Thin film composite (TFC) reverse osmosis membrane containing polyamide active layer on porous polysulfone support was developed at the scale of 1 m width x 100 m long in a batch using semi-automated mechanical casting and coating machines. The polysulfone support was made according to phase inversion method at the rate of 3-6 m/min., and the polyamide active layer on the polysulfone support was prepared by interfacial polymerization method at the rate of 0.3-0.5 m/min under different conditions. Since desalination of brackish water does not require the membrane with very high salt rejection efficiency, emphasis was placed on increase in the flux while maintaining the salt rejection at 94 +/- 2%. The membrane preparation conditions and structure-performance relationships were correlated by different techniques like porometry, infrared spectra, scanning electron microscopy and atomic force microscopy. The TFC membranes exhibited 94-96% salt rejection with water flux of 50-65 L/m(2).h when tested with 5000-1500 ppm salt solution at 250 psi. Surface modification of the TFC membrane with polymers containing hydrophilic groups was carried out to impart fouling resistance. Spiral modules of 4040 and 8040 size were made and tested them extensively in the field conditions in 500-2000 LPH brackish and sea water desalination plants. (C) 2011 Elsevier B.V. All rights reserved.