting a deadline of 15 September 2024, after which the previous version (IS 14543:2016) will be withdrawn. Therefore, any new plant setup must comply with IS 14543:2024.Key changes incorporated in the 2024 revision, based on BIS implementation guidelines and previous amendments, include updates to referred test method standards (Annex A), modifications to test methods for microbiological parameters like Aerobic Microbial Count (now IS 5402 Part 1) and Yeast & Mould (now IS 5403 Part 1), and numerous updates to test methods for various chemical parameters (e.g., Fluoride, Chloride, Sulphate, Calcium, Magnesium, Sodium, Phenolic compounds, Mineral oil, Mercury, Cadmium, Arsenic, Lead, Chromium, Nickel). Earlier revisions (leading to 2016/2024) had already modified limits for Barium, Cadmium, and Arsenic to align with WHO guidelines and adjusted the permissible pH range based on local conditions. This report focuses on compliance with IS 14543:2024.
Scope and Definition IS 14543:2024 prescribes the requirements, sampling methods, and tests for "Packaged Drinking Water (Other than Packaged Natural Mineral Water)". This specifically refers to water intended for human consumption, derived from various permissible sources, subjected to specific treatments to meet stringent quality standards, and then filled and sealed into containers of various types and sizes suitable for direct consumption without any further treatment by the consumer.
Source Water & Permitted Treatments The standard allows the use of water derived from a variety of sources, provided it is consistently available and potable or can be rendered potable through treatment. Acceptable sources include surface water (rivers, lakes), civic/municipal water supply, underground water (borewells, springs), or even seawater. The raw water must undergo treatments designed to remove impurities and ensure compliance with the final quality parameters. IS 14543 explicitly lists permitted treatments :
Physical Separation: Decantation, Filtration (including sand filters, depth filters, cartridge filters), Combination of filtration.
Chemical/Physico-Chemical: Aeration, Activated Carbon Filtration (for removal of colour, odour, organic matter, residual chlorine), Demineralization (removal of minerals, typically via RO or Ion Exchange), Remineralization (addition of minerals).
Advanced Treatment: Membrane Filter Filtration, Reverse Osmosis (RO), Distillation.
Disinfection: Chemical agents (like ozonation, chlorination - though residual limits apply) and/or Physical methods (like Ultraviolet (UV) treatment, silver ionization) to reduce microorganisms to safe levels.

If seawater is used, it must undergo desalination prior to these treatments. If remineralization is employed (a common practice after RO to improve taste and add minerals), the ingredients used must be of food-grade or pharmaceutical-grade quality and comply with relevant food safety regulations.

Mandatory Quality Parameters & Permissible Limits IS 14543:2024 sets comprehensive and stringent quality benchmarks that the final packaged water must meet. These cover a wide range of parameters :
Organoleptic & Physical: Appearance, Colour, Odour, Taste, Turbidity, pH, Total Dissolved Solids (TDS).
General Chemical: Parameters concerning substances undesirable in excessive amounts (e.g., Fluoride, Chloride, Sulphate, Nitrate, Iron, Manganese, Calcium, Magnesium, Sodium, Barium, Aluminium, etc.).
Toxic Substances: Heavy metals with significant health risks (e.g., Arsenic, Cadmium, Lead, Mercury, Chromium, Nickel, Selenium, Antimony).
Pesticide Residues: Limits for individual and total pesticide residues.
Radioactive Residues: Limits for Alpha and Beta emitters.
Microbiological: Absence of specific pathogens (E. coli, Coliforms, Faecal Streptococci, Staphylococcus aureus, Salmonella, Shigella, Vibrio cholerae, V. parahaemolyticus, Pseudomonas aeruginosa) and limits on general microbial counts (Aerobic Microbial Count, Yeast & Mould).

Meeting these numerous and strict parameters necessitates advanced water treatment processes and rigorous quality control. The plant must have a well-equipped in-house laboratory capable of testing most parameters frequently. However, highly specialized tests like pesticide residue analysis and radioactive residue testing often require outsourcing to BIS-recognized external laboratories due to the complexity and cost of the required equipment and expertise. Planning must account for both the substantial investment in the in-house lab and the recurring costs of external testing.Table 2.1: Key Permissible Limits as per IS 14543:2024 (Selected Parameters) (Note: Limits are based on the latest available information referencing IS 14543:2024, IS 14543:2016/2004, related standards, and notifications. Direct reference to IS 14543:2024 standard document is recommended for definitive values.)

Parameter Category	Parameter	Requirement (Max Limit unless specified)	Reference Snippets (Illustrative)
Organoleptic & Physical	Colour	2 Hazen units
	Odour	Agreeable
	Taste	Agreeable
	Turbidity	2 NTU
	pH	6.5 - 8.5	(Range modified in revisions)
	Total Dissolved Solids (TDS)	500 mg/L	(FSSAI re-operationalized limits, check latest)
Microbiological	Escherichia coli	Absent in 250 ml
	Coliform Bacteria	Absent in 250 ml
	Pseudomonas aeruginosa	Absent in 250 ml
	Aerobic Microbial Count @ 20-22°C / 72h	100 per ml	(Test method updated in 2024 )
	Aerobic Microbial Count @ 37°C / 24h	20 per ml	(Test method updated in 2024 )
	Yeast & Mould	Absent in 250 ml	(Test method updated in 2024 )
General Chemical	Fluoride (as F)	1.0 mg/L	(Test method updated in 2024 )
	Chloride (as Cl)	200 mg/L	(Test method updated in 2024 )
	Sulphate (as SO₄)	200 mg/L	(Test method updated in 2024 )
	Nitrate (as NO₃)	45 mg/L	(Test method updated in 2024 )
	Calcium (as Ca)	75 mg/L	(FSSAI re-operationalized limits 20-75 mg/L; check latest. Test method updated in 2024 )
	Magnesium (as Mg)	30 mg/L	(FSSAI re-operationalized limits 10-30 mg/L; check latest. Test method updated in 2024 )
	Barium (as Ba)	0.7 mg/L	(Limit modified in revisions to align with WHO)
Toxic Substances	Arsenic (as As)	0.01 mg/L	(Limit modified in revisions to align with WHO, e.g., from 0.05 to 0.01. Test method updated in 2024 )
	Cadmium (as Cd)	0.003 mg/L	(Limit modified in revisions to align with WHO, e.g., from 0.01 to 0.003. Test method updated in 2024 )
	Lead (as Pb)	0.01 mg/L	(Test method updated in 2024 )
	Mercury (as Hg)	0.001 mg/L	(Test method updated in 2024 )
	Chromium (as Cr)	0.05 mg/L	(Test method updated in 2024 )
	Nickel (as Ni)	0.02 mg/L	(Test method updated in 2024 )
Pesticide Residues	Pesticide Residues (Individually)	0.0001 mg/L
	Total Pesticide Residues	0.0005 mg/L
Radioactive Residues	Alpha Emitters	0.1 Bq/L
	Beta Emitters	1 Bq/L

Packaging and Container Specifications IS 14543 lays down strict requirements for the containers used for packaging drinking water to ensure the water remains safe and uncontaminated until consumption. Containers must be:
Clean and Hygienic: Free from any physical, chemical, or microbiological contaminants.
Colourless and Transparent: Allowing visual inspection of the water. An exception exists for containers of 5 litres and above made of Polycarbonate (PC) or Polyethylene Terephthalate (PET), which may use BIS-specified pigments or colorants (IS 9833), provided the transparency remains above 85% light transmittance. Blue-tinted bottles, though sometimes seen, require adherence to these transparency norms.
Tamperproof: The container and its closure system must be designed to provide clear evidence if the seal has been broken. Containers like jugs with built-in taps or reusable jars with simple threaded caps that are not tamperproof are explicitly disallowed.

