Ganesha Ecosphere Ltd. (GESL) which went into business in 1987 has over the years emerged as one of the leading PET-recycled RPSF manufacturers in India. Headed by Mr. Shyam Sunder Sharma, a first generation entrepreneur, who is now its Chairman and Managing Director, the company pioneered manufacture of recycled polyester staple fibre and yarn from PET bottle scrap in India, which is consumed by downstream units engaged in the manufacture of textiles (T-shirts, body warmers and apparels), functional textiles (non-woven air filter fabrics, geo textiles, carpets and car upholsteries) and fillings (for pillows, duvets, toys).
Headquartered in Kanpur, GESL has manufacturing units in Kanpur itself, Rudrapur (Uttarakhand) and Bilaspur (Uttar Pradesh), with a cumulative capacity of 97,800 tonnes per annum for RPSF and yarn. The company mobilises PET waste raw material through 20+ collection centres across India.
The Indian textile sector, which was primarily cotton dependent, is witnessing a shift in trend as demand for polyester fibre is picking up due to cotton price volatility and increased sourcing by global brands. Man-made fibre (MMF) still accounts for 40 per cent of the total fibre production in the country, while the ratio is 70 per cent globally. Hence consumption of polyester is likely to be more than double cotton fibre consumption by 2030.
This will be reflected in an increase in demand for man-made filaments, fibres and apparel accounting for more than half the total synthetic fibre produced by the industry. Besides, manufacturers of home and technical textiles are also expected to increase consumption of synthetic fibres.
Ganesha Ecosphere set up RPSF capacity of 21,000 tonnes per annum at Bilaspur during 2014-15. It also set up yarn spinning capacity of 25,920 spindles in 2013-14 and enhanced the Kanpur plant’s RPSF capacity to 27,000 tonnes per annum. The company has invested around Rs. 200 crores in these capacity expansions.
GESL has invested in a business model which is centred around long-term sustainability. It invested periodically in enhancing production capacities, from a modest 6,000 tonnes per annum to 87,600 tonnes, generating revenues at a CAGR of 28 per cent over the decade leading to 2014-15.
GESL has extended its operation from captive PET waste collection to staple fibre manufacture to yarn manufacture, thereby widening its value chain and making it possible to address the demand dynamics of each segment.
Besides, its R&D team played a pivotal role in the manufacture of dope-dyed polyester fibres across a range of colours, generating a premium over regular variants. The company’s manufacturing units are ISO 9001:2008, ISO 14001:2004 and OHSAS 18001:2007-certified. It received the Hohenstein Institute’s (Germany) authorisation to use the Oeko-Tex mark, validating the highest ecological standards.
The company installed high-end drawing and crimping machines ensuring production of top-quality fibres and yarns which can be dyed in a wide range of colours.
Total revenues of the company increased by 24.73 per cent from Rs. 501 crores in 2013-14 to Rs. 625 crores in 2014-15, thanks to an increase in volumes, post the fibre and yarn capacity expansion.
By Rajeswari Prasad