Faecal Sludge (FS) produced in developing countries has become a significant source of water pollution. The optimal treatment of FS can lead to a sustainable economy. In India, the second phase of the open defecation free (ODF) initiative (energy recovery by providing city- or town-level centralised FS treatment plants) has begun from 2019 to sustain millions of toilets. However, to achieve this goal, India must address significant knowledge gaps such as the type of available on-site sanitation treatments (OSTs), optimal time of emptying the OSTs, and variations in the FS characteristics with age. Thus, the present study analysed FS samples collected from Vadgaon Maval, Maharashtra, India, to understand the inter- and intra-variation in FS characteristics. The pH, electrical conductivity, total solids (TS), specific gravity (SG), organic matter (OM), chemical oxygen demand (COD), and pathogen content of FS samples were observed to be in the range of 7–7.65, 1.19–4.01 mS/cm, 1–123 g/L, 0.88–1.26, 18.4%–100%, 960–6080 mg/L, and 105–109 number/L of FS, respectively. The inter-variation of FS characteristics exhibited that the pH, EC, TS, and SG increased, whereas OM, settling, and drying capacity decreased with an increase in age. Fresh FS (excreta degraded for ≤3 years) was yellowish-brown in colour and exhibited low TS, low SG, and high OM. On the other hand, older FS (excreta degraded for >3 years) was blackish-brown in colour and exhibited high TS, SG, and pathogen content. This observation indicates that FS vacuum pumping may be difficult in the sludge zone after 3 years of excreta degradation, which may encourage the manual scavenging practice. Additionally, the analysis of FS treatment plant (FSTP) process control parameters (settled sludge volume, sludge volume index, and sludge drying capacity) indicated that the treatment time required for older FS is long, which increases the FSTP cost. Furthermore, FS intra-variation in OST exhibited that effluent FS could be directly sent for effluent treatment without any solid–liquid separation process. Thus, the present study can help practitioners in establishing or modifying FS treatment systems for addressing conditions based on the variation in FS characteristics at the town level in India. © 2021 Elsevier Ltd