Permitted materials for manufacturing these containers, along with their corresponding Indian Standards, are :

Polyethylene (PE): IS 10146
Polyvinyl Chloride (PVC): IS 10151
Polypropylene (PP): IS 10910
Polyalkylene Terephthalate (PET and PBT): IS 12252
Polycarbonate (PC): IS 14971
Polystyrene (PS): IS 10142 (Less common for bottles)
Sterile Glass Bottles
Plastic containers conforming to IS 15410 (which consolidates requirements for various plastic materials in contact with foodstuffs).

A critical requirement is that all plastic packaging materials must pass the overall migration limit of 60 mg/kg (or 10 mg/dm²) and show no visible colour migration when tested according to IS 9845. This ensures that no harmful substances leach from the plastic into the water. Specific limits for heavy metal migration (e.g., Barium, Cobalt, Copper, Iron, Lithium, Manganese, Zinc, Antimony) and phthalates (DEHP) are also defined, often referencing FSSAI (Packaging) Regulations.For water packaged in flexible pouches (often made of polyethylene film), specific guidelines exist (detailed in Annex E of IS 14543:2004, likely carried forward or updated) covering aspects like protective outer packing, printing ink safety, storage conditions (cool, dry, dust-free, away from chemicals/odors), personnel hygiene during handling (gloves, masks), mandatory film sterilization before pouch formation (e.g., using certified UV lamps with usage monitoring), sanitization of contact parts, and clear storage/handling instructions for the supply chain and consumers.The stringent requirements for packaging materials mean that procurement is a critical control point. Manufacturers must source materials only from suppliers who can provide evidence (like test certificates) of conformity to the relevant IS standards. The bottling plant itself needs procedures to verify incoming material quality and ensure the integrity of the final packaging, especially the tamperproof seal.

Mandatory Marking and Labeling IS 14543, along with FSSAI and Legal Metrology regulations, mandates specific information to be clearly marked on each container :
Product Name: "Packaged Drinking Water"
Brand Name: (If applicable)
Manufacturer's Name and Complete Address:
Net Quantity/Volume: Must comply with standard pack sizes specified under the Legal Metrology (Packaged Commodities) Rules (e.g., 250ml, 500ml, 1L, 1.5L, 2L, 5L, and multiples of 5L thereafter).
Manufacturing Date (Mfg. Date / Pkd. Date):
Expiry Date / Best Before Date: The shelf life duration is determined and declared by the manufacturer based on their own stability studies and validation.
Batch Number or Code Number: For traceability.
FSSAI License Number: Displayed as per FSSAI labeling regulations.
BIS Standard Mark (ISI Logo): Must include the license number (CML No.) granted by BIS.
Declaration Regarding Remineralization: If minerals are added.
Storage Instructions: E.g., "Store in a cool, dry place away from direct sunlight and strong odors".
Material Identification Code: The type of plastic used (e.g., PET, PE) should be marked on the container/lid, often with the corresponding recycling symbol as per IS 14535.
Upcoming Requirement (from July 2025): Amendments to Plastic Waste Management Rules mandate PIBOs (Producers, Importers, Brand Owners) to include traceability information (Name, CPCB Registration number, etc.) via an on-pack barcode, QR code, or unique number, with details notified to CPCB.

Section 3: Phase-Wise Plant Setup Plan

Phase 1: Site Selection and Feasibility Analysis (Delhi Context) Selecting an appropriate site is the foundational step and involves navigating several layers of regulations specific to Delhi, alongside technical and logistical considerations.
Water Source Assessment: The primary input is raw water. Potential sources in or near Delhi include municipal supply (DJB - Delhi Jal Board), or groundwater (borewells). A critical regulatory hurdle arises if groundwater is the intended source. Extraction of groundwater for commercial purposes, including bottling plants, requires a No Objection Certificate (NOC) from the Central Ground Water Authority (CGWA). CGWA often designates areas as Over-exploited, Critical, Semi-critical, or Safe based on groundwater levels. Obtaining an NOC for new groundwater extraction in notified Over-exploited areas is generally prohibited for such industries. Therefore, verifying the CGWA status of the proposed location is paramount. If groundwater use is restricted, reliance shifts to municipal supply or other approved surface sources, impacting infrastructure needs and potentially raw water costs. Initial testing of the chosen raw water source for key physical, chemical, and microbiological parameters is essential to determine the required level of pre-treatment and the overall feasibility.
Location Criteria: Beyond the water source, several factors influence site suitability :
Market Proximity: Closeness to target consumer markets in Delhi reduces transportation costs and delivery times.
Accessibility: Good road connectivity for incoming raw materials (packaging, chemicals) and outgoing finished products.
Space: Adequate land area is required for the plant building, storage (raw materials, finished goods), utilities, office, laboratory, and vehicle movement. Indicative figures suggest around 5000 sq. ft. of built-up area (with 3000 sq. ft. covered) might be needed for a 2000 LPH plant.
Utilities: Availability of a reliable and sufficient power supply is critical. A 2000 LPH plant might require a connected load of around 65 HP (~49 kW). A dependable source of potable water for non-process uses (cleaning, sanitation) is also necessary. Efficient drainage and waste disposal infrastructure must be available or planned.
Environmental Conditions: IS 14543 hygiene guidelines mandate that the site should be free from objectionable odors, smoke, dust, pests, and other potential contaminants, and not be subject to flooding.
Delhi Zoning & Regulations: Land use in Delhi is governed by the Delhi Master Plan (MPD-2021). The proposed site must be located in an area zoned for industrial activity compatible with food processing/bottling. Compliance with zoning is often a prerequisite for obtaining consent from the Delhi Pollution Control Committee (DPCC). Additionally, some areas in Delhi are designated as 'redevelopment areas' under MPD-2021, which may have specific procedures or requirements for industrial consents. Verifying the exact zoning and redevelopment status of the potential site with relevant authorities (DDA, MCD, DPCC) is crucial.

The confluence of these factors – water source viability (especially CGWA restrictions), zoning compliance under MPD-2021, infrastructure availability, and DPCC regulations – makes site selection in Delhi particularly complex. A comprehensive feasibility study addressing all these points is indispensable before committing significant investment. Relying solely on groundwater without confirming CGWA approval status carries substantial risk.

