Prepared for

Tetra Pak India Pvt. Ltd.

Final Report

Project code: 2015 EE04

Post-Consumer Tetra Pak

Cartons (PCCs) Management

Post Consumer Tetra Pak Cartons (PCCs) Management

ii

� � � � � � � � � � � � � � � � � � � � � � � � � � � � � � � �� � � � � � � � � � � ! " � � � # $ � " � $ � %& ' ( ) * + , - ./ 0 1 2 3 4 0 5 1 6 7 8 9 & 8 2 9 : / : ; 4 : 9 2 0 5 1 < / 4 4 1 = > : 5 : ? 8 7 8 5 2@ 8 A B 8 C D E F & D 8 ' 5 8 9 ? G : 5 H ( 8 1 0 6 9 I 8 1 ) 5 1 2 E 2 6 2 8 *J / 9 0 K 8 I 2 ( 8 L 0 9 2 @ 0 * + , - M ' ' , N O

P � ! � � $ % � � ! " � $ � %/ 9 0 K 8 I 2 > 0 5 E 2 0 9 E 5 ? 4 8 C C& ' ( ) Q R S T + N . U + - , , 0 9 + N . U + - - -B : 9 V : 9 E W 8 2 D X C 0 I ; Y Z [ \ ] S L 7 I ^ 2 8 9 E * 9 8 1 * E 5) _ 4 4 0 7 L C 8 ` a b 0 H D E ( 0 : H c \ d + N . U + - N N 0 9 + N . U + - N M@ 8 A B 8 C D E e - - , , , f g R h A A A * 2 8 9 E E 5 * 0 9 ?) 5 H E : ) 5 H E : i j - k B 8 C D E < , = - -

Post Consumer Tetra Pak Cartons (PCCs) Management

iii

l m n o m p m qB 9 W 6 5 8 8 C / : 5 H 8 G a B E 9 8 I 2 0 9 3 r r ( ' a & ' ( )s q o t u o v w x y t n m z { o | w { } q> 9 W 0 6 9 : V D > : 5 6 K : a ~ 1 1 0 I E : 2 8 � 8 C C 0 A a & ' ( )s q } � m u { � m w �B 9 ~ C : ; 4 D : 5 H B 8 ; : a ~ 1 1 0 I E : 2 8 � 8 C C 0 A a & ' ( )> 9 � : E � E 1 D : 5 > : C E ; a ( 8 1 8 : 9 I D ~ 1 1 0 I E : 2 8 a & ' ( )> 9 � : V E 9 W D : 9 7 : a ( 8 1 8 : 9 I D ~ 1 1 0 I E : 2 8 a & ' ( )> 1 � 9 E L : C E � E ; 9 : 7 a ( 8 1 8 : 9 I D ~ 1 1 0 I E : 2 8 a & ' ( )> 1 / 9 : 5 : C E 4 D : � : 5 a & ' ( )> 9 ( W 6 9 8 1 D a ~ 1 1 0 I E : 2 8 � 8 C C 0 A a & ' ( )B 9 W 6 7 E 2 � 6 7 : 9 r : 6 2 : 7 a � 8 C C 0 A a & ' ( )> 9 � 8 H / 9 : ; : 1 D W D : 9 7 : a ~ 1 1 E 1 2 : 5 2 > : 5 : ? 8 9 a & ' ( )> 9 ( : K B 8 8 L & 9 E L : 2 D E a ) 5 2 8 9 5 a & ' ( )� � { q m w u � � m w �> 9 _ : 9 7 E 5 H 8 9 W E 5 ? D a � 8 C C 0 A a & ' ( )� � o { } q o w x � m w �> 1 W L : 5 H : 5 : 4 D : 2 2 8 9 K 8 8 a ~ 1 1 E 1 2 : 5 2 ' H E 2 0 9� m u q m { w q o w x � z z o z { w t u m> 1 @ E 1 D : & : 5 8 K : a & ' ( )> 9 W D G : 7 W 6 5 H 8 9 @ : G : 9 a & ' ( )> 9 W A : L : 5 B : 1 a & ' ( )> 1 b : ; 1 D 7 E W 6 V 9 : 7 : 5 E 6 7 a & ' ( )

