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Projects  /  Hydracycle  /  Industrial design

Hydracycle

A greywater recycling system that fits an apartment and needs no new plumbing

DisciplineIndustrial design
ScopeFinal year project, SADA NUST
Year2025
Made withSolidWorks, KeyShot
Hydracycle unit, final render
01Brief02Research03Benchmark04Users05Ideation06How it works07Architecture08Specification09Variants10Making11Prototype12In place13Outcome
01
Brief & objective

Water clean enough to use twice

The problem

Around 70% of what a Pakistani household drains is greywater, sink, shower and washing machine water that never touched sewage. It leaves the house clean enough to flush a toilet with.

01Per capita water has fallen from 5,260 m³ to under 900 m³
02Existing recycling systems need plumbing work a renter cannot do
03Tanks and treatment plants do not fit a two-bedroom flat
04Nobody knows how much water they are actually throwing away
The objective

One appliance-sized unit that sits where a washing machine sits, takes greywater in at the trap, and gives it back for flushing, gardening and laundry.

01Fits an apartment, 400 × 300 × 900 mm, floor-mounted
02Connects to existing plumbing, no structural work
03Treats 100-150 litres a day, biologically then physically
04Sensors report level and quality, and ask for service
02
Research

A country running out of water

Pakistan crossed the water scarcity threshold years ago and is still falling. These numbers set both the case for the product and its size.

860 m³Per capita water in 2023, down from 5,260 m³ in 1951, PCRWR
70%Share of household wastewater that is greywater, UNEP, 2020
150-200 LWater an urban household uses per day, WASA
50%Of that could be reused with basic recycling, World Bank
SourceShareReusable for
Showers45%Toilet flushing, gardening
Sinks & basins25%Toilet flushing, cleaning
Dishwashers20%Toilet flushing, gardening
Washing machines10%Toilet flushing, laundry reuse

Estimates for urban households. Showers and sinks carry the volume; the washing machine is the easiest to plumb into.

Run the numbersDrag the household size and watch what a house throws away.
4people
Water used a day160 L
Of that, greywater112 L
Flushing and gardening it could cover72 L
That is 26 m³ a year going down the drain, at 40 L per person a day and greywater at 70% of it.
03
Benchmark

Every system that works costs more than the house saves

I took four systems apart on paper: what they recover, what they cost landed, what they ask of the owner. The technology is settled; the access is not.

Everything effective sits above $4,000 and needs a professional install into pipes a renter does not own. Diverter valves at $50-200 move water but treat none of it. That gap is the brief: treatment at a domestic price, plumbed in without touching the wall.

SystemCostRecoveryLimitation
Hydraloop 300~$4,000 excl. installCuts household use ~45%Cost puts it out of reach; fixed size
Aqua2Use$500-1,000Recycles up to 75% dailyFiltration only, no treatment for reuse indoors
Aquacell$6,000-8,000 installedRecovers up to 70%Building-scale; too large for an apartment
GreenLife$4,500-6,000 installedRecycles up to 80%Complex install, high maintenance cost
Diverter valves$50-200Diverts up to 50%Moves greywater, treats none of it
04
Users

Four households, one bill

Interviews across Karachi, Lahore, Islamabad and Peshawar, renters, owners, students. None owned the pipes they wanted to change.

What separated them was permission and skill, not willingness. It had to work for someone who cannot drill a wall and should not have to learn what an MBBR is.

Zara KhanArchitect, 29, Karachi
Rented two-bed with her partnerHigh water bills, no reuse options, wants sustainable living without a complex install
Ahmed KhawarSchool teacher, 35, Lahore
Owns a small home, two kidsRising utility bills, summer shortages, little awareness of reuse systems
Yasir MehmoodEngineer, 45, Islamabad
Smart home, solar and IoTWants everything integrated and monitored, dislikes waste
Alina RaufStudent, 22, Peshawar
Shares a flat with a friendLimited water access, no plumbing skills, no space
05
Ideation

Two hundred thumbnails to find a form worth living with

Ideation ran in two passes. The first worked the system out: where greywater is collected, how filtration, storage and control stack, and what fits under a sink or beside a washing machine.

The second pass was form. Trolleys, backpacks, bins and appliance shapes against the same internal volume, until it settled on a fluted body on castors, domestic equipment, not plant machinery.

Hydracycle ideation sheets, system diagrams, module studies and form exploration
Ideation sheets, system and module studies on the left, form exploration to the resolved body on the right
06
How it works

Seven stages, inlet to outlet

Greywater enters at the trap, drops its solids, then meets biofilm carriers that eat the organic load. Air flotation lifts the remaining soap and grease off the top.

The filter model adds a final physical stage; the filterless one relies on biology and flotation alone. Treated water waits in the tank until a toilet or tap asks for it.

01
Greywater intakeWater enters through the inlet pipe from sink, shower or machine
02
Pre-filtrationLarge particles, hair and lint are trapped before anything else
03
MBBR chamberBiofilm carriers degrade the organic matter
04
Foam fractionation & air flotationSoap, grease and light particles are floated off
05
Filtration chamberFinal physical filtration, filter-based model only
06
Water storage tank20-40 L of treated water held for reuse
07
Outlet controlSolenoid-regulated release to toilets or irrigation
Flow rate8-10 L/min average
Daily capacity100-150 litres treated per day
Reuse yield60-100 L/day depending on version
Filtration efficiency85% on the filter model
Lifespan5-7 years with maintenance

Tested with simulated greywater from detergent and washing cycles.

07
Architecture

Nine parts and a material for each

The body is Alucobond, light, corrosion-proof, foldable on a press brake, which is what made a one-off prototype possible. Everything wet is HDPE or stainless.