Phase 2: Plant Layout and Design (Adhering to IS 14543 Annex B/G Hygiene Guidelines) Once a feasible site is identified, the next phase involves detailed planning of the plant layout and infrastructure design, with strict adherence to the hygiene requirements mandated by BIS IS 14543. This is not merely an operational consideration but a core compliance requirement verified during BIS inspections.
Layout Principles: The fundamental principle is to design a workflow that prevents cross-contamination. This typically involves ensuring a unidirectional flow of materials: raw water intake -> storage -> treatment -> filling/capping (high hygiene zone) -> labeling/packaging -> finished goods storage -> dispatch. The layout must provide adequate space for operations, cleaning, maintenance, and movement of personnel and materials.
Dedicated Areas: The plant must have clearly defined and physically separated areas for different functions to maintain hygiene and prevent mix-ups :
Raw Water Receiving and Storage Area
Water Treatment Plant Area
Quality Control Laboratory
Bottle Blowing Area (if applicable, separate from filling)
Bottle Rinsing, Filling, and Capping Room (maintained under positive pressure and highest hygiene standards)
Coding, Labeling, and Secondary Packaging Area
Storage Area for Packaging Materials (bottles, caps, labels, cartons - clean and protected)
Finished Goods Storage Warehouse
Utility Room (Boiler, Compressor, Electrical Panel, DG Set)
Personnel Change Rooms and Toilets (separate from processing areas)
Administrative Office
Hygiene Infrastructure (IS 14543 Annex B/G): The design must incorporate specific structural and facility requirements outlined in Annex B of IS 14543 (and assessed via Annex G checklist during inspection) :
Floors: Must be constructed of waterproof, non-absorbent, washable, non-slip, and non-toxic materials. They should be free of crevices and easy to clean and disinfect, with adequate slopes for drainage towards trapped gullies.
Walls: Similar requirements – waterproof, non-absorbent, washable, non-toxic, light-colored, smooth surface without crevices, up to an appropriate height for operations.
Ceilings: Designed and finished to prevent dirt accumulation, minimize condensation, mould growth, and flaking. Must be easy to clean.
Windows & Doors: Windows should be easy to clean, constructed to minimize dirt accumulation, and fitted with insect-proof screens if openable. Doors should have smooth, non-absorbent surfaces; where appropriate (like entering filling rooms), they should be self-closing and close-fitting. Air curtains or double doors are recommended for high-hygiene zones.
Lighting & Ventilation: Sufficient natural or artificial lighting must be provided throughout the plant. Adequate ventilation (natural or mechanical) is required to prevent excessive heat, steam condensation, dust, and contaminated air, ensuring air flows from clean to less clean areas.
Piping & Drains: All piping for water, effluent, and utilities should be installed so as not to contaminate water or impede cleaning. Potable water lines must be clearly identified and separate from non-potable lines, with no cross-connections. Drainage systems must be designed to handle expected loads and prevent backflow or pest entry.
Personnel Facilities: Adequate, separate, and conveniently located changing facilities and toilets must be provided. Toilets must not open directly into production areas. Hand washing facilities with warm/hot and cold running water, soap/disinfectant, and hygienic hand-drying means (e.g., paper towels, air dryers) must be available at strategic locations, especially at entrances to processing areas.
Pest Control: Buildings should be designed and maintained to prevent entry and harborage of pests (insects, rodents, birds).
Layout Submission: The detailed plant layout plan is a mandatory document required for both the BIS certification application and for obtaining DPCC Consent to Establish. BIS officers will physically verify the actual layout against the submitted plan during the factory inspection. Any deviations or non-compliance with hygiene design principles can lead to rejection or delays in certification. Therefore, meticulous planning and adherence to IS 14543 Annex B/G during the design phase is critical for project success.
Phase 3: Infrastructure and Civil Works Following the finalization and approval of the site and plant design, the construction or modification of the physical infrastructure begins.
Building Construction/Modification: The construction must strictly follow the approved layout plan. Materials used for floors, walls, ceilings, doors, and windows must meet the hygiene specifications outlined in IS 14543 Annex B. The overall construction should be sound, durable, and maintained in good repair to prevent structural failures or hygiene compromises.
Utilities Setup: Installation of essential utilities is carried out during this phase :
Power: Ensuring a stable and adequate electricity supply, including installation of transformers if required, and considering backup power through a Diesel Generator (DG) set.
Water Supply: Establishing connections for the raw process water source and a separate, reliable supply of potable water (meeting IS 10500 standards) for cleaning, sanitation, and personnel use.
Drainage and Effluent System: Constructing an efficient drainage system for process wastewater, floor washings, and sanitary waste, leading to an appropriate effluent management system (details in Section 9).
Waste Management Facilities: Allocating space and infrastructure for temporary storage of solid waste (packaging rejects, general waste) and potentially hazardous waste (used oils, lab chemicals) pending proper disposal.

Section 4: Water Treatment Process Implementation

The core of the plant is the water treatment system, designed to purify the raw water to consistently meet the stringent quality parameters of IS 14543:2024. The specific configuration may vary slightly based on raw water quality, but a typical multi-barrier approach is employed.

Process Flow Diagram & Description A representative process flow for a packaged drinking water plant is as follows :
Raw Water Intake & Storage: Water from the source (borewell/municipal) is received and stored in raw water tanks.
Pre-filtration:
Multi-Grade/Sand Filter: Removes larger suspended solids and turbidity.
Activated Carbon Filter: Removes chlorine (if present in municipal supply), dissolved organic matter, colour, and odour.
Dosing (Optional): Antiscalant chemical may be dosed before RO to prevent scaling on membranes if raw water has high hardness/scaling potential.
Micron Filtration: Cartridge filters (typically 5-10 micron, followed by 1 micron) remove finer particulate matter to protect the RO membranes.
High-Pressure Pump: Increases water pressure to overcome osmotic pressure across RO membranes.
Reverse Osmosis (RO): Semi-permeable membranes remove the vast majority (95-99%+) of dissolved salts (TDS), heavy metals, microorganisms, and other impurities. This stage produces two streams: purified water (permeate) and reject water (concentrate).
Permeate Storage: Treated water (permeate) from RO is stored in intermediate tanks.
Post-Treatment (Optional/Common):
pH Correction: If RO permeate is acidic, pH may be adjusted.
Remineralization: Food/pharma grade mineral salts (e.g., Calcium, Magnesium salts) are added to improve taste and meet potential minimum mineral requirements.
UV Sterilization: Water passes through a UV sterilizer where UV-C light inactivates any remaining microorganisms without adding chemicals.
Micron Filtration (Post-UV): A final polishing filtration step (e.g., 0.2 or 0.5 micron) before ozonation/filling.
Ozonation: Ozone gas is dissolved into the water for final disinfection and to provide a residual disinfectant effect in the bottled product.
Ozone Contact Tank: Water is held for a specific duration to allow sufficient contact time for ozone disinfection.
Point of Filling: Ozonated water is piped directly to the bottling machine.
Technical Specifications for Key Treatment Stages
Pre-treatment: Sand filters typically contain layers of graded sand and gravel. Activated carbon filters use granular activated carbon (GAC) with a high surface area. The size and capacity of these filters depend on the raw water flow rate and impurity levels. Regular backwashing is required to maintain filter efficiency.
Reverse Osmosis (RO): This is the primary purification barrier.
Operating Pressure: Must be sufficient to overcome the osmotic pressure of the feed water and drive permeate flow. For typical brackish water sources in India (TDS < 2000 ppm), operating pressures often range from 150-250 psi (approx. 10-17 bar) , though systems might be designed for higher pressures depending on specific membrane types and recovery goals. The required pressure increases significantly with higher feed water TDS.
Rejection Rate: Measures the percentage of dissolved salts removed. Modern Thin Film Composite (TFC) brackish water membranes typically achieve 95-99%+ salt rejection. This ensures the permeate water has very low TDS.
Recovery Rate: Represents the percentage of feed water converted into product water (permeate). For brackish water systems, recovery rates typically range from 60% to 85%. Higher recovery rates are more water-efficient but result in a more concentrated reject stream and require careful design to prevent membrane fouling/scaling. A significant volume of reject water, often 30% or more of the feed water (potentially 3-5 liters reject per liter product), is generated and requires management.
Remineralization: Post-RO water is often very low in minerals, affecting taste. Controlled addition of food/pharma grade calcium and magnesium salts is common. FSSAI regulations have specified desirable ranges (e.g., Calcium 20-75 mg/L, Magnesium 10-30 mg/L) for packaged water, making remineralization often necessary for compliance and consumer acceptance.
UV Sterilization: A critical disinfection step using UV-C light (typically at 254 nm wavelength) to damage the DNA of microorganisms, rendering them unable to reproduce.
Dosage: The effectiveness depends on the UV dose delivered, measured in millijoules per square centimeter (mJ/cm²). A minimum dose of 40 mJ/cm² is widely recommended for drinking water disinfection, sufficient to inactivate common bacteria, viruses, and chlorine-resistant protozoa like Giardia and Cryptosporidium. Higher doses might be targeted for specific resistant organisms or as a safety factor. The delivered dose is a function of UV intensity (lamp power, distance), exposure time (determined by flow rate and chamber design), and the UV Transmittance (UVT) of the water (clarity). Post-RO water generally has high UVT, allowing efficient UV disinfection. UV is also used for sterilizing packaging film in pouch filling machines.
Ozonation: The final disinfection barrier, providing a residual effect within the sealed bottle. Ozone (O₃) is a powerful oxidant generated on-site.
Concentration & Contact Time (CT Value): Effective disinfection relies on achieving a specific "CT" value (Concentration of disinfectant × Contact Time). Ozone is highly effective with a low CT value (around 0.4 for 99.99% kill) compared to chlorine (CT around 60). Industry recommendations typically involve applying ozone to achieve a dissolved concentration of 1.0 to 2.0 mg/L (ppm) in the water, with a contact time of 4 to 10 minutes in a dedicated contact tank. This aims to achieve a residual ozone level of 0.1 to 0.4 ppm at the point of bottling, ensuring disinfection of the water, bottle interior, and cap during the filling process. Ozone naturally decomposes back to oxygen, leaving no harmful residue if properly controlled.