Post Consumer Tetra Pak Cartons (PCCs) Management

11

� � � �� � � � �� � � � �� � � � �� � � � �� � � � �� � � � �� � � � �� � � � �� � � � �� � � � � �

� � � � � � �   ¡ � � ¢ � £ � ¤ � ¡ �   ¥   � ¦   ¡

Executive Summary

Tetra Pak is a multinational company that develops, manufactures, and markets systems for

processing, packaging, and d istributing food products. Tetra Pak cartons are primarily made

from paper. A Tetra Pak carton is composed of 75% paperboard , 20% polyethylene, and 5%

aluminium. As part of environmental initiatives, Tetra Pak has undertaken various activities

for collecting and recycling Post-Consumer Tetra Pak Cartons (PCCs) and is working with

non-governmental organizations (NGOs) and waste pickers to segregate PCCs.

The overarching objective of this study is explor ing the collection and recycling practices

of PCCs and the current quantum of Tetra Pak cartons procured/ retrieved by waste dealers.

Also to assess the actual quantum of PCC reaching paper mills that recycle paper from low -

grade paper waste and fate of pulping rejects. Value chain and economics in collection and

recycling was also studied . These studies also helped in understand the quantity of PCCs

reaching dumpsites. Ultimately this predicts the needs to upscale collection and recycling:

economics, awareness, infrastructure, and so on.

The survey design was com prehensive and exhaustive enough to capture the

overarching scope and facilitate the objectives of the study. Survey partners were identified

in each of the identified cities for conducting survey as per the scope given to them. The

survey partners were asked to take photographs and film the critical parts of the sampling

exercise. TERI professionals visited each survey partner in their respective city to guide the

survey teams and supervise the exercise.

The study revealed that the PCC are collected by ragpickers, small scale waste paper

dealers, large scale dealers and sent to recycling units. The outcomes of the study revealed

the percentage of respondents dealing and PCC and have been depicted in figure 1.

Kolkatta, Guwahati and Hyderabad revealed that 100% of the respondents at all three levels

were dealing in PCC

§ ¨ © ª « ¬ ­ ® ¯ ¬ ° ± ² ³ ´ ¬ ³ µ ° ´ ¬ ¶ · ¨ ³ © ¨ ³ ¸ ¹ ¹ ¶ µ ° ª « º ¬ » ¼ ¨ µ ¨ ¬ °

