In a city grappling with water shortages and erratic monsoons, a Central government industrial facility in Bengaluru has quietly achieved what many private and public sector units struggle to implement—a self-sustaining, closed-loop water management system.
The Rail Wheel Factory (RWF), located in Yelahanka, has emerged as a benchmark in industrial water efficiency, significantly reducing its dependency on municipal supply through comprehensive rainwater harvesting and groundwater recharge mechanisms.Once reliant on the Bangalore Water Supply and Sewerage Board (BWSSB) for nearly 200 kilolitres of water daily, the 191-acre facility has, since 2019, achieved complete self-sufficiency for its production needs. The plant now harnesses up to 1,600 kilolitres of water every day in a circulation system that cools the high-heat furnaces used to forge railway cast wheels and axles. Around 200–300 kilolitres evaporate during this process and are replenished using rooftop-harvested rainwater, eliminating the need for fresh water from external sources during most of the year.
At the heart of this transformation is an intricate network of rooftop harvesting tanks, stormwater drains, and filtration systems. Rainwater is filtered through mesh grates and gravity-settling chambers before entering five main tanks, from where it is routed directly into the plant’s cooling systems without the need for pumping. This design not only conserves water but also saves significant energy, contributing to the factory’s sustainability goals.Established in 1984 under the Ministry of Railways, RWF is one of just two foundries in India producing cast steel wheels for freight trains. Foundries are typically resource-intensive and pose significant environmental challenges. Yet, RWF has turned this perception on its head by investing in long-term, low-tech but effective eco-interventions.
Beyond rooftop systems, the factory has converted its low-lying areas into three acres of catchment ponds and revived six old wells—once filled with debris—which now act as vital reserves. These ponds are fed by stormwater drains equipped with check dams and a four-stage gravel-based filtration system. Even in peak summer, the two main wells—Damodar and Kandaswamy—remain more than half full, supported by feeder wells that enhance recharge capacity and reduce the need for mechanical pumping.Despite being a government entity without access to Corporate Social Responsibility (CSR) funds, RWF’s initiative is internally financed and driven by its staff. Employees contributed hands-on labour during the installation phase, operating machinery and even digging recharge pits, underlining the factory’s culture of sustainability and civic responsibility.
In addition to water conservation, the factory has installed a secondary fume extraction system to curb air pollution. Dust and particulate matter generated during casting are extracted through large ducts and filtered before the air is released into the atmosphere.Looking ahead, RWF plans to desilt its pond beds, interconnect all recharge systems, and deepen storage areas to enhance rain capture. Discussions are underway to collaborate with non-profit organisations for future environmental upgrades.
The success of the Rail Wheel Factory signals what is possible when legacy industries embrace sustainable practices. In an era of growing climate uncertainties, it offers a compelling model for public-sector industries across India to decouple their operations from stressed civic water infrastructure.
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