The successful operation of this multi-barrier system requires precise control and monitoring. Pre-treatment protects the RO membranes. RO provides the primary purification. Post-RO remineralization addresses taste and mineral content. UV provides chemical-free primary disinfection. Ozonation offers final disinfection with residual protection in the package. Each stage's performance impacts the final product quality and compliance with IS 14543:2024.

Section 5: Automated Bottling and Packaging Operations

Once the water is treated to meet IS 14543 standards, it enters the automated bottling and packaging line, designed for high throughput, hygiene, and consistent product presentation.

Process Flow A typical automated line involves the following sequence :
Bottle Feeding: Empty bottles are fed onto the conveyor line, either from storage (if sourced externally) or directly from an in-house blow molding machine via air conveyors.
Rinsing: Bottles are inverted and rinsed internally, often with ozonated water or product water, to remove any dust or contaminants before filling.
Filling: Bottles are filled with the treated, ozonated water using high-speed, precision filling valves (often rotary fillers) to ensure accurate volume and minimize spillage and contamination.
Capping: Caps are automatically placed and sealed onto the bottles immediately after filling to ensure product integrity and tamper-proofing.
Coding: Filled and capped bottles pass through a coding machine (e.g., continuous inkjet or laser printer) that applies mandatory information like Batch Number, Manufacturing Date, and Expiry Date directly onto the bottle or cap.
Labeling: Bottles move to a labeling machine where brand labels (containing other mandatory information like BIS mark, FSSAI No., Net Quantity, etc.) are applied. Various technologies exist, such as wrap-around hot melt glue labeling (for BOPP labels), pressure-sensitive sticker labeling, or sleeve labeling.
Final Packaging: Labeled bottles are grouped (e.g., 12 bottles of 1L) and packed into secondary packaging, typically using an automatic shrink wrapping machine that bundles them in printed or clear plastic film. Cartons may also be used.
Palletizing: Packed cases may be automatically stacked onto pallets for storage and transport (optional, depending on scale). Integrated Rinser-Filler-Capper monoblock machines are common, combining these three critical steps into a single synchronized unit within a controlled environment to enhance hygiene and efficiency.
Bottle Manufacturing/Sourcing The plant can either manufacture its own PET bottles or source them from external suppliers.
In-house Manufacturing: Requires investment in PET Blow Molding Machines, along with supporting equipment like high-pressure air compressors, chillers, and bottle molds specific to the desired shapes and sizes. This requires sourcing PET preforms as the raw material. Offers greater control over bottle supply and design but adds complexity and cost.
Sourcing Bottles: Simpler approach, but requires careful supplier selection. Suppliers must guarantee that the bottles conform to the relevant IS standards (e.g., IS 12252 for PET) and migration limits, providing necessary documentation.
Rinsing, Filling, Capping This stage is paramount for maintaining water quality and safety. Rinsing ensures bottle cleanliness. Filling must be volumetric or level-controlled for accuracy and performed under hygienic conditions (often in a positive pressure room) to prevent airborne contamination. The capping process must apply the cap securely to create a leak-proof and tamper-evident seal, as mandated by IS 14543.
Coding and Labeling Accurate application of all mandatory information is a legal requirement. Coding machines must reliably print durable batch codes and dates. Labeling machines must apply labels accurately and securely, ensuring all legally required information (Brand, Manufacturer details, Net quantity, FSSAI No., BIS Mark with CML No., Vegetarian/Non-Vegetarian logo, Storage instructions, etc.) is clearly visible and legible.
Packaging Material Quality Standards (Preforms, Caps) The quality of primary packaging materials directly impacts product safety and integrity.
PET Preforms (if blowing in-house): Must be sourced from reputable manufacturers. They should be made from PET resin conforming to IS 12252 and suitable for food contact. Good quality preforms ensure uniform wall thickness, high clarity, and minimal defects upon blowing, reducing rejection rates.
Caps: Typically made from High-Density Polyethylene (HDPE) or Polypropylene (PP) conforming to food-grade standards (e.g., IS 10146 for PE, IS 10910 for PP). Caps must provide a secure, leak-proof seal and be compatible with the tamper-evident features of the bottle neck. Specific designs like Alaska caps (common for water bottles) or CSD (Carbonated Soft Drink) type closures exist. Rigorous quality control by the cap supplier is essential.
Final Product Packaging and Storage Secondary packaging (shrink wrap, cartons) protects the primary containers during handling and transport. Finished goods must be stored in a dedicated warehouse area that is clean, cool, dry, and protected from direct sunlight, pests, strong odors, and potential contaminants like chemicals or paints. Proper stacking and handling procedures should prevent damage to the packaging.

Section 6: Establishing the In-House Quality Control Laboratory

A crucial element for ensuring consistent product quality and compliance with IS 14543 is the establishment and operation of a well-equipped in-house quality control (QC) laboratory.

BIS Mandate for In-house Lab The Bureau of Indian Standards mandates that all manufacturers holding an IS 14543 license must establish and maintain an in-house laboratory. This laboratory must possess the necessary facilities, calibrated equipment, and qualified personnel to conduct the physical, chemical, and microbiological tests prescribed in the standard and its associated Scheme of Inspection and Testing (SIT). The adequacy of the lab is a key assessment point during BIS factory inspections.
Essential Laboratory Equipment Setting up the lab requires significant investment in various instruments and apparatus. Annex D of the IS 14543:2024 Product Manual provides an indicative list of required test equipment. While some highly specialized tests (like pesticides, radioactive residues, certain pathogens) might be outsourced to BIS-approved external labs, the in-house lab must be capable of performing routine and critical analyses frequently.Table 6.1: Mandatory Laboratory Equipment (Indicative List based on IS 14543:2024 PM Annex D)

