Industry Overview
Poly-Ethylene Terephthalate (PET) is one of the most widely used plastics, with PET bottles extensively used for mineral water, soft drinks, and other applications. After use, PET bottles retain significant material value and can be recycled into a range of products. Post-consumer PET bottles are collected by waste collectors and purchased by kabadiwallahs or waste traders, who arrange segregation, sorting, and further sale to vendors or recyclers. Non-PET components such as caps, neck rings, and labels are removed before the bottles are shredded and washed to produce recycled PET (r-PET) washed flakes.
Washed flakes are predominantly used to manufacture polyester fiber, which serves as filling material for cushions and pillows and can also be converted into fabrics for clothing and upholstery. A smaller proportion of recycled PET is used to manufacture PET straps, monoYarn, sheets, and other products. The PET recycling value chain involves waste collectors, kabadiwallahs, small and medium traders, recyclers, and manufacturers using recycled PET as a raw material. The report indicates that discarded PET bottles fetch waste collectors Rs. 20-25/kg, while r-PET products sell at anywhere between Rs. 50-60/kg. It also estimates the PET recycling business in India to be around Rs. 5,000- 10,000 crore in a given year.
Cost Estimation
| Particular | Value |
|---|---|
| Plant Capacity | 20 MT/Day |
| Land & Building (4935 sq.mt.) | Rs. 5.70 Cr |
| Plant & Machinery | Rs. 9.80 Cr |
| Working Capital for 1 Month | Rs. 3.70 Cr |
| Total Capital Investment | Rs. 20.09 Cr |
| Rate of Return | 27% |
| Break Even Point | 66% |
Content Index
- INTRODUCTION
- PET RECYCLING
- VALUE CHAIN OF PET RECYCLING
- CHARACTERISTICS/APPLICATIONS
- THE MAJOR CHARACTERISTICS OF POLYESTER YARNS INCLUDE
- SPECIFICATIONS OF PRODUCTS
- MARKET OVERVIEW
- REGIONAL SEGMENTATION ANALYSIS:
- SALIENT TRENDS OF THE POLYESTER YARN MARKET
- KEY PLAYERS IN THE POLYESTER YARN MARKET ARE
- MARKET-O-NOMICS
- FORMULATION
- THE POLYESTER TEXTURIZED YARN IS MANUFACTURED WITH THE FOLLOWING COMPOSITION
- PRODUCT YIELD IS AS FOLLOWS:
- RAW MATERIALS DETAILS
- POST-CONSUMER PET BOTTLES
- CLEANING AGENT
- FINISH OIL
- ANTISTATIC OIL
- CHEMICAL USED FOR PURIFICATION
- MANUFACTURING PROCESS STEPS/PROCESS FLOW
- STEP - A
- PRODUCT: PET GRADUALS
- STEP - B
- PRODUCT: POLYESTER YARN (PY)
- EFFLUENT TREATMENT FACILITY
- UTILITIES REQUIREMENT (ESTIMATED - MONTH)
- WASTE EFFLUENT/FLUE GAS EMISSION (ESTIMATED)
- GREEN BELT
- WATER
- EMISSION
- WASTE MANAGEMENT (ESTIMATED)
- BIS SPECIFICATION
- POTENTIAL TURNKEY PLANT/EQUIPMENT SUPPLIERS/CONSULTANT
- BOILERS
- SUPPLIERS OF EFFLUENT TREATMENT PLANT
- D.G. SETS
- SUPPLIERS OF INSTRUMENTATION & PROCESS CONTROL EQUIPMENTS
- LABORATORY TESTING EQUIPMENT
- ENGINEERING CONSULTANTS/CONTRACTOR
- STORAGE TANKS
- LABORATORY EQUIPMENT AND LAB TESTING EQUIPMENT
- GOVT. LICENSE DETAILS
- PLANT & MACHINERY (MAJOR)
- PRINCIPLES OF PLANT LAYOUT
- MAJOR PROVISIONS IN ROAD PLANNING FOR MULTIPURPOSE SERVICE ARE:
- PLANT LOCATION FACTORS
- PRIMARY FACTORS
- RAW-MATERIAL SUPPLY:
- MARKETS:
- POWER AND FUEL SUPPLY:
- WATER SUPPLY:
- CLIMATE:
- TRANSPORTATION:
- WASTE DISPOSAL:
- LABOR:
- REGULATORY LAWS:
- TAXES:
- SITE CHARACTERISTICS:
- COMMUNITY FACTORS:
- FLOOD AND FIRE CONTROL:
- PROJECT MANAGEMENT
- PROJECT HANDLING
- PROJECT SCHEDULING
- PROJECT CONSTRUCTION SCHEDULE
- POTENTIAL RISKS
- ANTICIPATED ENVIRONMENTAL IMPACTS
- CONSTRUCTION PHASE
- OPERATION PHASE
- MITIGATION MEASURES (PROPOSED)
- HEALTH SAFETY & ENVIRONMENT
- SAFETY & OCCUPATIONAL MEASURE (STORAGE/HANDLING)
- PROPOSED IMPLEMENTATION SCHEDULE
- PROJECT FINANCIALS
- BASIS & PRESUMPTIONS (FOR PROFITABILITY WORKINGS)
- PRELIMINARY PLANT LAYOUT
- SAFETY DATA SHEETS
Appendix
- APPENDIX – A:
- 01. PLANT ECONOMICS
