1. Customer Background

UFLEX LTD. is a leading integrated flexible packaging and plastic recycling company in India, with operations spanning composite flexible packaging, PET bottle flake recycling, and functional film production. Its industrial footprint covers the entire South Asian region, making it a benchmark enterprise in India’s plastic packaging industry. The company’s factories generate multiple types of waste, including composite film trimmings, PET bottle flakes, and printed waste films.

2. Core Pain Points

1. The variety of waste streams is extensive: adhesive‑containing composite films, printed films, and PET bottle flakes exhibit significant differences in characteristics. The existing single recycling line cannot handle all these materials, resulting in extremely low sorting efficiency.

2. Adhesive‑containing composite films are not fully degummed, and PET bottle flakes often contain labels and sand impurities, leading to insufficient purity in the recycled pellets. As a result, the material can only be sold on the low‑end market, yielding low added value.

3. With India tightening its solid waste environmental regulations, the company faces pressure to ensure compliant waste disposal and needs to improve internal resource utilization rates.

3. Our Solution

We implemented a dual‑line solution for the customer: an **adhesive‑specific composite film recycling and pelletizing unit** combined with a **PET bottle flake pelletizing machine**.

• The composite film line is equipped with a thermal washing and degumming module and a high‑speed friction cleaning system to remove surface adhesives and ink.

• The PET bottle flake line features flotation separation, label air‑classification, and multi‑stage rinsing processes to thoroughly eliminate impurities from the flakes.

• Both lines share a centralized electrical control and water‑circulation system, reducing capital investment and operational energy consumption.

4. Quantified Business Outcomes

1. The factory has achieved 100% closed-loop recycling of production trimmings, reducing annual purchases of virgin plastic raw materials by 3,160 tons.

2. The company’s overall waste resource utilization rate has increased from 62% to 100%, saving over US$900,000 annually in landfill and export costs.

3. Impurity levels in recycled pellets have been controlled below 1%. Recycled composite film can now be used to produce industrial packaging substrates, while recycled PET granules are suitable for fibers and injection molding applications, boosting waste‑processing revenues by 45%.

4. The water‑circulation system achieves an 88% reuse rate, reducing wastewater discharge by 80% and fully complying with local environmental regulations.

5. Project Value

This project helped the customer establish an integrated multi‑category plastic waste recycling system, addressing key environmental compliance challenges while transforming waste from a “cost item” into a “revenue driver,” thereby supporting the expansion of the company’s circular economy business segment.