Category	Key Equipment	Primary Purpose	Reference Snippets
Physical & Organoleptic	Nessler Tubes / Spectrophotometer	Colour comparison / measurement
	Nephelometer / Turbidity Meter	Measurement of Turbidity
	pH Meter (with electrodes)	Measurement of pH
	Conductivity Meter	Measurement of Electrical Conductivity (for TDS estimation)
	Analytical Balance	Precise weighing for TDS (Gravimetric), reagent prep
	Hot Air Oven	Drying samples (TDS Gravimetric), Sterilization
	Desiccator	Cooling dried samples (TDS Gravimetric)
	Water Bath	Temperature control for reactions/incubations
	Thermometer / Temperature Probe	Temperature measurement
	Beakers, Flasks, Pipettes, Cylinders	General glassware
Chemical (General & Toxic)	Titration Apparatus (Burettes, stands)	Volumetric analysis (e.g., Alkalinity, Chloride, Hardness - Ca, Mg)
	Spectrophotometer (UV-Vis)	Colorimetric analysis (e.g., Nitrate, Nitrite, Fluoride, Iron, Manganese, etc.)
	Hot Plate / Heating Mantle	Heating samples/reagents
	Magnetic Stirrer	Mixing solutions
	Advanced (May be outsourced initially)
	Atomic Absorption Spectrophotometer (AAS) with lamps/Graphite Furnace	Heavy metal analysis (Pb, Cd, Cr, Cu, Ni, etc.)
	Inductively Coupled Plasma (ICP-OES / ICP-MS)	Multi-element analysis (Metals, Minerals)
	Ion Chromatograph (IC)	Anion/Cation analysis (e.g., Fluoride, Chloride, Sulphate, Nitrate, Bromate)
Microbiological	Autoclave	Sterilization of media and glassware
	Hot Air Oven	Sterilization of dry glassware
	Incubators	Maintaining specific temperatures for microbial growth (e.g., 20-22°C, 37°C)
	Laminar Air Flow Chamber / Biosafety Cabinet	Providing sterile environment for microbiological work
	Microscope	Observation of microorganisms
	Membrane Filtration Assembly (Manifold, Funnels, Vacuum Pump)	Filtering water samples for microbial enumeration
	Colony Counter	Counting microbial colonies on plates/membranes
	Water Bath	Temperature control for media preparation/tests
	Weighing Balance	Weighing media and reagents
	pH Meter	Adjusting media pH
	Refrigerator	Storage of media and samples	-
	Glassware (Petri dishes, test tubes, flasks, pipettes)	Culture and testing
	Culture Media & Reagents	Specific media for different tests (e.g., PCA, Chromogenic Agar)

Scheme of Inspection and Testing (SIT) BIS mandates a detailed Scheme of Inspection and Testing (SIT) that licensees must follow. The SIT, outlined in the Product Manual for IS 14543:2024, specifies the parameters to be tested, the test methods to be used, the frequency of testing, the point of sampling (raw water, treated water, finished product, packaging), and the level of control required for each parameter. This forms the backbone of the plant's routine QC operations and record-keeping for demonstrating ongoing compliance to BIS.Table 6.2: Summary of Scheme of Inspection and Testing (SIT) for IS 14543:2024 (Illustrative Frequencies)

Stage / Material	Parameter Group	Examples of Parameters	Typical Frequency (as per SIT )	Level of Control
Raw Water	Organoleptic, Physical, Basic Chemical, Micro	Colour, Odour, Taste, Turbidity, pH, TDS, Key Microbes	Initial comprehensive testing. Then, periodic checks (e.g., Quarterly) for key parameters.	R (Record keeping), C (Calibration)
Treated / Finished Water	Organoleptic & Physical	Colour, Odour, Taste, Turbidity, pH, TDS	Each Control Unit / Batch / Daily	R, C, T (Testing)
	Disinfection Residual	Residual Free Chlorine / Ozone	Each Control Unit / Continuously / Frequently	R, C, T
	Microbiological (Key Indicators)	E. coli, Coliforms, P. aeruginosa, Aerobic Count	Each Control Unit / Batch / Daily	R, C, T
	Microbiological (Other Pathogens)	Yeast & Mould, Salmonella, Shigella, Vibrio etc.	Less Frequent (e.g., Weekly/Monthly/Annually - some may be outsourced)	R, C, T
	General Chemical (Undesirable)	Nitrate, Fluoride, Chloride, Sulphate, Ca, Mg, etc.	Weekly / Monthly / Quarterly	R, C, T
	Toxic Substances	Heavy Metals (As, Cd, Pb, Hg, Cr, Ni etc.)	Annually / Biennially / Less Frequent (often outsourced)	R, C, T
	Pesticide Residues	Individual & Total	Annually / Less Frequent (outsourced)	R, C, T
	Radioactive Residues	Alpha & Beta Emitters	Once in 5 years (outsourced)	R, C, T
Packaging Material (Bottles/Caps/Film)	Conformance to IS Standards	Dimensions, Material properties, Migration tests	Incoming material check (certificates), Periodic testing (e.g., Annually for migration)	R, C, T

(Note: 'Control Unit' typically refers to a defined quantity of production, e.g., one day's production or a specific batch size. Frequencies are indicative and should be confirmed from the official IS 14543:2024 SIT.)

This rigorous testing schedule underscores the need for efficient lab operations, reliable equipment, sufficient consumables, and meticulous record-keeping. All test records must be maintained systematically and made available for scrutiny during BIS surveillance audits.

Required Personnel Operating the QC lab effectively requires trained and qualified personnel. BIS mandates the appointment of competent individuals :
Chemist: Responsible for conducting physical and chemical tests. Requires a relevant degree (e.g., B.Sc./M.Sc. Chemistry).
Microbiologist: Responsible for microbiological testing. Requires a relevant degree (e.g., B.Sc./M.Sc. Microbiology). One competent person may handle both roles if qualified and if the workload permits. Their qualifications, experience, and competence are verified during BIS inspections. Supporting laboratory technicians may also be needed depending on the workload. Medical fitness certificates for laboratory staff and other workers handling water might also be required as part of overall hygiene compliance.

Section 7: Essential Machinery and Equipment

A packaged drinking water plant requires a range of specialized machinery for water treatment, bottling, packaging, quality control, and utilities. Procurement should focus on reliable equipment from reputable manufacturers, ensuring compatibility, efficiency, and compliance with hygiene standards.

Consolidated List The following table provides a checklist of essential machinery and equipment, consolidated from various sources describing plant components and vendor offerings.Table 7.1: Key Machinery and Equipment Checklist

Category	Equipment	Function	Reference Snippets
Water Treatment Plant	Raw Water Feed Pump(s)	Transfer raw water to storage/treatment
	Raw Water Storage Tank(s)	Buffer storage for raw water
	Multi-Grade / Sand Filter	Removal of suspended solids
	Activated Carbon Filter	Removal of chlorine, organics, odour, colour
	Dosing Pump(s)	Metering antiscalant, remineralization solutions, pH correction chemicals
	Micron / Cartridge Filter Housing & Elements (e.g., 10, 5, 1, 0.5, 0.2 micron)	Fine particle removal before & after RO/UV
	High-Pressure Pump (RO Feed)	Pressurize water for RO membranes
	Reverse Osmosis (RO) Skid (Membranes, Pressure Vessels/Housings)	Primary demineralization / purification
	Permeate / Treated Water Storage Tank(s)	Store RO permeate / blended water
	UV Sterilization System (Chamber, Lamps, Control Panel)	Disinfection using UV-C light
	Ozonator (Ozone Generator - Corona Discharge/UV)	Generate ozone gas for disinfection
	Ozone Contact Tank	Allow contact time for ozone disinfection
	Interconnecting Piping & Valves	Stainless Steel (SS 304/316) or UPVC for water lines
Bottling Line	Bottle Blowing Machine (Semi-auto / Fully Auto)	Optional: Produce PET bottles from preforms
	Air Compressor (High & Low Pressure)	If blowing bottles: For machine operation & blowing
	Chiller	If blowing bottles: Cool molds and compressed air
	Bottle Molds	If blowing bottles: Specific shapes/sizes
	Air Conveyor System	Transport empty bottles (esp. from blower)
	Rinser-Filler-Capper Monoblock (Rotary/Linear)	Integrated rinsing, filling, capping
	Cap Feeder / Elevator	Supply caps to the capper
	Belt Conveyor System	Transport filled bottles between machines
	Coding Machine (Inkjet / Laser)	Print batch code, dates on bottles/caps
	Labeling Machine (Hot Melt Glue / Sleeve / Sticker)	Apply labels to bottles
	Shrink Wrapping Machine (Semi-auto / Fully Auto)	Bundle bottles into packs
	Palletizer	Optional: Stack cases onto pallets
Laboratory	QC Lab Equipment	As listed in Table 6.1
Utilities	Electrical Control Panel(s)	Control and distribute power to machinery
	Backup Generator (DG Set)	Ensure continuous operation during power outages
	Boiler (Steam/Hot Water)	Optional: For hot water generation (cleaning/sterilization)
	Air Compressor (General Plant Air)	Provide compressed air for pneumatic controls/tools	-
Material Handling	Pallet Jacks / Hand Trucks	Manual movement of materials/pallets	-
	Forklift	Optional: For heavier lifting, pallet movement	-

