Avro India expanding recycling capability for difficult-to-process plastic waste

India’s leading manufacturer of plastic-molded furniture Avro India Limited is set to address one of India’s most complex environmental challenges—recycling difficult-to-process plastic waste—with the launch of its second state-of-the-art greenfield recycling facility in Ghaziabad (located in the North Indian State of Uttar Pradesh).

Plastic recycling vertical operating under Avro Recycling Limited, (a 100% owned subsidiary of Avro India Limited), expanded further by adding the second facility to recycle rigid plastic waste. The second plant commissioned in the last quarter of 2025, has processing capacity of 500 metric tons per month (MTPM). The capacity is scheduled to scale up further to double by Q4 of FY 2025–26. In India, fiscal year spreads over April-March period.

“We have ventured into plastic recycling about three-years ago with the opening of the first recycling site in Ghaziabad to process the flexible plastic waste. Now we have forayed into recycling of rigid plastic waste also with the opening of second site. Both the units have processing capacity of 500 metric tons each per month. We now set to double flexible and rigid capacity to 2,000 MTPM by March 2026 which includes washing as well as extrusion,” informed Sushil Aggarwal, Chairman and Whole-Time Director, Avro India Limited in an exclusive interaction on the sidelines of the press conference organized by the company in New Delhi last week.

By March 2026, the cumulative processing capacity of both the plants expected to double to reach 2,000 MTPM of flexible as well as rigid plastic waste. While it also operates two moulded plastic furniture plants in Ghaziabad.

The capital expenditure invested in the second rigid plastic recycling plant stands at INR 250 million as of date, with plans to invest an additional INR 300 million by FY 2027 as part of further expansion in recycling vertical. The second recycling site commenced commercial production from January 2026. As part of its long-term sustainability vision, the company also plans to expand pan-India through future greenfield recycling projects.

Founded in 2002, Avro India Limited has consistently delivered durable, high-quality, and affordable plastic-molded furniture to households, businesses, and institutions across India. Today, the company enjoys nationwide presence and is listed on both the NSE (National Stock Exchange) and BSE (Bombay Stock Exchange).

Sushil Aggarwal, Chairman and Whole-Time Director (middle) with Sahil Aggarwal, Managing Director and Nikhil Aggarwal, Whole-Time Director

Avro plans to set-up multi-locational greenfield plastic recycling sites 

Interestingly, the company plans to open multiple recycling plants in different parts of the country. “We are also working on setting-up pan-India network of 4-6 ‘mother and baby’ recycling plants by 2027, aimed at decentralizing waste processing and accelerating India’s transition to a circular economy. Through innovation, scale, and collaboration, the company aims to play a defining role in positioning India as a global leader in sustainable plastic management.” 

Avro aims to further increase the plastic recycling capacity to more than double once the ‘mother and baby’ plants becomes operational from 2,000 MTPM to 5,000 MTPM by end fiscal 2027. The ambitious multi-locational expansion involves additional investment. “The total investment in the recycling vertical would go up to INR 1 Billion by end fiscal 2027 in the upcoming multiple greenfield plastic recycling sites.”  The company has a vision of achieving recycling capacity of 10,000 MTPM in the years to come.   

Avro pioneered eco-system of plastic furniture industry in India

India generates 26,000 tons of plastic waste every day, equalling 9-10 million tons annually. As per independent global studies India is regarded as the largest contributor of mismanaged plastic waste.

“India’s plastic challenge cannot be solved through fragmented efforts. It requires scale, technology, and intent. At Avro, we have invested years of research to build a system that converts complex plastic waste into valuable raw material. Our vision goes beyond recycling and focuses on building a nationwide ecosystem that transforms waste into an opportunity.” He further noted, “India’s plastic crisis is not about lack of awareness or policy but it is about lack of scalable recycling of hard, contaminated plastics, which are now overwhelming land, air, water and public health systems.”

The promoter regarded as a pioneer in manufacturing the affordable plastic-molded furniture using 90% recycled plastics. “With our consistent efforts, currently almost INR 50 billion molded-plastic furniture industry eco-system created in the country.” The promoter is also a National President of AIPMFMA (All India Plastic Moulded Furniture Manufacturers Association).  

According to him,” Less than 10% of plastic waste is truly recycled back into usable material and the reminder is burnt, dumped in landfills etc. Flexible and multilayer plastics forms the largest and least recycled waste stream.”

Plastic waste in India is projected to double within the next decade and cleanup and healthcare costs will exceed recycling investments. Studies found 1kg of mismanaged plastic emits up to 2.5 kg of CO2 equivalent gases. “Plastic waste is not a climate, health and generational issue – not just an environmental one.”   

Deployed proprietary technology

Historically, difficult-to-process plastic waste—such as cement bags, salt bags, sugar bags, putty bags, and calcite packaging—was considered largely non-recyclable and was either downcycled or handled by the unorganised sector.

After more than three-years of intensive research, trials, and technological innovation, Avro has developed a proprietary system capable of upcycling such complex plastic waste at scale, enabling the responsible processing of nearly 1 million metric tonnes per annum (MTPA) of such waste generated in India.

Avro recycling sites operates on mix of Indian, Chinese and European recycling lines. “We have also deployed proprietary technology which separate/segregate polymers like PP, HDPE, LDPE, PET as well as color. Only few companies have been able to develop and deploy this type of technology in India.”

The company purchase plastics scrap round the year with 100% advance payment through industries, scrap traders, collectors, segregators, freelancers etc covering almost huge area spreading over 1,000 to 1,500 km.  

The recycled granules produced at the Ghaziabad-based recycling plants are fully utilized in the manufacture of high-value end products, including plastic furniture, air coolers, washing machines, automotive components, and other industrial and consumer applications. These granules are available at up to 40% lower cost than virgin plastic, while meeting stringent technical and durability standards—helping manufacturers remain cost-efficient, compliant, and environmentally responsible.  

With the implementation of Extended Producer Responsibility (EPR) norms by the Government of India—mandating the use of at least 30% recycled plastic content in rigid plastics—brand owners are facing a significant supply gap of high-quality recycled raw materials. Addressing this challenge, Avro India has emerged as the largest and most reliable organised player in the flexible plastic recycling space, offering consistent volumes at industrial scale.

Targeting 5 million pieces of plastic furniture by 2027

With the ongoing recycling expansion, Avro plans to achieve manufacturing of 5 million pieces of plastic furniture annually by 2027. Last year, it manufactured 3 million pieces and targeting 3.5 million pieces this fiscal. The plastic furniture vertical has annual revenue of INR 1 Billion.

Avro has built one of India’s most extensive distribution networks, comprising over 30,000 retailers, supported by more than 300 distributors across 24 states to sell its plastic furniture. It also sells its product range online platforms like Amazon, Flipkart etc.

The company manufactures a diverse product range backed by a three-year guarantee, ensuring durability and weather resistance for both indoor and outdoor applications. Its key competitive advantage lies in a highly cost-effective pricing strategy, with products priced approximately 40% lower than national and established brands, driven by low overheads and operational efficiency. High-volume production at its Ghaziabad facility has positioned Avro as the largest player in North India and among the top five plastic-moulded furniture companies nationwide.

Avro India Limited is one of India’s leading manufacturers of plastic furniture and recycled polymer solutions. With advanced manufacturing infrastructure, a strong national presence, and a firm commitment to sustainability, Avro is actively contributing to India’s circular economy by transforming plastic waste into high-value, durable products.