Chambers stack on a stainless base plate with adjustable footings, so an uneven floor does not put the unit out of level.

Exploded view of the Hydracycle unit with material callouts
Rendered part set, casing panel, filtration column, storage tank, base plate and plumbing
Part set, rendered apart, casing panel, filtration column, storage tank, base plate and the inlet plumbing
01
Outer bodyAlucobond, 400 × 300 × 900 mm
02
Filtration tankHDPE, ⌀160 × 500 mm
03
MBBR chamberHDPE, ⌀160 × 500 mm, biofilm carriers inside
04
Base plateStainless steel, custom-fit with adjustable footings
05
Water storage tankHDPE, 20-40 L food grade
06
Pipes & drainagePVC, 25 mm and 40 mm
07
SensorsFloat, level and turbidity / TDS
08
Control buttonsABS, mode, reset, power
09
FittingsSS316 throughout the wet path
08
Specification

What is inside the unit

400×300×900Body, in millimetres
100-150 LTreated per day
20-40 LStorage tank
MBBRPlus air flotation
ComponentTypeFunction
Power supply unit·Converts 220-240 V AC to operating voltage
Water level sensorFloatMonitors level in each chamber
Water quality sensorTurbidity / TDSFeeds efficiency back to the controller
Control PCB·Processes sensor data and commands
Solenoid valve·Regulates flow between chambers and outlet
Indicator LEDs·Full, low water, power, service
Toggle buttonsABSMode, reset and power
Wiring & connectorsInsulatedConnections between components
09
Variants

Three sizes, two ways of treating

The unit is sold against the fixture it sits next to, kitchen sink, washing machine or washroom. That decides the inlet, the footprint and the volume.

Each of the three comes filter-based or filterless. Filterless drops the final stage and the monthly cartridge with it, at some cost in efficiency.

Kitchen sinkKS-001-F / KS-001-NFUnder the counter, beside the trap. The smallest inlet and the dirtiest water.
Washing machineWM-001-F / WM-001-NFStands next to the machine at the same height. Cleanest source, easiest reuse loop.
WashroomWR-001-F / WR-001-NFBetween basin and cistern. Shortest run from treated water back to a flush.
10
Making

Folded, welded, bolted

Panels are CNC-cut and folded from Alucobond, chambers moulded HDPE, base frame laser-cut and MIG-welded. No process a Lahore workshop does not already run.

Assembly is six stages: base and footings, chambers, piping, electronics, casing, then a leak and power-up test.

PartMaterialProcess
Outer body panelsAlucobondCNC cutting, folding and bonding
ChambersHDPE / FRPRotational or injection moulding
Base frame & footingsStainless steelLaser cutting and MIG welding
MBBR flow cylinderHDPEExtrusion and thermal welding
Screws and fastenersSS316Pre-machined
Sensor housingsABSInjection moulding
Alucobond bodyLightweight, corrosion-proof, weather-resistant, and it folds, which is why the prototype exists
HDPE tanks & pipesDurable, non-toxic and UV-resistant, food grade where treated water is stored
Stainless steelHolds up in a permanently wet enclosure, carries the load of full chambers
ABS controlsLight, cheap and durable enough for a button pressed twice a week
11
Prototype

Built in the workshop

I built the working prototype by hand in the last weeks: panels folded on the press brake, stainless frame welded, acrylic chambers bonded and pressure-checked.

The lab rig at IESE gave the media a reference to work against. Everything else came from hardware shops, submersible pump, push-fit connectors, a ball valve.

Multi-chamber filtration rig at IESE
The IESE lab rig, the media reference
Ball valve and push-fit connectors
Valves and push-fit connectors, laid out
Submersible pump and tubing on a bench
Pump, tubing and fittings sourced locally
Alucobond panel at a press brake
Alucobond going through the press brake
Folded Alucobond body
The body, folded on three sides
Welded stainless chamber
Stainless chamber, seams welded and sealed
Two bonded acrylic cylinders
Acrylic cylinders bonded and checked for leaks
Acrylic chambers with brass fittings
Chambers tapped for brass push-fit inlets
Internal frame inside the casing
Internal frame and brackets, from above
Casing on castors with shelves fitted
Shelves fitted, casing on castors
Assembled frame with chambers and storage bottle
Full stack, chambers above, storage below
Finished casing taped up
Casing masked before finishing
Finished Hydracycle prototype, closed
The finished unit, fluted door, castors, inlet hose run to the sink
Hydracycle prototype with the door open, showing the internal stack
Door open, filtration column above, media chamber and storage tank below
12
In place

Where it stands

Appliance proportions on purpose, the unit is meant to read as a thing that belongs next to a washing machine, not as equipment.

Hydracycle under a kitchen counter beside the sink
Kitchen, under the counter, beside the trap
Hydracycle beside a washing machine
Laundry, same height as the machine it feeds from
Hydracycle in a bathroom beside the toilet
Washroom, shortest run back to a cistern
13
Outcome

What it saves

40%Reduction in household water wastage
60-100 LGreywater reused per day
85%Filtration efficiency, filter model
5-7 yrsService life with maintenance

Installation is four levelling footings, an inlet and an outlet. Filters are cleaned monthly; sensors self-calibrate, and an alert light handles clogs and overflow.

On the bill, that is roughly a quarter off an urban household’s water cost, with payback in three to five years, the number that decides whether any of this gets bought. The project sits against SDG 6 and SDG 9.

Hydracycle app, final screens
Companion projectThe app that monitors it
Hydracycle App
Hydracycle, final render
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