Section 8: Navigating Regulatory Approvals in Delhi

Establishing a water bottling plant in Delhi requires navigating a complex web of licenses and approvals from various central, state, and local government bodies. Failure to obtain any mandatory clearance can halt the project or lead to legal penalties. Proactive planning and potentially engaging regulatory consultants are advisable.

Checklist of Mandatory Licenses The regulatory landscape involves multiple agencies. Obtaining all necessary permits is time-consuming and documentation-intensive.Table 8.1: Mandatory Licenses and Approvals for Water Bottling Plant in Delhi

License / Approval	Issuing Authority	Relevance / Notes	Reference Snippets
1. Business Registration	Registrar of Companies (RoC) / Local Registrar	Legal entity formation (Pvt Ltd, LLP, Partnership, Proprietorship)
2. FSSAI License	Food Safety and Standards Authority of India (FSSAI)	Mandatory for all food businesses, including water bottling. Central or State license depends on production capacity. BIS license often a prerequisite.
3. BIS Certification (IS 14543:2024)	Bureau of Indian Standards (BIS)	Mandatory product certification for packaged drinking water. Allows use of ISI mark.
4. CGWA NOC (Groundwater Extraction)	Central Ground Water Authority (CGWA)	Mandatory only if using groundwater (borewell). Subject to area notification status (may be denied in over-exploited zones).
5. DPCC Consent to Establish (CTE)	Delhi Pollution Control Committee (DPCC)	Mandatory before starting construction or installing machinery. Requires compliance with environmental norms & zoning.
6. DPCC Consent to Operate (CTO)	Delhi Pollution Control Committee (DPCC)	Mandatory before starting operations. Issued after CTE, plant setup, and verification of pollution control measures. Validity depends on category (likely 5 years for Orange).
7. Factory License	Chief Inspector of Factories, Govt. of NCT of Delhi	Required if the plant meets the definition under the Factories Act (typically based on number of workers and use of power).
8. Municipal / Trade License	Municipal Corporation of Delhi (MCD)	General license to operate a trade/business within municipal limits.
9. GST Registration	Goods and Services Tax (GST) Department	Mandatory for tax compliance (supply of goods).
10. Trademark Registration	Controller General of Patents, Designs and Trade Marks	Optional but highly recommended to protect the brand name.
11. EPR Authorization (Plastic Waste)	Central Pollution Control Board (CPCB)	Mandatory for Producers, Importers, Brand Owners (PIBOs) using plastic packaging. Requires registration and fulfilling recycling obligations.
12. Fire Safety Certificate / NOC	Delhi Fire Services	Mandatory, ensures compliance with fire prevention and safety norms.
13. SSI / Udyam Registration	Ministry of Micro, Small & Medium Enterprises (MSME)	Optional, for accessing MSME benefits, subsidies, schemes.
14. EPF / ESI Registration	Employees' Provident Fund Organisation (EPFO) / Employees' State Insurance Corporation (ESIC)	Mandatory if the number of employees crosses the statutory threshold (e.g., 10 or 20 depending on the Act).

The sheer number of agencies involved highlights the fragmented nature of the regulatory approval process. DPCC classification is particularly important; while lists "Mineralized water" under Green, lists "Mineralised Water/Water Treatment Plant" under Orange. Given the processes involved (RO reject, potential emissions), classification as Orange appears more likely and is a safer assumption for planning, implying stricter norms and a 5-year CTO validity versus 10 years for Green. Direct confirmation with DPCC based on the specific project details is recommended.

Step-by-Step Guidance for Key Approvals
BIS Certification (IS 14543:2024):
Application: Submit application (Form V) online via BIS portal with required fees.
Documentation: Upload supporting documents: Business registration, Factory layout plan, List of machinery, List of testing equipment & calibration details, Raw material details & test certificates, Process flow chart, In-house lab details, Quality control personnel details, Trademark certificate, Authorization letter, Location map etc..
Factory Inspection: BIS officer conducts on-site inspection to assess manufacturing infrastructure, production process, quality control system, hygiene practices (as per Annex G checklist), and verify documentation.
Sample Testing: Officer draws samples of finished product, which are sealed and sent to a BIS-approved laboratory for testing against all parameters of IS 14543:2024. Applicant bears testing charges.
Grant of License: If inspection report and lab test results are satisfactory, BIS grants the license, allowing use of the ISI Mark with the assigned CML number.
Timeline & Cost: Process can take several weeks to months. Costs include application fee (~₹1000), inspection fee (~₹7000), license fee (~₹1000), marking fee (variable), and sample testing charges (variable).
FSSAI License:
Registration/Application: Apply online on the FSSAI portal (FoSCoS). Choose State or Central license based on production capacity/turnover.
Documentation: Submit required documents: Business registration proof, Identity/Address proof, Plant layout, List of directors/partners, Machinery list, Water source details, Water test report (NABL accredited lab), FSMS (Food Safety Management System) plan, Supplier list, Form IX (Nomination of Person), etc..
Inspection: FSSAI officials may inspect the facility to verify compliance with food safety and hygiene standards (Schedule 4 requirements).
License Grant: Upon satisfactory verification, the license is issued.
Timeline & Cost: Typically 1-2 months. Fees range from ₹2000 to ₹7500 depending on license type and duration.
DPCC Consent (CTE & CTO - Assuming Orange Category):
CTE Application: Apply online on the DPCC portal before construction/installation.
CTE Documentation: Submit application form, consent fee, project report (detailing process, capital investment, pollution potential), site/layout plan, proof of land possession (ownership/lease), PAN card, authorization letter, undertaking, potentially proof of CGWA/DJB permission if applicable.
CTE Scrutiny & Grant: DPCC reviews the application for compliance with zoning, environmental norms, and proposed pollution control measures. CTE is granted if satisfactory. Validity is typically 1-7 years.
Plant Setup: Construct the plant and install machinery, including pollution control equipment (e.g., RO reject management system).
CTO Application: Apply online for CTO before commencing operations.
CTO Documentation & Inspection: Submit CTO application form, fees, CTE copy, proof of pollution control device installation, monitoring reports (if required, e.g., noise, effluent analysis), PAN, authorization letter, potentially proof of CETP membership (if applicable). DPCC officials will likely inspect the site to verify compliance and operational readiness of pollution control systems.
CTO Grant: If compliance is verified, CTO is granted, typically valid for 5 years for Orange category industries. Renewal is required before expiry.
CGWA NOC (If applicable):
Application: Submit application to CGWA online or through regional office.
Documentation: Requires detailed hydrogeological report prepared by an accredited consultant, site plans, water requirement details, water balance, conservation measures proposed, etc.
Assessment & Inspection: CGWA assesses the application based on groundwater availability, impact assessment, and area status (notified/non-notified). A site inspection may be conducted.
NOC Grant: NOC is granted with specific conditions on withdrawal quantity, monitoring, recharge, etc., if the application is approved and the area permits extraction.

