rPET fibre is becoming the first choice fibre amongst the users

Ganesha Ecosphere (GESL) entered into business in 1987. Over the years, the company has emerged as one of the leading rPET Fibre manufacturers in India. They have pioneered the manufacture of rPET fibre and rPET yarn from pre and post-consumer PET bottle scrap. B P Sultania, Joint President, GESL, shares the recent innovations of the company and their key regulations, in this conversation with Divya Shetty.

Given the increasing demand for rPET products, could you elaborate on how GESL is strategically positioning itself to support and contribute to the growth of this sector?
Yes, the demand for rPET products is growing in the worldwide. Of late, the entire world has now recognised the need to emphasise to recycle plastics waste and particularly PET bottle scrap.
GESL was the first company in India to enter into plastics recycling way back in 1994 by putting up a small line of 350 metre/month to produce recycled polyester staple fibre. After facing the teething problems, our growth accelerated since 2006 with the acceptability of the rPET fibre into Yarn spinning, on wovens and fibre fill applications.
Now, GESL has 4 plants at different strategic locations in India with a combined rPET recycling capacity of around 15000 metre/month to produce recycled PSF, spun yarn, filament yarn, B2B and textile grade chips. Virtually, GESL commands a market share of around 15 per cent in Indian market.

Can you share the various technical textiles segment the company caters to and some of the recent innovations that GESL has introduced in the rPET products, particularly within specific sectors?
Technical textiles is one of the core segment where GESL is optimising to offer specific qualities such as high tenacity, high bounce hollow conjugated fibre, flame resistant, moisture absorption/evaporation/ management, anti-static, anti-bacterial, UV resistant, short cut fibre for re-inforcement and other specialised functionalities to meet the specific needs of the diverse industries and sector.
GESL products well caters to both woven and non-woven textile sector. The rPET fibre is used in big volumes for yarn spinning to be converted finally into apparels. We produce fine denier fibre in grey and dope dyed in small batches to cater with the specific requirements of the end user spinner.
In nonwovens, the rPET fibre is becoming the first choice fibre with the users due to a vast range of deniers/cut lengths and dope dyed in small batches for use in nonwoven carpets, felts, geo-textiles and other allied applications.
The Home textiles business is increasing in India where the hollow conjugated fibre is mainly used for filling into cushions, pillows and quilts etc. GESL is well catering into this sector with a market share of around 25 per cent.
GESL is also producing recycled FDY Yarn which is used mainly for home textiles.

Sustainability is a key focus in today’s market. What sustainable initiatives has GESL implemented to address environmental concerns?
Sustainability remains to the core of heart in GESL.
Post-consumer Pet bottle scrap is our raw material which is converted into washed flakes for further use in fibre/yarn and B2B chips.
rPET bottle flakes are used to make recycled fibre. Recycled fibre is used to make recycled Spun yarns. rPET bottle flakes are used to make B2B chips. B2B chips are again converted into Pet bottles. This is the best example of circular economy. The use of rPET bottle flakes results into replacement of virgin raw material like PTA/MEG and reducing greenhouse gas emission by up to 75 per cent.
GESL has installed solar panels in its plants which replace/reduce the use of other energy sources that have larger effects on the environment. These solar energy technologies do not produce air pollution or emission of greenhouse gases. GESL has already installed solar panels of around 17 per cent of the total power requirements and adding further.

What sets GESL apart in the market? Could you elaborate on the unique selling propositions (USPs) that distinguish the brand from its competitors?
GESL is a multi rPET product making company offering recycled PSF, spun yarn, filament yarn, B2B and textile grade chips etc. A major part of its products are for textiles segment where there are huge demands. Being the largest recycled PSF making company, GESL is producing various types of recycled fibre for different applications.
Yarn spinning: Fine denier fibres in grey and dope dyed in small batches. We have 300 plus doped dyed colours.
Nonwovens: Fine denier and coarse denier fibre up to 70 deniers for use in nonwoven carpets, geo-textiles, felts etc.
Home textiles: Hollow and hollow conjugated fibre in different deniers for use in fibre fill applications and carpet yarns etc.
Fibre for re-inforcement: Short cut fibre for mixing with cement, paper and battery separators etc.
In Spun yarn, the company is making dope dyed spun yarn in various counts. We have already started a small capacity for making recycled FDY yarns in grey and dope dyed followed by recycled POY and DTY.
As such, our aim is to serve and cater with the needs of different end users in the best possible way which makes our brand distinguished from other competitors who are confined to a particular segment only.

Considering the evolving landscape of environmental regulations, how does GESL navigate and adhere to these regulations in the production and distribution of rPET textiles?
GESL is well equipped to meet, adhere and navigate to Environmental regulations regarding rPet textiles. By diverting plastics from landfills and Ocean, rPET actively combats pollution. Moreover, its lower carbon emissions and reduced energy consumption during production contribute to a more sustainable future.
GESL has also introduced bio-degradable fibre which is 100 per cent degraded into fertile sand in just one year after disposal into landfill.
GESL holds quality certifications like Oekotex class 1, ISO, SEDEX, Global recycling standards (GRS), Ocean bound Plastics (OBP) and confirming to laws regarding Water and Air Pollution. We have s strong affiliation with various international Brands like TARGET, INDITEX, C&A and IKEA etc.
We are providing full traceability of the recycled content in the final product. GESL is fully committed to save the planet by protecting the environment and reducing the air, water and land pollution.
GESL has also introduced bio-degradable fibre which is 100 per cent degraded into fertile sand in just one year after disposal into landfill.

Are there any upcoming projects or initiatives that GESLis excited about, and that the industry should be aware of?
Expansions and new projects are always on-going in GESL. More B2B chips line will be added into coming year. Recycled POY and DTY yarn must go on stream in the second quarter of FY 2024-25. GESL wish to maintain into leadership into rPET business.