Scientists at the CSIR–Indian Institute of Chemical Technology (CSIR-IICT), Hyderabad, have developed an innovative technology that converts hard-to-recycle Fast Moving Consumer Goods (FMCG) plastic wrappers into valuable resources such as clean fuels, plastics feedstock, and hydrogen. The breakthrough could address one of the recycling industry’s most persistent challenges — managing multi-layer plastic packaging, which is typically considered unrecyclable and often ends up in landfills or incinerators.
Tackling the Challenge of Multi-layer Plastic Waste
Multi-layered plastic wrappers used for snacks and other FMCG products are difficult to recycle because they contain several layers of polymers, aluminium, and additives. Traditional recycling methods cannot easily separate these materials, making them a major contributor to plastic pollution.
To overcome this challenge, a research team from the Chemical Engineering and Process Technology (CE&PT) department at CSIR-IICT, led by scientist Vineet Aniya, has developed a process that transforms discarded wrappers into useful fuels and chemical raw materials. The research team includes Chandan K. Munaghala, Syed Mohammed Razak, and Naresh Kathula, working under the guidance of CSIR-IICT Director D. Srinivas Reddy and Distinguished Scientist N. V. Choudhary.
How the Technology Works
The process begins with collecting and shredding FMCG plastic wrappers, which are then compressed and fed into a specialised reactor. Inside the reactor, the material undergoes controlled catalytic pyrolysis, a thermal process that breaks down plastics at high temperatures in the absence of oxygen. During this stage, the plastic decomposes into vapours. These vapours are then cooled and condensed, producing a liquid known as Plastic Pyrolysis Oil (PPO).
PPO resembles crude petroleum in appearance — dark, viscous, and containing higher sulphur levels along with traces of metals and particulates. Although thicker than conventional refinery feedstock, this oil can still be used in several industrial applications, including fuel for ship boilers and other energy systems.
Upgrading Plastic Pyrolysis Oil into High-Value Products
However, the CSIR-IICT team did not stop at producing pyrolysis oil. Instead, the researchers developed additional steps to upgrade the oil into higher-value fuels and petrochemical building blocks. Through advanced processing, the team successfully converted the oil into hydrogen, a key fuel for India’s emerging green energy economy, light olefins such as ethylene, propylene, and butylene. These olefins serve as essential feedstocks for manufacturing new plastics and petrochemical products, making the process part of a potential circular plastics economy.
Dual Processing: Catalytic Cracking and Steam Reforming
The technological breakthrough lies in the combination of two advanced processes:
*Catalytic cracking, which converts the pyrolysis oil into light olefins
*Steam reforming, which produces hydrogen from the upgraded feedstock
By integrating these processes, the system can extract multiple high-value products from a single waste stream. As a result, plastic waste that was once considered unrecyclable can now become a source of fuel, petrochemicals, and clean energy.
Scalable Model for Urban Waste Management
The researchers believe that the model is highly scalable and suitable for decentralised deployment across India. Under this model, small decentralised plants can process around one ton of FMCG plastic waste per day. The resulting oil can be collected and transported to central processing facilities. These facilities can then produce refined fuels, olefins, or hydrogen. This approach could help urban municipalities manage plastic waste more efficiently, while simultaneously creating new value chains for the chemical and energy industries.
Turning Waste into Economic Opportunity
According to Vineet Aniya, the technology also offers strong economic potential. “What was once a liability for municipal bodies has now become the primary input for a profitable fuel and chemical production unit,” he explained. Because waste plastic is available at virtually zero cost, even smaller decentralised plants could operate profitably while contributing to waste management and energy production.
Supporting India’s Growing Energy and Plastic Demand
India’s demand for plastics continues to rise at approximately six percent annually, while imports of fossil-based naphtha, a key petrochemical feedstock, have been increasing by nearly nineteen each year. By converting plastic waste into olefins and hydrogen, this technology could partially reduce the country’s dependence on imported petroleum resources. As reported by thehindu.com, in the future, scientists suggest that a portion of India’s petrochemical feedstock may come not from oil fields, but from the nation’s growing plastic waste streams, turning an environmental problem into a valuable resource.
