SGPPL and CFlo pioneer C&D waste management in Surat with ~96% material recovery

Surat Green Precast Private Limited (SGPPL) Surat, Gujarat, India Construction & Demolition Waste

Surat Green Precast Private Limited (SGPPL) won Surat Municipal Corporation's 2018 PPP tender to recycle the city's C&D waste without a tipping fee, and invested in a mobile CFlo recycling plant launched in March 2019. The 300 TPD facility recovers approximately 96% of materials from the feed as recycled sand and aggregates, cutting 508 tonnes of CO2 emissions annually and reclaiming 30,000 sq yards of land from landfill each year.

The Challenge

In 2018, Surat Municipal Corporation initiated a tender under a public-private partnership framework to select a waste processor for a new recycling facility to manage the city's construction and demolition waste without imposing a tipping fee. SGPPL emerged as the winning bidder and needed a plant capable of scientifically processing the substantial C&D waste generated across Surat, gathered from 10 collection centres and transfer stations, spanning cement concrete, cement mortar, bricks, rubble, stone, sand and soil.

The Solution

CFlo's C&D Waste Processing plant handles up to 300 TPD, producing high-grade washed and dewatered sand by removing oversize and ultra-fine particles. The plant includes a specialised segregation system, debris handling system, crusher and a multiple-section screening unit, with complete automation and remote control for high yield. Finished products span oversize, 20mm aggregate, 20mm to +5mm aggregate, Zone II concrete sand and Zone IV plaster sand; the plant was later configured to produce sand exclusively at 5mm to match market demand, while retaining flexibility to make all four products.

Hourly water usage is restricted to just 6-8 m3 and power to 120 kWh. CFlo took a collaborative approach from the initial investment, running an onsite training workshop for local contractors and regulators to maximise use of recycled products. The recycled sand and aggregates are reused in construction and value-added products such as tiles, blocks and pavers, an approach now being adopted in several other Indian cities.

300 TPD

C&D waste processing capacity

~96%

recovery of materials from the feed

508 tonnes

CO2 emissions cut annually, equal to burning 250,000 kg of coal

30,000 sq yards

land reclaimed from landfill, unlocking Rs 100 crores of real estate each year

The Results

The plant also saves 9,100 Gigajoules of energy annually, enough to power 3,000 Indian homes for a year.

"Our vision is to build the best product from waste, cause no unnecessary harm to the environment, use business to inspire and implement a solution to the environmental crisis in construction projects, is superbly exhibited by the commissioned plant. From a total of 50 points in 2020, ranking points for C&D waste management for Swachh Survekshan 2021 have been doubled to 100 points: 50 points for recycling and 50 points for reusing the products. We already got all products tested by the National Institute of Technology, Surat (SVNIT) and have started producing paver blocks from recycled sand and aggregate. We have achieved a compressive strength of 50 n/mm2 while using 100% recycled material."
– Mr Kanoj Lakhani, Managing Director, SGPPL

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