We recycle more plastic than we consume
Bisleri International Pvt Ltd, one of India’s leading packaged drinking water companies, has undertaken a project to upcycle PET bottles to create apparels, shoes, and other products, thus contributing to the circular economy. The project is part of the company’s initiative ‘Bottles for Change’ which aims to raise awareness about post-consumer plastic and encourage people to consider used plastic as a valuable resource for recycling, rather than waste. In an interview with Fibre2Fashion, Bisleri International CEO Angelo George shares his perspective on how the company’s PET upcycling process is making a positive impact on the planet.
What are the key factors driving the demand for a sustainable lifestyle, and how has this shift impacted consumer behaviour in recent years?
Consumer behaviour is undergoing a significant transformation as people are becoming increasingly conscious of the environmental and social issues. As a result, consumers are making deliberate choices on products and services with a reduced impact on the environment. Consequently, there is an expectation for businesses to actively contribute to positive change, and consumers also desire governments and other stakeholders to take responsibility.
This shift is particularly evident in industries such as consumer goods, food and beverages, fashion, and mobility. The preference for local and organic food, reusable products, energy-efficient appliances, and renewable energy sources represents a transformative trend towards sustainable living. Furthermore, consumers are actively participating in discussions and initiatives related to recycling, water and biodiversity conservation, organic produce, and ethical sourcing.
How does upcycling of PET bottles into apparel contribute to the growth of the circular economy?
PET bottles are highly versatile and can be repurposed into a range of items. The upcycling process involves recycling and transforming used PET bottles into different products, exemplifying a circular approach that extends the lifespan of existing materials and reduces the need for new resources.
Upcycling PET bottles into apparel plays a vital role in advancing India’s circular economy objectives. By reducing the demand for virgin materials like petroleum, which is used to produce new synthetic fibres, it helps conserve valuable resources. Simultaneously, this practice diminishes the amount of plastic waste that would otherwise accumulate in landfills and oceans as the bottles are transformed into high-value products. Moreover, upcycling offers ecological benefits by lowering the carbon footprint compared to traditional textile production, which typically consumes substantial energy, water, and raw materials.
Scaling up upcycling practices can create significant employment opportunities and contribute to local economic development.
What challenges and opportunities do companies face when incorporating upcycled PET bottles into their production processes for apparel?
The conversion of PET bottles into apparel production processes presents both challenges and opportunities for companies. One primary challenge lies in ensuring a consistent supply of high-quality recycled PET material, which necessitates strict quality control measures. Additionally, specialised equipment and processes are required to convert the recycled material into fabric or other apparel components, potentially requiring investments in machinery and worker training.
However, this integration can also yield opportunities for companies. It can cater to the growing consumer demand for sustainable and eco-friendly products, allowing businesses to differentiate themselves from their competitors and build brand equity. Besides, it can help decrease the environmental impact of textile production, resulting in cost savings, improved environmental performance, and a better reputation for the organisation by being conscious and purpose driven.
What motivated Bisleri International to embark on sustainable practices and environmental stewardship?
Sustainability is embedded in the core of Bisleri International’s business strategy. We were one of the first companies in India to recycle plastic since the 1990s, and we are passionate about plastic circularity. Our commitment to sustainability is based on our core principle, the Bisleri Greener Promise, which anchors our programmes for conserving natural resources and ensuring plastic circularity.
We are one of the first FMCG companies in India to be plastic-neutral and water-positive. We recycle more plastic than we consume and replenish more water than we process for our business.
Our business model focuses on the responsible extraction of groundwater. We have plants spread across the country to extract groundwater evenly, rather than mega-size plants at central locations, which depletes the water table. The proximity to the market reduces the carbon footprint as well. Our manufacturing processes convert >90 per cent of water processed into finished goods, reducing wastage. All our plants have robust water harvesting systems, and we restore water bodies to help recharge groundwater. Bisleri also repairs and maintains check dams to conserve precious rainwater to benefit farmers in rural areas.
Our packaging materials have always been 100 per cent recyclable. Our approach has been to reduce, reuse and recycle plastic. Design innovations have helped us reduce over 10 per cent of virgin plastic consumption last year. Our focus on reusable containers to minimise virgin plastic consumption has made this segment almost 30 per cent of the business. Besides, we have been promoting the repurposing of used plastic in collaboration with recyclers.
