Surat Green Precast Private Limited (SGPPL), Gujarat

SGPPL and CFlo join forces to revolutionize C&D waste management, transforming it into high-grade sand and aggregates. This innovative approach reduces CO2 emissions and reclaims valuable land resources.

Surat Green Precast Private Limited (SGPPL) is a pioneering company at the forefront of revolutionizing construction and demolition (C&D) waste management in Gujarat. With an unwavering vision to scientifically manage and repurpose the substantial amount of C&D waste generated by the Surat Municipal Corporation (SMC), SGPPL has emerged as a true leader in the industry.

SGPPL’s Progressive Approach to C&D Waste Repurposing

In pursuit of their ambitious objective, SGPPL took a momentous leap by establishing a state-of-the-art C&D Waste Recycling plant in collaboration with CFlo - renowned experts in waste management. This remarkable partnership resulted in the commissioning of the plant, serving as a testament to SGPPL's unwavering dedication to implementing scientific and sustainable waste.

In 2018, Surat Municipal Corporation initiated a tender process under a public-private partnership (PPP) framework to select a waste processor for establishing a new recycling facility to manage the city's construction and demolition (C&D) waste without imposing a tipping fee. Surat Green Precast Pvt Ltd (SGPPL) emerged as the winning bidder. After conducting extensive research, SGPPL invested in a mobile recycling plant from us.

Our Integrated Facility Redefines Sustainable C&D Waste Recycling

Our C&D Waste Processing plant, equipped with state-of-the-art technology, is capable of processing up to 300 TPD of C&D waste. This integrated facility aligns with SGPPL's vision of creating a more sustainable Surat by efficiently recycling various waste materials such as cement concrete, cement mortar, bricks, rubble, stone, sand, and soil.The process involves the production of high-grade washed and dewatered sand by removing oversize and ultra-fine particles, contributing to a greener and more environmentally friendly approach to waste management.

Initially designed to manufacture four product types, including +80mm, -80mm to 5 mm, and -5mm sizes, encompassing concrete sand and plaster sand. The plant has now been modified to exclusively produce sand at a 5mm size due to market demand. Nonetheless, the flexibility remains to produce any of the four products if the demand changes in the future. The plant has a specialized segregation system, debris handling system, crusher and other required units including a multiple-section screening unit.

Our Innovative Solution

The 300 TPD plant powered by our advanced technology is designed to:

  • Efficiently recover aggregates, plaster, and sand from C&DW
  • Ensure high yield and production rates through complete automation and a remotely controlled system
  • Minimize water consumption by recycling and repurposing the resource
  • Occupy minimal space, minimizing the geographical footprint
  • Produce high-grade aggregates and concrete sand, enabling the production of value-added product

The hourly water usage of the plant is restricted to only 6-8 m3 & the power usage is limited to 120 KWH, promoting water & energy conservation.

The finished products are categorized as follows:

  • Oversize
  • 20 mm Aggregate
  • 20 mm to +5 mm Aggregate
  • Concrete Sand (Zone II)
  • Plaster Sand (Zone IV)

The project was launched in March 2019.

From the moment of the initial investment, we adopted a collaborative approach and established a close relationship with the customer. The company conducted an onsite training workshop to educate the local contractors and regulators to maximize the use of recycled products. Our skilled engineers and dedicated Project Manager ensured seamless project completion, benefiting the client at every stage from design to ongoing plant management.

Following a circular model, waste in Surat is gathered from 10 collection centres or transfer stations (TS). Our advanced waste management technology is utilized to process the collected waste, enabling a remarkable ~96% recovery of materials from the feed. The recycled sand and aggregates are effectively reused in construction and for the production of value-added products like tiles, blocks, and pavers. This successful approach is now being adopted in several other cities across India.

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

Apart from providing a sustainable source of sand and aggregates, this plant has a significant impact on the environment:

  • Reduces 508 tonnes of CO2 emissions annually, equivalent to burning 250,000kgs of coal.
  • Saves 9100 Gigajoules of energy, enough to power 3000 Indian homes for a year.
  • Reclaims 30,000 sq. yards of land from landfills, unlocking 100 crores worth of real estate each year.

We take great pride in partnering with this prestigious project, contributing to the development of smarter, greener, and more sustainable cities.

Surat Green Precast