YUGA
Vision · Strategy · Execution0%
YUGA
Plastic waste for plastic-to-fuel conversion
Product · YUGA PMC

Converting waste plastic into pyrolysis oil, gas and char

Overview

Plastic-to-fuel uses pyrolysis — heating mixed/non-recyclable plastic waste in the absence of oxygen — to produce pyrolysis oil (a fuel/feedstock), combustible gas (reused for heating) and carbon char. It turns a waste-management problem into a revenue stream.

The business is supported by India's Plastic Waste Management Rules, Extended Producer Responsibility (EPR) and the single-use-plastic ban, which create strong feedstock availability and policy backing.

Why this business

  • Solves waste — diverts non-recyclable plastic from landfill and oceans
  • Multiple revenue — pyrolysis oil, off-gas (self-fuel) and carbon char
  • Low feedstock cost — plastic waste is cheap and abundant
  • Policy support — EPR + SUP ban drive demand for plastic processing
  • Fast ROI — well-run units report payback within ~2–3 years
Demand

  • Pyrolysis oil sold as industrial furnace/boiler fuel or refinery feedstock
  • Carbon char used in low-grade carbon / brick / fuel applications
  • Off-gas recycled to fire the reactor (lower running cost)
  • EPR / circular-economy compliance projects for brand owners
Technical

FeedstockMixed/non-recyclable plastic (LDPE, HDPE, PP, multilayer)
OutputPyrolysis oil ~40–55%, char ~25–35%, gas ~10–20%
Plant typesBatch, semi-continuous, continuous
Key approvalsCPCB/SPCB consent, EPR registration, factory licence
Capacity rangeTypically 1–20+ TPD modules
Setup

Capacity to showEntry 5 TPD; Common 10 TPD; Larger 20 TPD+
Area required10 TPD: 1–2 acres practical plot (storage, segregation, fire safety, APC clearance need space)
Approx. cost (without land)5 TPD ₹1.5–2.5 Cr; 10 TPD ₹3–5 Cr; 20 TPD ₹6–10 Cr (incl. APC, utilities, tanks, civil/electrical)
UtilitiesElectricity, process heat/fuel, cooling water, scrubber water/chemicals, nitrogen/inerting where used, fire water, forklift/loader
ApprovalsSPCB CTE/CTO, plastic-waste processor / EPR registration, factory/fire, hazardous-waste authorization if triggered, storage permission, buyer legality
Best-use statesGujarat, Maharashtra, UP, Tamil Nadu, Karnataka, Telangana, Rajasthan, Delhi-NCR
Waste receiving & sorting lineBaling/opening, conveyor, magnetic separationShredder/granulator & size-reductionDrying / moisture removal where requiredPVC/chlorine rejection & feed-quality controlContinuous/semi-continuous pyrolysis reactorFeeding system with air-lock or screw feederCondenser train & oil-water separatorPyrolysis-oil storage tanks & loading pumpNon-condensable gas cleaning & reuseChar/residue cooling & collectionScrubber, stack, monitoring ports, safety systemsFire-fighting system & laboratory
Feedstock & Output

Per 10 TPD plastic input

Input
Mixed/non-recyclable plastic
10 tonnes/day
Output
Pyrolysis oil
~4–5.5 tonnes/day (40–55%)
Carbon char
~2.5–3.5 tonnes/day
Gas (reused to heat reactor)
~10–20%
Quality & Compliance

IS (BIS)
Pyrolysis oil — no single BIS product std; follows CPCB SOP
ASTM
ASTM D7544 (pyrolysis bio-oil) as a reference; fuel tests D240/D445
MSDS / SDS
MSDS/SDS mandatory for pyrolysis oil (flammable) & char
Investment & Returns

Indicative for a ~5–10 TPD plastic pyrolysis unit.

Plastic-to-Fuel

Cost & ROI

Investment (CAPEX)
₹1.5–2.5 Cr
Output / year
600–900 MT oil/yr
Revenue / year
₹2–3.5 Cr
Profit / year
₹0.4–0.8 Cr
Land required
~1 acre
Payback
2–3 yr

Indicative only — actual figures depend on capacity, location, raw-material price and utilisation. Contact us for an exact DPR.

Project investment (CAPEX)₹1 crore – ₹3 crore
Capacity basis~5 – 10 TPD (tonnes/day) plastic waste
Approx. annual revenue₹2 crore – ₹6 crore
Approx. gross profit (GP) margin30% – 40%
Approx. net profit / year₹40 lakh – ₹1.2 crore
Approx. payback period2 – 3 years
Where to build

Maharashtra, Gujarat, Tamil Nadu, Delhi-NCR, Karnataka

High urban plastic-waste generation, industrial furnace-oil demand, supportive PCBs.

Questions

A pyrolysis process that converts waste plastic into pyrolysis oil, gas and char without burning it in open air.

From feasibility to first commercial production - and the capital to fund it.