This Coimbatore-based startup is developing an eco-friendly alternative to single-use plastic

India's bioplastics market was valued at $320.13 million in 2021. It is expected to reach $1060.77 million by 2027 at a CAGR (compound annual growth rate) of 22.1 per cent. Tapping the need to provide bioplastic solutions, VS Veerasami researched on water soluble pellet technology which later led to the foundation of Greentech Bio Products, a biodegradable pellets manufacturing company, founded by his daughter Kavitha Rajan as the CEO.

Started in August 2021, Coimbatore-based startup GreenTech Bio Products manufactures water soluble pellets under the name of GreenPlast. Sustainable packaging solutions such as bags and films made with GreenPlast pellets dissolve in hot and cold water. These pellets made from non-plastic additives are non-toxic to the nature. The manufacturing unit of GreenTech Bio Products has a monthly production capacity of 125 tonne for pellets and 40 ton of films-bags. Since 2021 the startup has produced a total of 10-15 tonne per month, with an aim to reach full capacity of 125 tonne per month by end of next fiscal. GreenPlast pellets have clients in Kenya, Dubai and Chile. Three clients in India buy these pellets for manufacturing their own water-soluble pouches and bags. Other clients buy pouches, films, and garment sealing bags from the startup. In an interview with Bizz Buzz, Kavitha dwells upon the challenges she faced as a startup entrepreneur in the evolving market of bioplastic.

What are your plans charted ahead for GreenPlast?

My focus is on making these pellets accessible, economically feasible and available to all film extrusion manufacturers across India and abroad. For this to happen, I am looking at more pellet making units set up across India and abroad. We have also introduced a formulation of the pellets for water-soluble solid objects. With these, single-use plastic items such as ear-bud sticks, small containers, garment packing clips etc can be made. Once used, they can be dissolved in water and discarded. Similarly, our films can be used to make bubble wrap utilised in the e-commerce industry.

Any expansion plans in the near future?

My father always wanted to expand our facility into a bigger unit. Hence, we are looking out for investors who can support our plan. Second, we are in the process of setting up a manufacturing unit for water soluble solid objects. These can replace plastic earbuds, bottle caps, garment packaging items used for packing shirts, t-shirts and others. Water soluble packaging is the best alternative for most of the single-use items.

The government support that startups like yours seek?

We expect the government to fast-track approvals for certifications. We still do not have provision for "Water Soluble" pellets/bags/films manufactures. The government has tagged us under the "Compostable" producers list whereas we are the only water soluble pellets manufacturer on a larger scale. Faster approvals and certifications will let us thrive better during the initial stages of startup. From eight months we have been waiting for the Central Pollution Control Board (CPCB) approval. CPCB requires State Pollution Board certification first and then Central Institute of Petrochemicals Engineering and Technology certification. Unfortunately, we had done it the other way.

What kind of challenges GreenPlast had to face?

The very first challenge for my father was to convince us, the family, that it is possible for him to develop the formulation for water soluble biodegradable pellets and films. The second challenge was to set this up as a commercial plant where the formulation is made into pellets/resins. The most challenging part of making these pellets was arriving at the right proportion of PVA (polyvinyl acetate) and other non-plastic ingredients. It took nearly a year to bring balance between starch, oil and PVA.

Even though there are many patents registered for water soluble film, no single patent talks about the production capacity. Anyone can make something like this in a small scale at a laboratory, but it took years for my father to make the production worthy and at the same time economical. Lastly, as an industry, one of the challenges we face is the perception that people have about the product. When we claim our product as replacement for plastic, the first thought that comes to the mind of the customer is "Does this work like plastic?" Just because GreenPlast looks like plastic, it does not have to work 100 per cent like plastic as bioplastic properties differ from that of plastic. The idea of a replacement is that bioplastic has to decompose. Hence, these water-soluble bags/films will look like plastic, but behave like a paper bag when drenched in rain but it will completely dissolve only in hot water.

Is price a factor hindering in wider acceptance of alternative products, as plastic is comparatively cheaper?

Definitely! Price is a factor that hinders wider acceptance of alternative products. We are trying to create awareness among our buyers that the raw material and cost of the manufacturing process is high compared to normal plastics. We also educate them about the consequences and cost involved in disposing of single use plastic and how this extra cost can counteract to lessen that burden.

According to you, which other difficult to recycle plastic product needs an alternative to be found?

We need more innovative sustainable products in terms of sanitary products which has lot of plastic usage and difficult to recycle as they are discarded at various levels and is hard to contain them. There are lots of smaller plastic objects which go unnoticed such as the clips we use in packaging shirt.

What is the reason behind the never ending menace of plastic and its aftermath such as landfills?

According to a report titled Global Plastics Outlook: Economic Drivers, Environmental Impacts and Policy Options by OECD, the plastic waste generated per person vary from 221 kg in the United States to 114 kg in some European nations and 69 kg in Japan and Korea. While only nine per cent of the global plastic waste is recycled, plastic consumption has quadrupled over the past 30 years, driven by growth in population, income levels and emerging markets. With close to 30 metric ton of plastic waste in seas and oceans, and a further 109 metric ton accumulated in rivers, it is suffice to say that the situation is indeed a matter of grave concern. Indiscriminate use of single use plastics like straws and carry bags only compound to the problem in hand.

The government, consumers or makers of hard to recycle plastic, by whose initiative would it be possible to bring the problem of plastic pollution under control?

Dealing with plastic pollution requires a collaborative approach because it is a complex issue to solve and it has multiple stakeholders involved. Sometimes, in spite of banning single use plastic, it surfaces in the market because it is so widely used and the alternatives are not feasible for many. The right way to deal with the problem is to first create grassroot level awareness about plastic pollution and to find an economically viable alternative to plastic. We cannot merely expect one individual or organisation to change the status quo. The government, industry bodies and companies like us should work together in addressing this issue.