By K. Gopalakrishnan
Ushering in a New Era of Sustainability
In an era where environmental degradation and resource scarcity pose critical challenges, revalyu Resources is charting a transformative path in PET recycling. With the recent commissioning of its second plant at the Nashik site, India, the company has achieved a significant milestone: creating the world’s largest chemical PET recycling facility. This state-of-the-art facility not only boosts global recycling capacity but also demonstrates the potential of innovative technology to address pressing environmental issues while driving economic and industrial progress.
Makarand Kulkarni, CEO of revalyu India
A Bold Vision for PET Recycling
revalyu Resources has long envisioned a world where plastic waste is no longer discarded but continually recycled, promoting a circular economy. This vision is now a reality at its Nashik facility, where over 20 million post-consumer PET bottles are transformed daily into 160 tonnes of high-quality recycled PET chips and polymers. The company’s patented glycolysis-based chemical recycling technology enables it to replicate this process efficiently and sustainably, meeting the growing demand for high-quality recycled polymers across diverse industries.
Dr. Vivek Tandon, the founder of revalyu Group, emphasized the groundbreaking nature of this achievement:
“This is a revolutionary moment for the PET plastic recycling industry. Finally, the world has a commercially proven, scalable, profitable, and environmentally sustainable recycling technology that can truly reverse engineer used PET plastic into virgin-grade quality PET polymer.”
The process is a game-changer, producing recycled PET with 75% less water and 91% less energy compared to conventional methods, while maintaining the quality and versatility required by industries such as textiles, packaging, and automotive manufacturing.
Setting New Benchmarks in Recycling Capacity
The Nashik site, with its robust infrastructure, is a testament to revalyu’s commitment to global sustainability. The facility currently houses two plants with a combined capacity of 160 tonnes per day. By 2025, a third plant—already under construction—will increase the site’s recycling capacity to 280 tonnes per day, equivalent to processing approximately 35 million bottles daily. This ambitious expansion is part of a $100 million investment to scale operations and meet rising global demand for sustainable materials.
The company aims to establish a 240-tonnes-per-day PET recycling facility in the United States by 2027. Beyond this, revalyu is pursuing partnerships and investments to increase its global production capacity to over 1,000 tonnes per day by 2030.
Jan van Kisfeld, Managing Director of revalyu Group, highlighted the broader impact of this achievement:
“Imagine PET being recycled continuously, creating a sustainable cycle. Our new plant demonstrates that this process is commercially viable on a global scale while maintaining an impressively low environmental footprint. It supports customers in reaching their sustainability goals with high-quality, 100% recycled PET.”
This continuous recycling process aligns seamlessly with the company’s mission to create a world where plastic waste is no longer an environmental burden but a valuable resource.
Integrating Technology with Sustainability
revalyu’s innovative glycolysis-based technology forms the cornerstone of its operations. Unlike conventional PET manufacturing, this process requires significantly less water and energy, making it both environmentally sustainable and economically viable. Automation enhances operational efficiency, scalability, and replicability, enabling revalyu to expand its model globally.
At Nashik, sustainability extends beyond recycling processes. The facility incorporates zero liquid discharge systems, rainwater harvesting, and a transition to renewable energy sources, achieving a 60% reduction in CO₂ emissions compared to traditional recycling practices.
Makarand Kulkarni, CEO of revalyu India, underlined the strategic importance of the Nashik site:
“This environmentally sustainable chemical recycling process is scalable and replicable, giving our customers a competitive edge in their respective markets. It is a technology that will fundamentally change how industries approach sustainability.”
Beyond Recycling: Empowering Communities and Elevating Standards
revalyu’s influence extends beyond the industrial sphere. By fostering local employment, especially among individuals from marginalized farming communities, the company has created stable livelihoods and opportunities for skill development.
Employee welfare remains a key focus, as demonstrated by a seven-year accident-free record and a workforce happiness index exceeding 90%. These achievements reflect revalyu’s commitment to a holistic approach to sustainability, encompassing environmental, social, and economic dimensions.
Globally recognized certifications such as the Global Recycling Standard (GRS), OEKOTEX, and ISO standards further underscore revalyu’s dedication to maintaining ethical, sustainable, and high-quality production standards.
Global Expansion: Scaling Sustainability Worldwide
revalyu’s Nashik facility is only the beginning of its ambitious plans. The company aims to establish a 240-tonnes-per-day PET recycling facility in the United States by 2027. Beyond this, revalyu is pursuing partnerships and investments to increase its global production capacity to over 1,000 tonnes per day by 2030.
This bold vision ensures that the company remains at the forefront of the global recycling movement, setting benchmarks for others to follow. Dr. Tandon articulated this aspiration, saying,
“We continue to seek global partners to join us in our expansion as we deliver the highest quality sustainable (r)polymer to customers and take care of our planet for future generations.”
A Model for Sustainable Progress
revalyu Resources is leading a global transformation in PET recycling, turning environmental challenges into opportunities for innovation and progress. The Nashik facility, now the world’s largest chemical PET recycling site, is a shining example of how advanced technology and visionary leadership can drive meaningful change.
By combining scalable solutions, sustainable practices, and a commitment to empowering communities, revalyu is redefining industry norms and paving the way for a future where plastic waste is a valuable resource, not a problem. With its ambitious expansion plans, revalyu continues to inspire industries worldwide to adopt sustainable practices, ensuring a greener, cleaner planet for generations to come.