Post Consumer Tetra Pak Cartons (PCCs) Management

12

½ ¾ ¿ À ½ ¾ Á Â ½ ¾ Á Â Ã ¾ Ä Â Ã ¾ Å Ä Ä ¾ Æ ¿ Á Á ¾ Á Á ½ Á ¾ Â ¿ Â ¾ Å Å ½ ¾ Á Ã Å ¾ ¿ ¿ Â ¾ ½ ÅÁ ¿ ¾ À Ä ¾ ¿ ½

Ç È É Ê È Ë Ì Ç Í Í Î Ë Ï Ð Ñ Ì È Ð Ë Ð Ò Ó Ñ È Ô

½ ¾ ½ ½ ÕÂ ½ ¾ ½ ½ ÕÖ ½ ¾ ½ ½ ÕÅ ½ ¾ ½ ½ ÕÀ ½ ¾ ½ ½ ÕÁ ½ ½ ¾ ½ ½ Õ× Ø Ì Ð Ò É È Ê Ó Ê Ò Î Ë Ù É Ð Ì È

Ú Û Ü Ý Þ ß à Û á Þ Û â ã ß à ä Û Þ ß å Û à á ß æ ß Û Þ ß â à å ß â ß Û ç Û Þ è é ß æ Û à Ý ß â á ê ß à ä ë Ý ß ë ì à í â î ß è Û ç æâ ß î ß Û Þ ß æ Ü ë â ß á ê Û ç ï ð ñ ì â Û ä á ò ë ç ë ì ó ô ô ò ç å Û à á ß Ý Û Ý ß â õ Û Þ ß à ò ç ä ò á ò ß à ë ì ö Û ç ã Û Þ ë â ß ÷ ø ê Û ù Û úû ê ß Ý ë à à ò õ Þ ß â ß Û à ë ç à ì ë â ê ò ã ê ì â Û ä á ò ë ç ë ì ó ô ô ò ç á ê ß à ß á å ë ä ò á ò ß à ò à Û á á â ò õ í á ß æ á ë ê ò ã ê Ý â ò ä ßÛ ç æ Û ä ä ß Ý á Û õ ò Þ ò á è ì ë â â ß ä è ä Þ ò ç ã ë ì ó ô ô ò ç õ ë á ê á ê ß ä ò á ò ß à å ê ò ä ê ß î ß ç Û á á â Û ä á à à Ü Û Þ Þ å Û à á ßæ ß Û Þ ß â à ì â ë Ü ë í á à ò æ ß ä ò á è á ë à ß Þ Þ ó ô ô à á ë Þ Û â ã ß à ä Û Þ ß æ ß Û Þ ß â à ú û ê ß Û ç Û Þ è à ò à â ß à í Þ á à Û â ß à ê ë å çò ç ì ò ã í â ß ü ú

Survey revealed that in cities of Kolkata and Guwahati PCC was treated before selling by

separating aluminium and paper and aluminium was sold at a high price of Rs 45 to Rs 60

per Kg. The recycling rates were worked out with two scenarios of 26% and 29% recovery

rates by informal sector revealing an overall recycling rate of 42.85 percent and 45.52 percent

respectively. The results are as in figure 3 and figure 4.

§ ¨ © ª « ¬ ý ® ¯ ¬ ¼ » ¼ · ¨ ³ © « ¶ µ ¬ þ ¨ µ ÿ � � � « ¬ ¼ ² º ¬ « » � » ¨ ³ � ² « � ¶ · ° ¬ ¼ µ ² «

§ ¨ © ª « ¬ � ¸ ¬ « ¼ ¬ ³ µ ¶ © ¬ ² � ¸ ¹ ¹ ¶ ³ ¶ · » � ¬ ´ ¶ µ · ¶ « © ¬ ° ¼ ¶ · ¬ þ ¶ ° µ ¬ ´ ¬ ¶ · ¬ « · ¬ º ¬ · �

Post Consumer Tetra Pak Cartons (PCCs) Management

13

½ ¾ ½ ½ ÕÂ ½ ¾ ½ ½ ÕÖ ½ ¾ ½ ½ ÕÅ ½ ¾ ½ ½ ÕÀ ½ ¾ ½ ½ ÕÁ ½ ½ ¾ ½ ½ Õ× Ø Ì Ð Ò É È Ê Ó Ê Ò Î Ë Ù É Ð Ì È

Study also revealed that PCCs reaching paper mills was 0.36 percent of the total paper

received by the mill. On an average PCCs reaching dumpsite was 0.343 percent of total

waste reaching dumpsite.

Based on the study conducted TERI recommends the following:

1. PCC management can be effectively increased in cities with no or low market by

developing markets in these cities. Active recycling has significant contribution in the

overall recycling of PCCs. Hence, efforts should be made to upscale the capacity of the

existing collection centres and to install more such centres in other cities.

2. PCC management can be more efficient if the chain is small and there is better price in

the market for the collectors.

3. Awareness among recyclers about the potential for using PCCs is important. This should

be done by highlighting statistics and case studies of mills consuming PCCs for paper

production.

4. R&D should be carried out for efficient technologies for separating paper from PCCs and

usage of polyethylene and aluminium recovered thereafter. Paper mills and recyclers

should also be involved so as to create a better market.

5. Kolkata, Guwahati, Hyderabad and Chennai reported the highest informal recycling rate

for PCCs. Many ragpickers in Kolkatta and Guwahati reported that they separated paper

and aluminium from the PCCs before selling them to kabadiwalas. The management of

PCCs should be further studied and lessons should be replicated at other places along

with proper environmental pollution control measures.

6. Such an exercise (to study the management of PCCs in major cities and identify the

recycling rates) may be repeated in every 3 years to assess the improvement in recycling

rates.

§ ¨ © ª « ¬ � ® ¯ ¬ ¼ » ¼ · ¨ ³ © « ¶ µ ¬ þ ¨ µ ÿ � � « ¬ ¼ ² º ¬ « » � » ¨ ³ � ² « � ¶ · ° ¬ ¼ µ ² «