Wednesday, October 22, 2025
FlexiblesUflex’s new pyrolysis plant and MLP recycling machine

Uflex’s new pyrolysis plant and MLP recycling machine

First pyrolysis plant in North India

-

Uflex’s new pyrolysis plant and MLP recycling machine

First pyrolysis plant in North India

-
pyrolysis plant in India
The first ever pyrolysis process plant in North India, the new pant will not only protect the environment by converting plastic wastes into energy but also nurture a healthier tomorrow. Photo: The Packman

Uflex recently commissioned its new pyrolysis plant at its packaging division in Noida. The first ever pyrolysis process plant in North India, the new pant will not only protect the environment by converting plastic wastes into energy but also nurture a healthier tomorrow. The pyrolysis plant once again reaffirms Uflex’s commitment towards a greener future through economically viable solutions for handling plastic waste in the society. Pyrolysis process works as a sustainable waste to energy technology with an ability to handle any plastic waste.

At its pyrolysis plant, Uflex converts about six tonnes of discarded waste material generated everyday from printing, unused trim, laminates, tubes and other unprocessed material into liquid fuel, hydrocarbon gas and carbon black which is further utilized in its manufacturing processes.

Pyrolysis oil produced from the process is passed through a separator to separate oil and moisture. Photo: The Packman

“After the Government’s Plastic Waste Management Rules, 2016, which call for comprehensive overhauling of plastic waste management systems, we started our own recycling plant. However, there are certain wastes which cannot be recycled. Event if you recycle it, you cannot produce any usable products. So, we now put those waste into the pyrolysis process and produce different forms of fuels – light distillate oil (LDO), hydrocarbon gas and carbon black,” said SS Parmar, senior vice president, Energy Group, Uflex.

Pyrolysis plant generates 2,000 liters fuel daily

Uflex consumes nearly one lac liters of fuel daily to run its generators, industrial boilers and furnaces at its Noida plants. “The new pyrolysis plant generates nearly 2,000 liters of fuel daily which is just a small fraction of what our plants actually require. But that doesn’t dissuade us from running the pyrolysis plant because our primary goal is to have a process in place for effective management of the waste that otherwise cannot be recycled,” said Parmar.

SS Parmar, senior vice president, Energy Group, Uflex. Photo: The Packman

Pyrolysis process

In this process, the polymer waste stored in the raw material facility is taken to a shredder which is cut into smaller pieces and then fed into the air lock feeding system. The waste material is chemically decomposed at elevated temperatures in the absence of oxygen. This reaction takes place inside the pyrolysis reactor and occurs at temperatures ranging from 430 to 500 degree Celsius. Thereafter, the pyrolysis reactor converts the polymer waste into pyrolysis oil, hydrocarbon gas and carbon black powder in the ratio 45:45:10 respectively. Mixture of pyrolysis oil vapor and hydrocarbon gas exits the pyrolysis reactor and is subjected to fractional condensation to get separate fraction of hydrocarbon gas, pyrolysis wax and pyrolysis oil. Pyrolysis wax is fed into the reactor for further reprocessing.

“While we use the oil to run our industrial boilers, 75% of the hydrocarbon gas produced in the process is used for running the boilers within the pyrolysis plant for heating the plastic waste. The remaining gas is used for the multi stage evaporation plant within our premises. This is basically to vaporize the dirty water – high total dissolved solids (TDS) – generated by effluent treatment plant, which comes out of the RO plant where you get 90% good water and 10% rejected water. Since throwing away of this rejected water is not safe, it needs to be vaporized. Some residues may still exist which can be used in landfills,” explained Parmar.

“Carbon black powder is cooled and packed into bags for further use as solid fuel. It has a calorific value similar to coal. One may burn it in PET coke fired steam boilers, firewood boilers or other similar boilers just like any other solid fuel,” added Parmar.

New machine for MLP recycling at IndiaPlast 2019

Anil Maitraya, senior general manager, operations, Packaging Division, Uflex. Photo: The Packman

“We have been involved in plastic recycling since 1995. Today at our Noida plant, we recycle six tonnes of plastics daily. The plant has two machines for recycling plastics such as PP, PE, BOPP, and BOPET into reusable plastic granules. Recently, we have developed a machine that can recycle multi-layered plastics (MLP) as well,” said Anil Maitraya, senior general manager, operations, Packaging Division, Uflex.

Uflex’s plastic recycling plant, Noida: The plastic waste is melted and mixed in the extruder to be shaped into long strands that are cooled in a water tank. The cooled strands are then passed through an air shower which evaporates the moisture. The dry strands are fed into a pelletizer which cuts them into granules. Photo: The Packman

“It is difficult to recycle MLP because the polymers involved in different layers have different melting points. The challenge is to bring these multi layers to a homogeneous form which can be melted homogeneously to flow together and form recyclable pallets. We have partnered with a company to develop a compatibilizer which can bring all these material to a coupling bond so that they can be melted on a single temperature. We will exhibit this machine at IndiaPlast 2019, Hall 14 Stand B1,” concluded Maitraya. IndiaPlast 2019 will be held between 28 February and 4 March at India Expo Center, Greater Noida.

Uflex’s plastic recycling plant, Noida: The pelletizer cuts the dry strands into granules. Photo: The Packman

Mahan Hazarika
Mahan Hazarika
Mahan Hazarika assumes the role of Editor at The Packman, a position he has held since 2017, reflecting a distinguished decade-long tenure specializing in journalism within the printing and packaging sectors. Beyond his professional realm, he nurtures a deep appreciation for music, travel, and films, finding inspiration and relaxation in these pursuits.

LEAVE A REPLY

Please enter your comment!
Please enter your name here

This site uses Akismet to reduce spam. Learn how your comment data is processed.

Latest news

Heidelberg India signs MOU with Sri Kaliswari Group to launch MK Masterwork Demo and Training Center

On 15 October 2025, a Memorandum of Understanding was signed between Thomas Frank, managing director, Heidelberg Asia Pacific, and...

Asahi Photoproducts to host second AWP Environment Event at CIIE 2025 in Shanghai

Asahi Photoproducts, a leader in sustainable flexographic plate technology and a division of Asahi Kasei, will exhibit at the...

New president, vice-president, board members and re-elections at GRA

The Global Rotogravure Association (GRA) is pleased to announce the election of new officers and board members during its...

Amcor announces operational launch of new MDO line in Peru

Amcor, a global leader in developing and producing responsible packaging solutions, announced the installation and operational readiness of a...
- Advertisement -spot_img

Ranpak brings AI-driven packaging intelligence to Logistica Next 2025

Ranpak, a global leader of sustainable paper-based automated packaging solutions for e-commerce and industrial supply chains, will exhibit its...

London Packaging Week 2025 sees strong rise in visitors

London Packaging Week 2025 has recorded a 15% growth in attendance, attracting 5,752 unique visitors to Excel London. Now...

Must read

Lay’s celebrates farmers with limited-edition packs

Continuing its commitment to celebrating the journey from soil...

Sun to debut advanced solutions at CorrExpo 2025

Sun Automation Group, a global leader in providing equipment...

You might also likeRELATED
Recommended to you