Safe drinking water is a basic criteria for good health and groundwater is the major source of drinking water. Reverse Osmosis (RO) is routinely used for removal of TDS with sacrificing huge volume of water. Electrochemical scale removal has also been recognized, where Ca and Mg bicarbonates settle as CaCO3 and Mg(OH)2 respectively. The existing electrochemical method removes only temporary hardness and also could not be scaled up due to the poisoning of diaphragm and evolution of chlorine gas. The developed technology successfully removes both temporary and permanent hardness (partial) of water, and also chlorine evolution is prevented using zero-gap electrolyser. Zero gaps are maintained using microfiber mesh as diaphragm and diaphragm poisoning is prevented by inserting polypropylene mesh between electrode and microfiber mesh. The developed method is successfully scaled up and a 250 L capacity TDS removal plant has been set up at NCCCM/BARC, Hyderabad. Commercially available, cost-effective electrodes such as graphite and stainless steel mesh have been used as anode and cathode respectively. The zero-gap electrolysis set up reduces TDS from ~ 1000 to 500 mg/L of 200 L water in 8 h (9A with cell potential of 7 V) with current density of 4.6 and 3.6 mA cm-2 for cathode and anode respectively. The power consumption for treatment of 1000 L water (TDS 1000) is found to be 2.5 kWhr.