The Protoprint Project has evolved meaningfully since it's inception in 2012. For more recent updates on the project, please refer to this link. For historical context on the project, please continue reading below.
Improving wastepicker livelihoods and urban sustainability through the upcycling of plastic waste
About

The Protoprint Project (TPP) is a collaborative initiative to transform the informal recycling sector through the gradual implementation of a systematic and self-sustaining (circular) model for waste plastic recycling. Specifically, the project aims to move urban waste-pickers up the recycling value chain and improve livelihoods through the implementation of low-cost technology solutions coupled with community development, creative financing and public-private partnerships that improve plastic waste processing within urban environments and promote the integration of informal waste collectors and informal waste management MSMEs into formal value chains. The project is based in the city of Pune, home to over 3 million residents.

TPP seeks to set up an ecosystem that supports the development of self-managed waste-processing units that consists of waste-pickers members and use low-cost technology solutions and standardized processing techniques to convert plastic waste into plastic flakes which can be sold to end users via negotiated agreements with industrial-partners that ensure a fair wage for the individual workers. In doing so, each unit functions as a sustainable, replicable and scalable business that can eventually be leveraged to integrate its informal workers into the formal economy and to provide other benefits, such as healthcare, and function as sustainable, replicable and scalable business centres. In addition to the production of flakes, the TPP product team will work in collaboration with a sub-set of the units to further upcycle the plastic into high-value products such as fair-trade 3D printer filament and other similar consumer items with the goal that the development and sale of such products could provide even greater economic mobility to the waste-pickers. TPP will work in collaboration with European entities to ensure a standardized and rigorous certification of these products for customers in both the Indian and European markets.

Broadly speaking, TPP provides the technical, operational and financial support required to leverage market-driven solutions to recycling waste plastic, with the goal of facilitating upward-mobility among urban waste pickers and improving environmental outcomes through increased levels of plastic recycling.

Background

Plastic waste management has been increasingly recognized as a serious challenge in India. A governmental report in 2019 estimated that the country generates around 26000 tons of plastic waste every day, of which 9400 tons is left uncollected or littered. The vast majority of this plastic is generated in urban cities, that have grown dramatically in size over the past few decades. Plastic waste in these cities is often unsegregated from other forms of municipal solid waste and needs to be sorted before it can be effectively recycled. This is an extremely labour-intensive process that relies on informal workers, called waste-pickers, to segregate the plastics by hand. Despite the fact that these individuals form the base of the recycling pyramid, they work under dangerous conditions and come into daily contact with harmful materials, including hazardous and medical waste, resulting in much greater risks of injury and disease. They sell the plastic they collect to local middle-men, who in-turn aggregate and sell the material to scrap-dealers and recycling plants. While there is significant value generated in the recycling process, the waste-pickers themselves are poorly compensated for work that they do, often unable to escape poverty. Estimates suggest that there are over a million waste-pickers in India, mostly consisting of vulnerable populations such as migrants, women and children.

Waste plastic has been shown to have a number of negative impacts on the environment and on human health. Plastic run-off into rivers and streams contaminates water sources, kills aquatic life, poisons drinking water and results in the bio-accumulation of microplastics within the food chain, ultimately impacting humans. Plastic waste on land leaches toxic chemicals into groundwater and degrades soil. In India, waste plastic is often burned on street corners, releasing toxic air pollutants. The production of plastics involves the processing of fossil fuels, meaning that plastics have significant carbon footprints over their lifecycle. The growing concern around plastic waste has resulted in an effort to limit the production of virgin plastics through the adoption of an Extended Producer Responsibility (EPR) framework by the government that outlines the obligations that manufacturers and retailers have towards the management of their waste. Yet, progress on this front remains slow, partly due to the informal nature of the recycling industry that limits transparent data collection and integration into formal value chains.

Project Timeline

First attempts at shreding and extruding waste plastic. 2012.

Custom 3D printer platform to test filament made from waste plastic. 2013.

Setting up a pilot plastic processing facility at a dump site in Pune. 2014.

Experimenting with closed loop mobile 3D printing. 2014.

Processing waste plastic into 3D printer filament. 2015.

Early results with recycled 3D printer filament. 2015.

Working with the National Chemical Labs to improve filament quality. 2015-2019.

Experimenting with injection moulding to create products from waste. 2017.

Invited to exhibit Protoprint at the United Nations World Environment Day. 2018.

Setting up a permanent waste plastic processing facility in collaboration with the Pune Municipal Corporation. 2019.

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