Key learnings included the practical limits of manual SKU sorting, the importance of densifying material via baling (increasing density from 50kg/m³ to 300kg/m³), and the critical role of on-site wastewater treatment, which is typically handled by utilities in Europe but must be managed in-house in the African and Middle East context.

Design, Benchmarking & Procurement

The design and procurement phases were executed in alignment with international engineering standards. As part of the ideation and benchmarking process, the project team visited advanced recycling facilities in the Netherlands, Belgium, and Germany. Key learnings included the practical limits of manual SKU sorting, the importance of densifying material via baling (increasing density from 50kg/m³ to 300kg/m³), and the critical role of on-site wastewater treatment, which is typically handled by utilities in Europe but must be managed in-house in the African and Middle East context.

With insufficient space at the existing site, a greenfield location was selected to host the sorting facility. This was located approx. 10km from the main processing site where trucks can easily access without much hinderance. This allowed for optimal layout, lower rental rates, and long-term scalability. The team issued competitive tenders for each major equipment category, evaluating vendors on performance, service agreements, cost, and lead times. Strategic partnerships were secured with suppliers like Boretech and Erema to ensure the most cost-effective and reliable technology mix.

Washline & Downstream Design

Once baseline material flows were estimated, detailed washline concepts were developed for HDPE, PP, and PET. These included quality-enhancing process steps such as turbo washers, pre-wash, shredders, inspection conveyors and batch hot-wash units, along with bypass systems to supply cold-washed flakes when required.

Downstream, pelletising solutions were evaluated to ensure they aligned with customer specifications and washline output. The company also initiated engagement with international equipment suppliers to develop the region’s first rPET line, assessing infrastructure requirements such as space, power, and nitrogen inputs.

Construction & Site Execution

The construction phase encompassed extensive civil, mechanical, and electrical works. Regulatory compliance was tightly managed, including environmental impact assessments, structural approvals, and safety protocols. In April 2024, the team successfully commissioned a 4.6-acre greenfield site with a 28-SKU sorting line, a 120-ton baler, fire suppression systems, and space allocated for future expansion.

For the process facility, a mix of new warehouse construction and retrofits totalling over 10,000 sqm was pursued. Engineering solutions were implemented to address challenges such as low roof clearance (6m vs. the required 7m) and drainage design for the washlines. These were integrated with an effluent treatment plant capable of recycling 98% of water at a rate of 16m³ per hour.

Commissioning & Handover

Commissioning followed a structured plan covering equipment testing, operator training, and startup protocols. The PO washline was handed over in June 2024, followed by the PET washline in November 2024. Two new extruders were installed in December 2024, with the rPET line and SSP system in place by January 2025, pending final commissioning.