As a further initiative, revalyu Resources has started construction of a 200-tonne per day PET plastic recycling plant. This plant will be based on an existing proven and fully commercialised chemical recycling technology already in operation at its existing manufacturing plant based in Nashik
A leading chemical PET recycling company, revalyu Resources announced that it will invest USD 50 million during the initial phase of its strategic expansion in its first facility in the USA. The location for its new plant will be in Statesboro, Georgia where ground-breaking will take place in the first half of 2023 and commissioning of the facility is planned for 2024. The 43-acre Statesboro site will employ approximately 70 people. When the first phase is completed, the plant will be able to recycle and process over 225,000 pounds per day of used PET (polyester) waste into sustainable PET polymers (esters) and rPET chips.
In further expansion, the plant will have a capacity of up to 450,000 pounds. revalyu Resources built and commercialised the world’s first breakthrough chemical full glycolysis recycling plant in Nashik. It currently employs over 300 people. Used PET bottles are first converted into sustainable monomers, then filtered to remove all impurities before being re-polymerised. The result is a very pure sustainable PET polymer (ester) which can used to directly replace PET polymers produced from petrochemicals.
At present the company sells recycled PET pellets and filament yarns to over 60 repeat customers in over 15 countries. In 2022, Heraeus Group, a global Fortune 500 technology and family-owned company from Germany, acquired a major stake in revalyu Resources and is supporting the company’s expansion plans. Using breakthrough chemical recycling technology, revalyu Resources has already recycled over 6 billion bottles. The cost-effective recycling process extracts impurities efficiently and delivers recycled PET of highest purity.
The process uses 91% less energy and 67% less water than conventional polyester processes. Customer applications have shown that the quality of recycled PET from plastic bottles is equivalent to that of virgin PET and can be used as a direct replacement. Once converted into high-quality recycled PET, revalyu Resources’ rPET chips can be used to produce any kind of sustainable PET product. Currently, it is mostly used in the textile industry for applications such as seamless knitting, weaving, denim, automotive, furniture or technical textiles. The company is targeting recycling capacity of more than 2 million pounds per day by 2026.
“We thank all our US customers, partners and the Statesboro community for their support, trust and confidence in us. Expanding our operations to the US is an important milestone for our global expansion strategy. It brings us closer to our target of recycling more than 2 million pounds of used PET bottles per day by 2026 and contributes to solving the plastic waste problem,” said Jan van Kisfeld, Managing Director, revalyu Resources. “The recycling process is unique and delivers the world’s cleanest, highest quality and most sustainable polyester products to our customers,” he added.
“We have commercialised a breakthrough and environmentally sustainable technology and revalyu Resources will become the leading global brand for recycling polyester. We continue to seek strong partners globally who wish to work with us on the global roll-out of this technology,” stated Dr. Vivek Tandon, Founder, revalyu Resources. Benjy Thompson, Chief Executive Officer of the Development Authority of Bulloch County, commented: “Our community is very excited to welcome revalyu Resources to Statesboro-Bulloch County. The company has a respected reputation for their plastics recycling process and the positive effects it will have on the environment. We are very excited that our region will be the first US site for their truly innovative technology.”
Chemical PET Recycling Plant at Nashik
As a further initiative, revalyu Resources has started construction of a 200-tonne per day PET plastic recycling plant. This plant will be based on an existing proven and fully commercialised chemical recycling technology already in operation at its existing manufacturing plant based in Nashik. This new plant will significantly increase the company’s capacity to recycle used plastic bottles and help to reduce the amount of plastic waste in the environment. “As a company, we are committed to finding sustainable solutions to the growing need for recycled plastic,” said Makarand Kulkarni, CEO, revalyu Recycling (India).
“And we have successfully proven that chemical recycling of PET has significant advantages over legacy mechanical recycling processes. The new plant will also create a substantial number of jobs in the local community and we thank everyone for their support in the granting of all the necessary permits and licenses for us to start the construction,” he added. The new plant will also be located in Nashik and is expected to be operational within 12 months. It will use state-of-the-art chemical recycling technology to recycle used plastic bottles into high-quality sustainable polyester polymer (ester), rPET chips and filament yarns. “The construction of this modern chemical PET recycling plant is a significant step towards our commitment to continue to drive production costs down through scale and the use of breakthrough technologies to produce the world’s highest quality recycled PET polymers,” said Dr. Vivek Tandon.
“The new plant of revalyu Recycling will have a significant positive impact on the environment – for example, 91% less energy and 75% less water than conventional processes as per an independent lifecycle analysis. The new plant will be able to recycle approximately 25 million used plastic bottles a day from within India,” said Vikram Nagargoje, Co-Founder and COO of revalyu Resources. The company is a leading provider of sustainable solutions for plastic waste management. The company’s mission is to reduce the amount of plastic waste in the environment by developing innovative solutions for the recycling and reuse of plastic materials.
Polyester Recycling Technology: Aquafil Engineering and revalyu Recycling sign Agreement
revalyu Recycling (India) and Aquafil Engineering (Germany) have signed an agreement for using certain specific parts of Aquafil’s technology, alongside revalyu Resources’ own technology for the expansion of its chemical PET recycling plant based in Nashik. Founded in 1988, Aqualfil Engineering is one of the leading engineering companies for polyester, nylon and chemical recycling technology worldwide. It is part of the Aquafil Group which is present in seven countries and three different continents with over 2,800 employees at 19 production sites located in Italy, Slovenia, United States, China, Croatia, Scotland, Thailand and Japan.
Aquafil Group is a pioneer in circular economy also thanks to the ECONYL® and EverPET® Regeneration Systems which are innovative and sustainable processes able to create new products from waste and give life to an endless cycle. Aquafil Engineering is well-known for building and designing continuous and batch polycondensation plants for PET polymers for textile, film and bottle grades and is actively involved in the research, development and building of PET chemical recycling processes and plants. revalyu Resources’ Nashik plant is significantly increasing the size of its operations and expanding its PET chemical recycling capacity. As a result of this agreement, revalyu Resources will be able to use certain specific parts of Aquafil Engineering technology.