Tetra Pak and Gayatri Paper Mill collaborate for end-market expansion of polyAl

Tetra Pak's investment in a dedicated polyAl1 pelletising line at Gayatri Paper Mill in 2016 marked a significant milestone in the journey of polyAl recycling in India. Since then, the facility has been operational, producing high-quality pellets and embarking on innovative developments in end-use applications.

Background and initiative – establishing a local market for polyAl

PolyAl recycling faced challenges in finding diverse end-use applications in the region. The need to explore innovative solutions and collaborations with plastics manufacturers led to ground-breaking developments in polyAl content integration.

The primary objective of Tetra Pak's collaboration with Gayatri Paper Mill was to expand the local end-market for recycled polyAl materials. By investing in a state-of-the-art pelletising line, the aim was to develop and commercialise products made with polyAl.

PolyAl pelletising line in facility

Image: The dedicated polyAl pelletising line at Gayatri Paper Mill

Results – new possibilities for recycled materials

The dedicated polyAl pelletising line enabled Gayatri Paper Mill to produce top-quality pellets for various applications. Through ongoing trials with local plastics injection moulding companies, innovative solutions were discovered, such as blending polyAl with other polymers like polypropylene and high-density polyethylene (HDPE).

The innovative approach of blending polyAl with other polymers opened new possibilities for incorporating polyAl content into existing product manufacturing. This not only reduced waste but also contributed to the circular economy2 by creating value-added products from recycled materials.

The developments in polyAl content integration resulted in the manufacturing of returnable pallets and point-of-sale display stands. These products have gained popularity in local retail stores and are impacting promotional efforts and product shelving.

Looking ahead – growing demand, furthering innovation

With the success of the polyAl pelletising line and the growing demand for innovative products, Gayatri Paper Mill continues to explore further opportunities in polyAl end-use applications. The collaboration between Tetra Pak and Gayatri Paper Mill is a testament to the power of innovation.

Products made of polyAl

Image: Top-quality polyAl pellets can be used in a variety of end products

1The non-fibre component of carton packages is known as polyAl, which designates the layers of polyolefins and aluminium being used as barrier against oxygen and humidity to protect the food content in aseptic carton packages.

2The circular economy refers to a system in which materials never become waste and are kept in circulation through processes including recycling, reuse and composting. It tackles environmental challenges by decoupling economic activity from the consumption of finite resources. Source: Ellenmacarthurfoundation.org, What is a circular economy?

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Companies involved

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