Efficient Plastic Waste Handling


In a waste paper based paper mill, plastic waste (about 3% per ton of paper) in is generated loose forms. This case study depicts how handling of compacted bailed plastic waste imparts more efficiency in terms of storage, manpower & transport.

Implementing Industry

Daman Ganga Paper Mills is a medium sized company engaged in recycled packaging products. Company produce a range of recycled products such as Paper, Core-Board, Cores & Tubes, Fibre-Drums, Partition Boards, Insulation Boards, Acoustic Boards, etc. The company started its operation in the year 1982, with present production capacity of Kraft Board 60 Tons per day, with annual turnover of 50 Crores.

Implemented technology / technique


  • After screening, plastic waste was manually collected onsite and then transferred to another plant located within Vapi for making plastic roof sheets.

  • Plastic waste generated from the process is being stored onsite in loose condition and thus requires significant space, additional manpower to handle & transport the plastic waste from generation to storage area. 

  • Because of very high calorific value of plastic waste, this waste has potential to be used as fuel but due to Regulatory restrictions and consideration as Hazardous waste, industry has to incur significant cost for handling & disposal. Also, this plastic waste (non-PVC) from paper industry has good potential to be co-processed in cement industries, for which, it is essential to have viable storage and transportation costs.


  • Industry has installed an onsite “Bailing Machine”, which compresses the loose plastic waste into bails of proper dimensions with increased density as per requirement of cement industries for ease of handling & reduced transportation cost (high density bails). 

  • Gujarat Paper Mill Association (GPMA) in Vapi has started co-processing of plastic waste by sending it to cement industries located in Gujarat and nearby states with the help of Gujarat Pollution Control Board (GPCB) for incineration purpose.

  • It also reduced labour cost of about Rs. 500 per Ton of plastic waste.

  • The capital cost invested by industry is Rs. 5,00,000, with operating cost in terms of electricity consumption of bailing machine and operator cost.

  • Since, there is no direct monitory benefit but it gives indirect benefits in terms of saving space, environment friendly disposal (co-processing in cement industries) in place of incineration.

  • The rotary screen was installed prior to clarifier, which recovers 50%-60% of total fibre which was earlier going into the sludge (0.103 Ton/day).

Economic benefits

Waste is being used as fuel for cement industries with state of the art pollution prevention equipments ensuring reduced emissions (quantification in progress)

Contact details 

Mr. Banjul Shah, Director; banjul.shah@damanganga.com