- 02. LAND & BUILDING
- 03. PLANT AND MACHINERY
- 04. OTHER FIXED ASSESTS
- 05. FIXED CAPITAL
- 06. RAW MATERIAL
- 07. SALARY AND WAGES
- 08. UTILITIES AND OVERHEADS
- 09. TOTAL WORKING CAPITAL
- 10. TOTAL CAPITAL INVESTMENT
- 11. COST OF PRODUCTION
- 12. TURN OVER/ANNUM
- 13. BREAK EVEN POINT
- 14. RESOURCES FOR FINANCE
- 15. INSTALMENT PAYABLE IN 5 YEARS
- 16. DEPRECIATION CHART FOR 5 YEARS
- 17. PROFIT ANALYSIS FOR 5 YEARS
- 18. PROJECTED BALANCE SHEET FOR (5 YEARS)
Frequently Asked Questions
PET recycling is the process of collecting and converting discarded PET bottles into reusable recycled PET material. The process generally involves collection, sorting, removal of non-PET components, shredding, washing, and processing into washed flakes. These flakes can subsequently serve as raw material for products such as polyester fiber, fabrics, PET straps, monoYarn, and sheets. Recycling helps recover material value from post-consumer bottles while creating a supply of secondary raw material for downstream manufacturing.
Discarded PET bottles are processed through collection, sorting, cleaning, shredding, and washing operations. Caps, neck rings, labels, and other non-PET components are removed before the bottles are reduced to smaller pieces. Washing removes dirt and contaminants, producing washed PET flakes. The flakes can then be supplied to downstream manufacturers for conversion into recycled PET products, including polyester fiber and other applications described in the project report.
Recycled PET can be used to manufacture polyester fiber and several other products. According to the report, polyester fiber is used as filling material for cushions and pillows and can be converted into fabrics for clothing and upholstery. A smaller proportion of recycled PET is also used for PET straps, monoYarn, and sheets. The suitability of recycled PET for a particular application depends on factors such as purity, processing quality, material characteristics, and the requirements of the downstream manufacturing process.
The primary raw material for the project is post-consumer PET bottles, supported by process materials used during recycling and purification. The report specifically identifies cleaning agent, finish oil, antistatic oil, and chemicals used for purification among the raw-material details. Actual material specifications and consumption depend on the selected process, product requirements, feedstock quality, and operating conditions. Proper segregation and preparation of incoming PET bottles are important for maintaining consistent recycled material quality.
A PET recycling plant location should provide reliable access to raw materials, markets, utilities, transportation, labor, and waste-disposal infrastructure. The report identifies raw-material supply, markets, power and fuel supply, water supply, climate, transportation, waste disposal, labor, regulatory laws, taxes, site characteristics, community factors, and flood and fire control as important considerations. Evaluating these factors together helps support efficient plant operations, regulatory compliance, logistics management, environmental performance, and long-term project viability.
Environmental considerations in PET recycling include wastewater, emissions, solid waste, resource consumption, and proper handling of process materials. The project report includes provisions for effluent treatment, estimated waste effluent and flue gas emissions, water, emission management, waste management, green belt development, and proposed mitigation measures. Effective environmental management should address the specific characteristics of the selected process and ensure that wastewater, waste materials, and emissions are managed in accordance with applicable requirements.
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