Rudra Ecovation is shaping a more sustainable future for the textile industry
Rudra Ecovation is one of India’s largest recyclers of PET bottles, transforming plastic waste into high-quality recycled polyester fibres, yarns, and textiles. Based in Ludhiana and spanning 100 acres, the company processes 8.8 million PET bottles daily, championing sustainability through circular economy practices. Committed to quality, integrity, and responsible production, it aligns with UN Sustainable Development Goals, setting new standards for sustainability and innovation in the textile industry. Speaking to Fibre2Fashion, CEO & Executive Director VK Goyal and Director Ishani Malhotra discuss how their company integrates advanced recycling technology, eco-friendly dyeing, and nonwoven technical textiles to minimise environmental impact.
The global demand for sustainable textiles is growing rapidly. How do you see the future of recycled polyester and its role in shaping the fashion and textile industries?
The future of recycled polyester is pivotal to achieving the textile and fashion industry’s sustainability goals. As consumers increasingly demand eco-friendly and circular products, recycled polyester (rPET) serves as a cornerstone in reducing dependency on virgin polyester, which is derived from non-renewable fossil fuels.
At Rudra Ecovation, we envision rPET not only as a sustainable alternative but also as a driver of innovation in textiles. It offers comparable strength, durability, and versatility to virgin polyester, making it ideal for applications ranging from high-performance sportswear to everyday fashion. The transition to recycled materials directly contributes to lowering greenhouse gas emissions, reducing energy consumption, and minimising waste in landfills.
Moreover, the integration of recycled polyester into mainstream fashion encourages brands to adopt circular design principles. We believe that, in the near future, closed-loop recycling systems will become the norm, where discarded textiles are fully transformed into new products. At Rudra Ecovation, we are not just participants in this shift but aim to lead by example, investing in advanced recycling technologies and collaborating with global brands to drive this change forward.
Rudra Ecovation has established itself as one of India’s largest recyclers of PET bottles. What were some of the biggest challenges in scaling up this initiative, and how did the company overcome them?
Scaling up our PET recycling operations to become Asia’s largest vertically integrated plant was a journey fraught with challenges. The first hurdle was ensuring a consistent and reliable supply of raw materials—used PET bottles—from a fragmented waste collection ecosystem. We tackled this by establishing robust partnerships with leading waste aggregators to ensure uninterrupted supply.
The second major challenge was operational efficiency at scale. Recycling PET into high-quality products demands precision and consistency, and achieving this on a large scale required significant investment in state-of-the-art technologies and process automation. By deploying advanced sorting, cleaning, and polymerisation equipment, we ensured minimal contamination and maximum output quality.
Finally, raising awareness and combating the perception of recycled polyester as inferior to virgin polyester posed another significant obstacle. Through rigorous testing, certifications, and R&D, we have consistently demonstrated that our recycled yarns match, and in some cases exceed, the quality benchmarks of virgin alternatives. Today, Rudra Ecovation stands as a testament to what can be achieved when innovation, resilience, and purpose come together.
Your company transforms PET waste into high-quality textiles, including fibres and yarns that rival virgin polyester. How does your company align its recycling efforts with global sustainability goals, and what new innovations are you exploring to further minimise environmental impact?
At Rudra Ecovation, our mission aligns seamlessly with global sustainability frameworks such as the UN’s Sustainable Development Goals (SDGs), particularly SDG 12 (Responsible Consumption and Production) and SDG 13 (Climate Action). Every PET bottle we recycle represents a step towards reducing plastic pollution and conserving non-renewable resources.
We are committed to minimising our carbon footprint throughout the recycling process. This includes using energy-efficient machinery, optimising water consumption, and transitioning to renewable energy sources for our operations. Our vertical integration model further ensures transparency and reduces the environmental impact of transportation and intermediate processes.
In terms of innovation, we are actively exploring advanced technologies such as pyrolysis and shredding for textile recycling. Pyrolysis allows us to thermochemically break down complex polyester-based materials into their fundamental chemical components, which can then be used to create new, high-quality fibres and yarns. This process is particularly significant for end-of-life textiles that are difficult to recycle using traditional methods, such as blended fabrics. By incorporating pyrolysis, we aim to close the loop in textile recycling, ensuring that no material goes to waste.
In addition to pyrolysis, we are looking to leverage advanced shredding techniques to mechanically recycle textiles into fibres that can be re-spun into yarns or repurposed for nonwoven applications like insulation and padding. This approach enables us to recycle not just PET bottles but also post-consumer textiles, broadening the scope of our sustainability efforts.
These cutting-edge methods not only help us reduce waste but also contribute to lowering energy usage and emissions, making the overall recycling process more sustainable. Our R&D team continues to explore ways to integrate these technologies with our existing processes to further enhance efficiency and environmental performance. By combining chemical and mechanical recycling methods, we are redefining what is possible in textile circularity, ensuring that our efforts are both scalable and impactful.
With a production capacity of recycling 8.8 million PET bottles daily, how does Rudra Ecovation ensure the highest quality standards and maintain operational efficiency at such a large scale?
Maintaining operational efficiency and quality at such a scale requires a combination of cutting-edge technology, meticulous process control, and a skilled workforce. At Rudra Ecovation, we have invested in a fully automated sorting and cleaning system that ensures precise separation and removal of contaminants. This guarantees that only the highest-quality PET flakes are used for further processing.
Our polymerisation and extrusion processes are designed to meet stringent quality benchmarks, with real-time monitoring systems ensuring consistency. Additionally, our in-house testing laboratories conduct rigorous quality assessments at every stage, from raw materials to finished yarns.
Operational efficiency is achieved through continuous improvement practices, predictive maintenance of machinery, and advanced analytics to optimise production cycles. Our commitment to sustainability also extends to minimising waste generated during the recycling process. By implementing circular practices within our operations, we ensure that even production waste is repurposed, leaving no room for inefficiency.
We are also on track to significantly expand our capacity, increasing from 8.8 million PET bottles processed daily to 25 million bottles in the near future. This milestone will be achieved by scaling up our operations with new machinery and advanced automation, while maintaining the same high standards of quality and environmental stewardship. This expansion underscores our vision of becoming a global leader in sustainable recycling and our commitment to addressing the growing demand for eco-friendly materials.
Your company has been pioneering eco-friendly dyeing techniques and technical textile innovations. What are some of the latest developments in these areas, and how do they contribute to the circular economy?
One of the most significant advancements at Rudra Ecovation is our adoption of dope dyeing, an innovative and eco-friendly dyeing technique. Unlike traditional dyeing methods, which involve dyeing the fabric or yarn after production and require large quantities of water and chemicals, dope dyeing incorporates the colour directly into the polymer solution before it is extruded into fibres. This process eliminates the need for post-production dyeing, drastically reducing water usage, chemical waste, and energy consumption.
Dope dyeing ensures vibrant, long-lasting colours with superior consistency, while simultaneously addressing environmental concerns. It not only reduces pollution but also enhances the durability and quality of the final product. By integrating dope dyeing into our operations, we are contributing to a significant reduction in the environmental footprint of textile manufacturing.
In addition to dope dyeing, we are developing technical textiles with advanced functionalities such as moisture management, UV protection, and enhanced durability. These innovations support the circular economy by extending the lifecycle of textiles and reducing the need for frequent replacements.
Our commitment to sustainability and innovation drives us to continuously explore cutting-edge technologies. By incorporating eco-friendly practices like dope dyeing and focusing on high-performance technical textiles, Rudra Ecovation is not only meeting the demands of the present but also shaping a more sustainable future for the textile industry.
