Distilleries are one of Agro based industries which produces several types of liquors to serverncommunities as a drink, feedstock for other industries and power alcohol. While producing thesernvaluable products for consumption more than 6 times effluents with high COD and BOD values hasrnbeen produced. This effluent will cause huge disaster on environment if it is discharged withoutrntreatment. On the other hand treating such huge quantity of effluent will incur additional cost to thernproduction processes of the distilleries. Therefore, this study is conducted with the view of reducingrnthe volume of effluent generated through proper nutrient application and optimum recirculation ofrneffluent to fermenters.rnThis study was conducted first by making an optimization of macronutrients for the existingrnfermented wash sugar concentration of 15 brix and application of 62.51 and 14.51 mg/L of washrnfor Urea and DAP respectively has been found an optimum. Using this optimum nutrient dosage testrnfor effluent recirculation were conducted for the existing fermentable sugar concentration of 8.67%rn(15 brix). Data of alcohol% fermented wash, yeast cell mass count and residual sugar were generatedrnand analyzed using response surface methodology and application of 1% spent wash, 92% spentrnlees and 99% of the generated effluents were found to be safely re-circulated to fermenters.rnAnticipating future change in operating conditions of fermentation process the study has beenrnconducted at different fermentable sugar concentration of 8.67%(15 brix), 11.5%(20 brix) and 14.3%rn(25 brix). Data are generated and analyzed using response surface methodology and it was foundrnthat fermentable sugar concentration of 14.3%(25-brix), macro nutrients of 62.51mg/L Urea andrn31.26 mg/L DAP, recirculation of the generated 50% of spent wash, 68.5% of spent lees and 85.83%rnof process condensate taken as an optimum input and alcohol % fermented wash of 7.43, yeast cellrnmass of 2.40674E+008 and residual sugar concentration of 0.417% are found as a response variable.rnDetermination of different attribute of rectified sprit produced by using an optimum recirculationrnrate of effluent to fermenters and it is found in safe range from food safety and quality points ofrnview. Besides, sizing of equipments such as cooler, pump and piping required to handling effluentrnrecirculation were done. Moreover, financial analysis was carried out and it was found viable. Thernstudy shows that the initial investment will be fully returned within eleven months.