New Technology Pioneers a Plastic-to-Plastic Circular Economy, Cutting Waste and Reducing Carbon Footprint
India is grappling with an escalating plastic waste crisis, generating over 10.2 million tonnes annually. With 40% of this waste classified as single-use plastic, traditional recycling methods fail to handle contaminated and flexible plastics, leading to pollution across landfills, drainage systems, and oceans.
PolyCycl, an emerging leader in circular economy technologies, has unveiled Generation VI, an indigenous chemical recycling technology that converts low-value plastics into high-quality, food-safe polymers, sustainable fuels, and renewable chemicals. This innovation eliminates the need for downcycling or landfill disposal, creating a true circular economy for plastics.
PolyCycl’s patented ContiFlow Cracker™ technology thermally transforms plastic waste into virgin-equivalent raw materials, enabling their reuse in FMCG, pharmaceutical, and high-performance packaging applications. With a lower capital cost and higher efficiency than similar chemical recycling technologies in Europe and the U.S., Generation VI represents a leap forward in India’s fight against plastic pollution.
Breaking the Plastic Pollution Cycle: How PolyCycl’s Generation VI Works
– Pyrolysis-Based ContiFlow Cracker™: A fully-continuous thermo-chemical process that converts single-use and hard-to-recycle plastics into purified liquid hydrocarbons.
– PyOilClean™ Refining Technology: Removes contaminants such as halogens and heteroatoms, producing high-value, circular chemical feedstocks.
– Plastic-to-Plastic Recycling: Instead of downcycling, this process restores waste plastics to their original polymer form, making them suitable for food packaging, pharmaceutical containers, and high-performance materials.
Unlike mechanical recycling, which degrades plastics over time, chemical recycling ensures that every recycled polymer meets virgin-quality standards, maintaining strength, safety, and durability.
– Most plastic recycling today results in low-grade materials that can’t be reused for high-value applications,- says Amit Tandon, Founder & CEO of PolyCycl. – Our technology breaks plastics down to their molecular building blocks, allowing them to be reconstituted into new, high-performance materials.
Scalability and Cost-Efficiency: A Breakthrough for India’s Plastic Waste Management
One of the biggest challenges in plastic waste recycling is scalability. PolyCycl’s technology solves this with a modular design, enabling processing capacities of 15 to 100 tons per day (TPD).
✅ Lower Costs, Higher Returns: The capital cost is 50-75% lower than competitors such as BASF and Dow Chemical, making large-scale adoption feasible.
✅ Industry-Leading Conversion Rates: Yields 65-75% chemical feedstock recovery, ensuring minimal waste.
✅ Profitable & Sustainable: With a project EBITDA exceeding 50%, it combines economic viability with environmental impact.
India’s Extended Producer Responsibility (EPR) rules require brands to use 10% recycled content in flexible packaging and 30% in rigid plastics by 2025-26. PolyCycl’s technology is designed to help FMCG giants like Unilever, Nestlé, and Hindustan Unilever meet these requirements seamlessly.
A Step Towards a Circular Economy in Plastic Waste Management
With three out of four FMCG products in India packaged in flexible plastics, the need for sustainable alternatives has never been greater.
– The plastic waste problem is complex and requires multiple solutions,- says Amit Tandon. – From better product design and stronger EPR policies to innovative recycling technologies, we need a multi-pronged approach. Our goal is to make chemical recycling mainstream and enable true circularity in plastics.-
By reducing reliance on fossil-based raw materials by up to 90% and cutting greenhouse gas emissions by 40%, PolyCycl’s Generation VI technology is poised to redefine India’s sustainability roadmap.
At Prittle Prattle News, featuring you virtuously, we celebrate commitment and innovation. Led by Editor-in-Chief Smruti Bhalerao, our platform is dedicated to sharing impactful stories that inspire change and create awareness. Follow us on LinkedIn, Instagram, and YouTube for more stories that matter.