FROM SCRAP TO SOLUTION: GRAVITA INDIA’S SUSTAINABLE PRODUCTION OF RECYCLED PLASTIC GRANULES

From Scrap to Solution: Gravita India’s Sustainable Production of Recycled Plastic Granules

From Scrap to Solution: Gravita India’s Sustainable Production of Recycled Plastic Granules

Blog Article

Introduction


The global plastic waste crisis has emerged as one of the most pressing environmental challenges of our time. With over 400 million tons of plastic produced annually and less than 10% effectively recycled, the need for sustainable alternatives is more urgent than ever. India alone generates more than 3.4 million tons of plastic waste per year. Amidst this growing concern, Gravita India Ltd. has positioned itself at the forefront of circular plastic manufacturing, transforming waste into value through its Plastic Granules division.


Gravita’s mission to build a sustainable future is deeply embedded in its plastic recycling operations. Leveraging modern technology, rigorous quality control, and a commitment to resource recovery, Gravita converts plastic scrap into high-quality recycled plastic granules that serve multiple industries. This article explores how Gravita India is addressing environmental issues, creating economic value, and enabling industries to move toward sustainability.






The Need for Recycled Plastic Granules


Plastic pollution is primarily a result of single-use plastics and non-biodegradable materials entering landfills and oceans. Recycling plastic into granules provides a way to:





  • Reduce dependence on virgin plastic




  • Decrease carbon emissions




  • Divert waste from landfills




  • Save energy and resources




Plastic granules—also known as plastic pellets—are the raw material used in the manufacturing of new plastic products. By producing granules from post-consumer or post-industrial plastic waste, Gravita creates a circular loop where plastics are reused rather than discarded.






Gravita’s Manufacturing Process: From Waste to Granule


Gravita India follows a meticulous and controlled multi-stage process to convert plastic waste into reusable granules:



1. Collection & Sourcing


Scrap plastic is collected through Gravita’s widespread network of domestic and international sourcing hubs, ensuring a consistent supply of raw materials like:





  • HDPE (High-Density Polyethylene)




  • LDPE (Low-Density Polyethylene)




  • PPCP (Polypropylene Copolymer)




  • ABS (Acrylonitrile Butadiene Styrene)




  • Other industrial plastic scrap




2. Sorting & Washing


Plastic waste is sorted by polymer type and color to ensure batch consistency. It is then washed using industrial-grade washers to remove dirt, labels, and contaminants—critical for high-grade applications.



3. Shredding & Extrusion


The cleaned plastic is shredded and fed into an extruder, which melts and compacts the material. The molten plastic is then cut into uniform granules or pellets through a cooling system.



4. Screening & Quality Testing


Gravita subjects its granules to stringent quality tests, such as:





  • Melt Flow Index (MFI)




  • Tensile Strength




  • Elongation




  • Ash Content




  • Impact Resistance




This ensures the plastic granules meet customer specifications and industry standards, including ASTM and ISO benchmarks.






Product Portfolio: Types of Recycled Plastic Granules


Gravita manufactures a wide range of plastic granules used across industries:





  • HDPE Granules: For containers, pipes, industrial components




  • PPCP Granules: Suitable for automotive, packaging, and appliances




  • ABS Granules: Used in electronics, helmets, toys




  • Custom Blends: Developed to meet specific MFI, density, and color requirements




Each grade is tailored to ensure consistent flow, durability, and application-specific performance.






Applications Across Industries


Gravita’s recycled plastic granules are used in numerous sectors, including:





  • Automotive: Bumper parts, battery casings, interiors




  • Packaging: Bottles, crates, containers




  • Electricals: Housings, insulation materials




  • Textiles: Fiber production for clothing




  • Consumer Goods: Toys, household items, plastic furniture




This wide applicability highlights how Gravita is helping reduce virgin plastic usage in mainstream industrial production.






Manufacturing Footprint: India & Africa


Gravita’s plastic granule operations span multiple geographies:





  • India:





    • Jaipur (Rajasthan): HQ and primary R&D facility




    • Chittoor (Andhra Pradesh): High-capacity production




    • Mundra (Gujarat): Export-oriented manufacturing






  • Africa:





    • Ghana, Senegal, Mozambique, and Tanzania: Plants set up to recycle local scrap and supply domestic markets






This global presence not only enables efficient raw material sourcing and production but also supports local employment and regional sustainability.






Capacity & Performance Metrics


As of FY2024:





  • Installed Capacity: ~24,300 Metric Tons (MT)




  • Current Production: ~8,500 MT




  • Target Capacity by FY2027: Over 25,000 MT




  • EBITDA/MT for plastics: ~₹20,000 – ₹21,000




The segment has shown high growth potential, with expected CAGR of 30–40% over the next few years. Plastic granules now represent an emerging contributor to Gravita’s total revenues and profitability.






Sustainability & Environmental Impact


Gravita’s recycled plastic granules directly support:





  • Circular economy practices




  • Lower greenhouse gas emissions




  • Reduced dependence on fossil fuels




  • Compliance with EPR (Extended Producer Responsibility) laws




For example, recycling 1 ton of plastic saves approximately 2,500 liters of oil and prevents 1.5 tons of CO₂ emissions. Gravita’s circular approach turns waste into raw material, avoiding landfill accumulation and resource extraction.






Regulatory Alignment: EPR & ESG Goals


Gravita’s operations align with India’s Plastic Waste Management Rules and Extended Producer Responsibility (EPR) mandates. The company also helps manufacturers comply with ESG (Environmental, Social, Governance) goals by providing:





  • Traceable documentation




  • Lab-tested recycled inputs




  • EPR credits




  • Audit and compliance support




Clients gain not only reliable materials but also a greener brand image, improving stakeholder trust.






Future Outlook & Expansion Plans


Gravita plans to:





  • Expand capacity in India and Africa




  • Introduce e-waste derived polymers




  • Integrate biodegradable plastic additives




  • Increase share of export-grade granules




  • Pursue joint ventures with global brands




With a vertically integrated model that includes sourcing, manufacturing, and consulting, Gravita is poised to become a major global player in sustainable plastic solutions.






Conclusion


Gravita India’s plastic granules division is a perfect example of how industrial innovation can contribute to a greener planet. By transforming post-consumer and industrial waste into high-quality plastic granules, Gravita addresses environmental challenges while creating economic value.


Whether you are a manufacturer seeking sustainable raw materials, a policymaker looking for scalable recycling models, or a conscious consumer supporting circular economy practices—Gravita India represents a step toward a cleaner, greener future.

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