Interview with Magpet Polymer: Closing the Loop with New Bottle-to-Bottle-Recycling Plant

Question: What field of business are you in?

Devendra Surana: Magpet is part of Magnum Group, one of the leading manufacturers of flexible plastic packaging products in India. Since our foundation in 1978 we’ve continuously expanded our business both in terms of revenue and products. Today, we provide a broad range of PET preforms for all kinds of bottles, jars and containers. The materials are food-graded and thus comply with the highest possible safety standards.

Question: What is your vision for the future?

Devendra Surana: Being progressive is part of our company DNA. This includes adopting new technologies and gradually expanding our expertise. As a family-owned enterprise, we listen carefully to the market and identify fields where we can make a difference. In many ways, plastics recycling is still in its infancy, even though the potential is there! As a result, it is a logical step for us to offer plastics packaging made from high-quality recyclates. We are convinced that recycled materials are becoming more and more important in the future, and we can contribute to this trend as a reliable partner to our customers. The plastic materials recycled with our new Coperion-Herbold system are approved by the European Food Safety Administration (EFSA) and the U.S. Food and Drug Administration (FDA). Moreover, the material is brand owner approved which is another positive sign for all of our food customers. Therefore, we comply with the highest food safety standards worldwide.

Question: Why did you decide on Herbold Meckesheim and Coperion equipment?

Devendra Surana: Herbold and Coperion demonstrated their strength in offering an integrated system which ensures that all production steps are optimally aligned. The set-up includes shredding and washing equipment from Herbold Meckesheim, a twin screw extruder as well as material handling equipment from Coperion and several feeding solutions from Coperion K-Tron. The complete system is not only reliable, but also allows us to gain an advantage in terms of efficiency and cost savings. Recycling processes are still relatively complex compared to the production of virgin polymers. With the integrated solution from Herbold and Coperion, we are in the position to save on operating costs, logistics costs, and energy consumption. In addition, Herbold and Coperion are very dedicated to continuous improvements and innovations. This does not only match our philosophy but is also valuable for potential modernizations in the future. For us, buying the entire recycling line from one source was definitely the right choice. 

Question: Why do you think twin screw extrusion technology is ideal for recycling processes?

Indroneel Goho: In my opinion, twin screw extruders have a number of advantages. Two decisive factors for us were the gentle handling of the product as well as its potential in terms of throughputs. Thanks to the ZSK twin screw extruder’s high 18 Nm/cm³ torque, the PET’s residence time in the extruder is short which leads to minimal polymer chain degradation. This makes sure that our recycled products meet our high-quality requirements. Furthermore, the ZSK twin screw extruder is extremely powerful. Our current set-up is designed for a throughput of 5,500 kg/h.

Question: How do you source the raw material?

Indroneel Goho: Sourcing raw material for a PET recycling plant typically involves several steps and partnerships to ensure a steady supply of post-consumer PET (polyethylene terephthalate) bottles. Therefore, we will make use of several methods.

Collaboration with waste Aggregators & waste pickers: 

• Waste Aggregators and Middlemen: We are collaborating with waste aggregators and scrap dealers who buy post-consumer PET from waste pickers and other informal waste collectors.
• Waste pickers/Informal sector: We are building direct relationships with waste pickers or NGOs that work with the informal waste sector to collect PET bottles. This does not only help secure raw material supply but also creates social impact by improving their income and working conditions.

SmartBins with the objective of boosting the collection, awareness & community drive:

• We’re installing our SmartBins in strategic locations like residential areas, schools, hospitals, supermarkets and malls, to encourage consumers to return used PET bottles.
• We’re running campaigns and awareness programs like #BeAGreenAmbassador and #EcoRevive to encourage consumers to recycle PET bottles properly and earn green reward points. This can lead to a higher rate of direct collection from the general public.

Contracting with waste management firms:

• Many waste management companies already segregate and collect plastic waste. Collaborating with these firms ensures a steady flow of PET bottles directly to the recycling plant. We have collaborated with Sahaas Zero Waste Management Company & Recykal.

Partnerships with brand owners/producers:

• Under EPR regulations, brand owners or manufacturers of PET products are responsible for ensuring the collection and recycling of post-consumer plastic. As a recycler, we form partnerships with these brands to source the material directly from them or their collection partners.
• Take-back programs: Some brands run their own take-back programs where consumers can return used PET bottles. We partner with such brands to access the returned bottles.

Direct collection from events & industries:

• Event collection programs: Partnering with event organizers (sports events, concerts, festivals) to collect PET bottles at the event sites.
• Industrial PET waste: We’re collecting scrap from PET bottle manufacturing plants or other industries that generate PET waste during their production processes.

Municipal waste collection systems:

• We’re partnering with local municipalities or waste management companies to collect used PET bottles from households, businesses, and public spaces.

By utilizing a mix of these sourcing strategies, we can secure a reliable and consistent stream of raw materials to operate at scale. Initiatives like our SmartBins and partnerships with waste pickers and local communities align well with sustainable sourcing strategies.

Thank you for these interesting insights. We wish you all the best for expanding your recycling business and look forward to a close partnership in the upcoming years.