India’s new plastic waste management rules now allow up to 60 per cent recycled plastic content in rigid food packaging, a move that experts say could reduce plastic waste but will require strict safety checks, better recycling systems and stronger industry coordination.
Scientists and recyclers in Bengaluru believe the target is ambitious but achievable if the country improves the way plastic waste is collected, cleaned and processed.
Suryasarathi Bose, professor of Materials Engineering at the Indian Institute of Science in Bengaluru, explained that rigid packaging includes food containers commonly used by delivery platforms such as Swiggy and Zomato. According to him, the biggest concern is food safety.
He said recycled plastic used for food packaging must pass strict contamination tests set by the Food Safety and Standards Authority of India. These tests are designed to ensure that harmful chemicals from recycled plastic do not leak into food. He added that even if a product contains 60 per cent recycled plastic, it still has to meet all food safety standards.
Bose also pointed out that rigid food packaging must maintain enough mechanical strength to remain durable and safe for use. He explained that India’s current plastic collection and sorting system is still inefficient, making high-quality recycling difficult.
According to him, plastic waste meant for food-grade recycling should ideally be collected separately before it enters mixed garbage streams. He gave the example of milk pouches, saying they should be returned directly for recycling instead of being thrown into regular dustbins. This would help avoid contamination and improve recycling quality.
He further explained that different types of plastic cannot be mixed because chemical migration can occur between polymers. For example, polyethylene milk pouches mixed with polystyrene or thermocol materials can create safety risks.
After collection, plastics must go through multiple stages including washing, shredding and pellet formation. These pellets are then supplied to manufacturers who mould them into food containers or other packaging products.
However, Bose warned that recycling itself creates another environmental challenge in the form of microplastics released during shredding. He also stressed the importance of traceability in recycled products.
According to him, manufacturers will now have to clearly mention the amount of recycled and virgin plastic used in each product. This system will help future recyclers know how many times a material has already been processed.
He said many countries already follow such systems and India can also successfully adopt them.
Recycling companies are also preparing for the transition. Srichakra Polyplast, a recycling company that converts segregated plastic into pellets, says demand for recycled material is increasing.
The company’s chief operating officer, Satish Kumar Gunturu, said the firm receives segregated plastic waste and carries out washing, decontamination and shredding before converting it into pellets and granules.
He admitted that using 60 per cent recycled material in food-grade packaging may be difficult initially, but believes it can become possible as brands increase adoption and demand grows.
Gunturu also noted that appearance could become a challenge because recycled plastic often changes the clarity and colour of products. Clear plastic bottles, for example, may become slightly opaque after recycled content is added.
Still, he believes strict compliance and quality testing can ensure safe food-grade packaging. He added that the recycling industry in India is likely to expand rapidly to meet future demand.
According to him, digital tracking systems managed by the Central Pollution Control Board are already helping monitor recycling targets and Extended Producer Responsibility obligations.
He also said increasing the use of recycled plastic could reduce India’s dependence on crude oil and help lower landfill waste.
However, plastic manufacturers say the new rules place too much burden on small industries.
Vijaya Kumar V, president of the Karnataka State Polymers Association, said packaging producers are facing stricter environmental penalties even though they only manufacture packaging materials and do not directly pack products.
He criticised the lack of awareness programmes and consultations by pollution control authorities before introducing nationwide amendments. According to him, many questions raised by industries regarding Extended Producer Responsibility systems remain unanswered.
He also argued that small-scale manufacturers lack manpower and resources to create consumer awareness campaigns. In his view, brand owners who promote packaged products should also share responsibility for waste management and recycling efforts.
Industry representatives say the government must improve recycling infrastructure and provide clearer implementation guidelines if it expects manufacturers to fully comply with the new regulations.