Section 9: Operational Readiness

Beyond infrastructure and licenses, achieving operational readiness involves meticulous planning for manpower, raw materials, and waste management.

Manpower Planning The required workforce depends significantly on the plant's capacity (e.g., 2000 LPH vs. 5000 LPH) and the level of automation implemented. Based on industry norms and provided estimates , the following structure can be considered:Table 9.1: Estimated Manpower Requirements (2000 LPH / 5000 LPH)

Role	Key Responsibilities	Required Skills / Qualifications	Estimated No. (2000 LPH)	Estimated No. (5000 LPH)
Plant Manager	Overall plant operations, compliance, P&L	Degree (Engg./Food Tech.), Mgmt. Experience	1	1
Production Supervisor	Oversee daily production, scheduling, operator management	Diploma/Degree (Engg./Science), Supervisory Exp.	1	1-2
QC Chemist	Chemical & Physical testing (water, materials), documentation	B.Sc./M.Sc. Chemistry	1	1
QC Microbiologist	Microbiological testing (water, environment), media prep	B.Sc./M.Sc. Microbiology	1	1
Machine Operators (Treatment Plant)	Monitor & operate WTP (Filters, RO, UV, Ozonator)	ITI / Diploma, Experience with WTP	1-2	2-3
Machine Operators (Bottling Line)	Operate Blower (if any), Filler, Capper, Labeler, Packer	ITI / Diploma, Experience with bottling machinery	2-3	3-5
Maintenance Technician (Mech/Elec)	Preventive & breakdown maintenance of machinery	ITI / Diploma (Mechanical/Electrical)	1	1-2
Storekeeper	Manage inventory of raw materials, spares, finished goods	Graduate/Diploma, Storekeeping experience	1	1
Logistics / Dispatch Staff	Handle loading, dispatch, documentation	Basic education, organized	1	1-2
Sales & Marketing Staff	Market development, order booking	Relevant degree/experience	1-2	2-3
Admin / Accounts Staff	Office admin, accounts, HR coordination	Graduate (Commerce/Admin)	1	1-2
Helpers / Unskilled Workers	Loading/unloading, cleaning, general assistance	Basic education	2-4	4-6
Total Estimated			~15-20	~20-28

(Note: Numbers are indicative and depend on shift patterns, automation levels, and specific operational strategies. Competence of QC personnel is verified by BIS. Medical certificates for workers may be required.)

Raw Material Sourcing and Management Establishing a reliable and quality-assured supply chain for all necessary raw materials is vital for uninterrupted production and compliance.
Packaging Materials:
PET Preforms: If blowing bottles in-house, source from manufacturers ensuring conformity to IS 12252 and food contact safety.
Caps (HDPE/PP): Source food-grade caps providing secure, tamper-evident sealing, conforming to standards like IS 10146/IS 10910.
Labels: Source labels suitable for the chosen application method (glue, sleeve, sticker) and printing requirements.
Shrink Film / Corrugated Boxes: For secondary packaging.
Supplier Verification: Obtain test certificates from suppliers confirming compliance with relevant IS standards and migration limits. Implement incoming quality checks.
Treatment Chemicals:
Antiscalant: If required for RO feed water.
Remineralization Salts: Must be food-grade or pharma-grade.
Cleaning Chemicals: Specific chemicals for cleaning RO membranes, plant sanitation (must be food-grade where contact is possible).
Laboratory Consumables: Ensure continuous supply of validated reagents, microbiological culture media, glassware, and other lab necessities.
Inventory Management: Maintain adequate stock levels (e.g., 2-3 months' worth of key packaging materials suggested ) while ensuring proper storage conditions (clean, dry, cool, away from contaminants) to prevent degradation or contamination. Implement a First-In, First-Out (FIFO) system.
Waste Management Plan Effective waste management is a critical operational and regulatory requirement, particularly concerning RO reject water and plastic waste.
RO Reject Water Management: Reverse Osmosis typically rejects 30% to 70% of the incoming raw water volume, resulting in a significant stream of concentrated wastewater (RO reject or ROC). This reject water contains concentrated salts and any chemicals used in pre-treatment. A management plan compliant with CPCB and DPCC guidelines is essential. Options include:
Discharge to Sewer: Only permissible if the reject water consistently meets the general standards for discharge into public sewers stipulated by CPCB/DPCC (parameters include pH, TDS, specific ions like Fluoride, Iron, Manganese). This requires regular testing of the reject water.
On-site Reuse (Non-Potable): Utilizing the reject water for purposes like toilet flushing, floor washing, gardening/horticulture (requires assessment of TDS, Sodium Adsorption Ratio (SAR), Chloride, Boron levels to ensure suitability for soil and plants ), cooling tower makeup, construction activities (avoiding contact with reinforcing steel due to high chloride potential ), or dust suppression/coal/ash quenching in other nearby industries.
Treatment for Disposal/ZLD: If discharge standards cannot be met or reuse options are limited, treatment is necessary.
Evaporation Ponds / Solar Evaporation: Suitable in areas with high evaporation rates and available land, but may face challenges during monsoon.
Multi-Effect Evaporator (MEE) / Crystallizer: Advanced thermal processes to achieve Zero Liquid Discharge (ZLD) by evaporating water and recovering salts. This is capital-intensive but may be required to meet stringent discharge norms or ZLD mandates. DPCC may require a time-bound action plan and bank guarantee for MEE installation if ZLD is mandated.
Plastic Waste (EPR Compliance): As a Producer/Brand Owner introducing plastic packaging (PET bottles, caps, labels, shrink film) into the market, the plant falls under the Extended Producer Responsibility (EPR) regime of the Plastic Waste Management Rules, 2016 (and subsequent amendments). Compliance involves:
Registration: Obtain EPR registration on the centralized CPCB online portal. Registration for plastic waste was indicated as having lifetime validity.
Target Fulfillment: Meet annual targets for collecting and processing (recycling, reuse, end-of-life disposal) an equivalent amount of post-consumer plastic packaging waste corresponding to the quantity introduced into the market. This is typically achieved by engaging registered Plastic Waste Processors (PWPs) or Waste Management Agencies (WMAs). Agreements with PWPs/WMAs are required.
Record Keeping & Reporting: Maintain detailed records of plastic packaging introduced and waste processed. File annual returns on the CPCB portal.
Labeling: Comply with marking/labeling requirements, potentially including the upcoming QR code/barcode system for traceability.
Awareness Plan: Implement a waste management awareness plan. Failure to comply with EPR obligations can lead to Environmental Compensation (EC) charges levied by CPCB.
Other Waste: Establish procedures for segregation and disposal of other waste streams, such as rejected packaging materials, used filters, laboratory waste, chemical containers, and general office/plant waste, in accordance with local municipal and pollution control regulations.

Both RO reject management and EPR compliance represent significant ongoing operational responsibilities and potential costs. These must be factored into the business plan from the outset, not treated as afterthoughts. Achieving ZLD for RO reject, if required, represents a major technological and financial commitment. EPR necessitates establishing partnerships and systems for waste collection and processing.

Section 10: Preliminary Cost Estimation and Technical Specifications

This section provides an indicative financial overview and summarizes the key technical parameters for establishing a 2000 LPH or 5000 LPH BIS-certified packaged drinking water plant in Delhi.