We have also invested in solar panels at our plants and are using electric delivery vehicles to improve energy efficiency and reduce carbon footprint in operations.
Can you explain the process followed to collect and process used PET bottles for recycling?
In 2018, we launched the programme ‘Bottles For Change’ to raise awareness that used plastic is a valuable resource that can be recycled. We educate people about the responsible disposal of used plastic and provide enabling systems to ensure that it is sent directly for recycling.
We advocate a 3-stage process – clean the used plastic, segregate it at the source, and send it directly for recycling. We also provide collection infrastructure to ensure used plastic reaches recyclers directly and does not end up in landfills. The programme is active in 7 cities, and we have managed to reach over 600,000 people so far. The footprint covers some of the largest corporates, educational institutions and housing societies in India. We have also introduced a user-friendly mobile app that allows individuals and organisations to register for the programme. Through the app, users can easily locate nearby plastic agents to collect the clean and segregated plastic, which is then sold to recyclers.
Once collected, PET waste is sorted, cleaned, and treated to remove other materials like caps, rings, or labels. The bottles are washed using a combination of hot and cold water and then processed through a PET treatment plant specially designed for recycling. Any irregular lumps or blocks of materials are crushed to produce flakes, which are then dried, mixed with pigments, extruded, and spun into filaments. These filaments are then cooled, collected, stretched, crimped, heat-treated, and cut into desired lengths depending on the final product. For example, for an apparel, the fibres are spun into yarn, wound onto bobbins, and woven into the fabric. It is then finished and dyed if necessary. Finally, the material is stitched to create various merchandise such as T-shirts and backpacks.
How does your upcycling initiative contribute to the concept of the circular economy?
Through our initiative, we have been able to collect valuable used plastic and upcycle them into highly valuable products. The upcycling practices have helped mitigate the requirement for natural resources and create new products, thereby reducing the impact on the environment.
Through our ‘Bottles for Change’ programme, we promote sustainability and create employment opportunities for rag pickers, aggregators, and recyclers who repurpose used plastic to create higher-value items. We aim to create a citizen movement where everyone joins hands in achieving the sustainable goals of our nation.
What products are created from the upcycling process of PET bottles?
PET is widely recognised as the most recycled plastic worldwide, owing to its flexibility and lightweight properties that help ease upcycling into different new products. PET bottles can be transformed into a range of high-value items such as apparels, bags, shoes, plant pots, window blinds and utility items. Besides, it can also be upcycled into hard-bound industry products such as benches and paver blocks, among others.
Can you share the impact Bottles For Change has created so far?
Bottles For Change aims to create awareness among people to treat used plastic as a valuable resource by segregating and responsibly disposing it off, thereby preventing it from entering landfills. Our initiative strives to bring behavioural change by inculcating best practices among people to build a greener environment.
Bottles for Change has made significant progress since its inception. We have successfully engaged with over 600,000 citizens through workshops and collection drives conducted at more than 3,500 housing societies, 680 educational institutions, 790 corporates, and 600 hotels and restaurants across 13 municipal corporations. All profits from the initiative are dedicated to improving the lives of the ragpickers.
Which cities in India is Bisleri currently working on for the Bottles for Change programme? Are you also partnering with NGOs?
The Bottles For Change programme has been successfully implemented in 9 corporations across 7 cities in India. We are committed to expanding our reach to other metro cities, such as Bengaluru, Hyderabad, and Pune. The initiative has garnered support from government authorities and social service organisations nationwide, with active partnerships established with NGOs and recyclers to promote plastic circularity.
Bottles For Change has also established a presence in some of the country’s most prominent educational institutions. We have partnered with renowned organisations to conduct research and development projects aimed at advancing sustainable practices in plastic circularity. Additionally, we have collaborated with the National Service Scheme (NSS) network at schools and colleges to educate and encourage students to become ambassadors of the mission. Our partnerships with organisations such as Parisar Bhagini Vikas Sanstha, Parisar Sakhi Vikas Sangh, Sampurna Earth, Akaar, Save the Earth Foundation, and the Indian Pollution Control Association (IPCA) have been instrumental in our mission to promote plastic circularity and create a more sustainable future.