Proposed Plant Capacity & Bottle Sizes The primary decision influencing scale and investment is the plant's production capacity, typically measured in Liters Per Hour (LPH) of treated water output. This report considers two common capacities: 2000 LPH and 5000 LPH. The product mix will likely include various PET bottle sizes conforming to Legal Metrology standards (e.g., 250ml, 500ml, 1 Litre, 1.5 Litre, 2 Litre) and potentially larger PET jars (e.g., 20 Litre) for bulk consumers.
Investment Breakdown Setting up a compliant water bottling plant requires substantial capital investment. The following table outlines the major cost components. Costs are highly indicative and can vary significantly based on location within Delhi (land cost), level of automation, choice of machinery vendors, building specifications, and specific regulatory requirements encountered. The estimates below attempt to synthesize data from various sources , but a detailed project report (DPR) based on specific quotations is essential for accurate budgeting.Table 10.1: Preliminary Cost Estimation (INR Lakhs) for 2000 LPH / 5000 LPH Plant in Delhi

Cost Head	Notes / Components	Estimated Cost (2000 LPH) (INR Lakhs)	Estimated Cost (5000 LPH) (INR Lakhs)	Reference Snippets
A. Fixed Capital
1. Land Acquisition / Lease	Highly variable in Delhi; assumes long-term lease or existing land	10 - 50+ (Lease/Purchase)	15 - 70+ (Lease/Purchase)
2. Building & Civil Works	~3000-5000 sq ft covered area; incl. hygiene features, warehouse, office, lab, utilities structure	20 - 40	30 - 60
3. Plant & Machinery	Water Treatment Plant (RO, UV, Ozone etc.), Bottling Line (Rinser, Filler, Capper, Labeler, Packer), Utilities (Compressor, Chiller if blowing)	25 - 50	40 - 80+	(Wide vendor variation)
4. Laboratory Setup	Equipment as per Table 6.1 (excluding high-end outsourced)	5 - 10	6 - 12
5. Utilities Setup	Electrical (Transformer, Panel, DG Set), Water Source (Borewell if permitted), Piping	5 - 10	8 - 15
6. Office Setup & Furniture	Basic office furniture, computers	1 - 3	2 - 4
7. Vehicles	Delivery Van(s) (Optional)	5 - 10 (if purchased)	8 - 15 (if purchased)
8. Pre-operative Expenses	DPR, Consultancy, Travel, Interest during construction	2 - 5	3 - 7
Sub-Total Fixed Capital (Indicative)		73 - 178+	112 - 263+
B. Working Capital (Initial Margin)
9. Licensing & Certification Fees	BIS, FSSAI, DPCC, CGWA, EPR, etc. (Initial + recurring aspects)	3 - 6	4 - 8
10. Initial Raw Material Stock	Packaging (Preforms/Bottles, Caps, Labels, Film), Chemicals (2-3 months)	5 - 10	8 - 15
11. Initial Operating Expenses	Salaries, Utilities, Maintenance, Marketing (3-6 months margin)	10 - 20	15 - 30
Sub-Total Initial Working Capital (Indicative)		18 - 36	27 - 53
TOTAL ESTIMATED PROJECT COST (Indicative Range)		₹ 91 Lakhs - ₹ 2.1 Crores+	₹ 1.4 Crores - ₹ 3.2 Crores+

Disclaimer: These figures are highly indicative estimates. Actual costs will depend heavily on specific choices regarding land, building quality, machinery supplier and automation level, and exact regulatory fees. A detailed financial analysis based on quotations is mandatory. Some sources suggest lower total costs , while older estimates are also in the ₹1.2 Cr range. Machinery costs alone show extreme variance in vendor quotes.

Key Technical Specifications Summary
Plant Capacity: 2000 LPH / 5000 LPH (Treated Water Output)
Raw Water Requirement: Approximately 3000-4000 LPH (for 2000 LPH product) / 7500-10000 LPH (for 5000 LPH product), assuming 50-70% RO recovery.
Treatment Technology: Multi-Grade Filtration, Activated Carbon Filtration, Micron Filtration, Reverse Osmosis, UV Sterilization, Ozonation, Optional Remineralization.
Bottling Line Speed (Indicative): ~30-40 BPM (for 2000 LPH) / ~80-100 BPM (for 5000 LPH), depending on bottle size.
Bottle Types/Sizes: PET Bottles (e.g., 250ml, 500ml, 1L, 2L), PET Jars (e.g., 20L).
Power Requirement (Indicative): ~40-60 kW (for 2000 LPH) / ~70-100 kW (for 5000 LPH).
Space Requirement (Indicative): ~3000-5000 sq ft Built-up Area.

Section 11: Conclusion and Strategic Recommendations

Summary of Critical Success Factors Successfully establishing and operating a BIS-certified packaged drinking water plant in Delhi is a complex undertaking requiring meticulous attention to multiple facets. Critical success factors include:
Unwavering Compliance: Strict adherence to the technical specifications, quality parameters, and hygiene guidelines mandated by BIS IS 14543:2024 is non-negotiable.
Regulatory Navigation: Proactively managing the intricate web of licenses and approvals from BIS, FSSAI, DPCC (CTE/CTO), CGWA (if applicable), CPCB (EPR), and local authorities is essential.
Robust Process Control: Implementing and maintaining effective water treatment processes (especially RO, UV, Ozonation) and rigorous quality control through a well-equipped in-house laboratory and adherence to the SIT.
Hygienic Plant Design: Designing the plant layout and infrastructure based on IS 14543 Annex B/G principles to prevent contamination and ensure operational hygiene.
Effective Waste Management: Developing sustainable and compliant solutions for managing RO reject water and fulfilling EPR obligations for plastic waste.
Sound Financial Planning: Accurate budgeting based on detailed project assessment, securing adequate funding, and managing operational costs effectively.
Quality Focus: Prioritizing consistent product quality and safety to build and maintain consumer trust, leveraging the ISI mark as a key differentiator.
Actionable Recommendations Based on the analysis, the following strategic recommendations are proposed:
Engage Expertise Early: Given the regulatory complexity in Delhi and the technical demands of IS 14543, engage experienced regulatory consultants and water treatment/plant design experts early in the planning phase.
Prioritize Site Feasibility: Conduct an exhaustive site feasibility study focusing on water source availability and legality (confirm CGWA status), compliance with Delhi's MPD-2021 zoning, DPCC requirements for the specific location, and infrastructure availability before finalizing the site.
Design for Compliance: Treat the plant layout and hygiene infrastructure design (based on IS 14543 Annex B/G) as a critical compliance activity, ensuring all requirements are met in the architectural and engineering plans.
Invest in Quality Machinery: Procure water treatment and bottling machinery from reputable vendors known for reliability, performance, and after-sales support. Ensure equipment meets food-grade and hygiene standards.
Establish Lab Capabilities Promptly: Plan and invest in the mandatory in-house QC laboratory from the project's inception. Procure necessary equipment and recruit qualified chemists and microbiologists well in advance of commissioning.
Develop Comprehensive Waste Plans: Formulate detailed, compliant, and costed plans for managing RO reject water (exploring reuse options before considering ZLD) and fulfilling EPR obligations (identifying and partnering with PWPs).
Create a Detailed Project Report (DPR): Move beyond preliminary estimates by developing a bankable DPR based on specific site conditions, vendor quotations for machinery, and detailed operational cost projections. This is crucial for accurate budgeting and securing financing.

Focus on Quality Culture: Instill a strong quality culture throughout the organization, emphasizing adherence to SOPs, hygiene practices, and the importance of the BIS certification and FSSAI regulations for long-term success and consumer trust.

Planning and Establishing a BIS-Certified Packaged Drinking Water Plant in Delhi (IS 14543:2024 Compliant)

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