Researchers at the Indian Institute of Technology Bhilai have developed an innovative
approach to convert discarded PET plastic bottles into a high-value reusable and 3D printable
material that can be reshaped, repaired, and recycled multiple times. The breakthrough offers
a promising solution for tackling plastic waste while supporting sustainable manufacturing
and the circular economy.
The research was led by Dr. Sanjib Banerjee of the Department of Chemistry, IIT Bhilai, and
carried out by Priyank Sinha, Bharatbhushan Meshram, and Onkarnath Verma under his
supervision. The findings have been published in the internationally reputed journal
“Materials Today Catalysis”, highlighting IIT Bhilai’s growing contribution to sustainable
materials research. The researchers have also filed an Indian patent application for the
developed technology.
PET bottles are among the most widely used plastic products in the world, particularly in
beverage bottles and food packaging, generating millions of tonnes of waste every year.
Although many PET bottles are recycled, conventional recycling methods gradually degrade
the quality of the material, limiting their reuse.
To address this challenge, the IIT Bhilai team first developed a green, magnetically
recoverable catalyst using waste eucalyptus leaves. The catalyst efficiently converts waste
PET bottles into a valuable chemical building block and can be easily separated with a
magnet and reused for multiple recycling cycles, making the depolymerization process
cleaner, more sustainable, and cost-effective. The recovered building block is then converted
into a high-performance dynamic 3D printable polymer that combines durability with
reprocessability.
The technology transforms discarded PET bottles from an environmental burden into
valuable engineering materials, demonstrating a true “waste-to-wealth” approach. By
reducing plastic waste, decreasing reliance on virgin petroleum-based raw materials, and
enabling repeated reuse instead of disposal, it has the potential to lower the environmental
and carbon footprint of plastic products. Such sustainable material technologies can play an
important role in advancing a circular economy and promoting cleaner manufacturing
practices.
One of the most remarkable features of the newly developed material is its ability to change
shape when heated and retain the new shape after cooling. The researchers demonstrated this
by repeatedly molding the material into different objects without significant loss of
performance. Unlike conventional thermoset plastics, which cannot be reshaped once
manufactured, the new material can be repaired and remolded multiple times, significantly
extending its service life.
According to Dr. Sanjib Banerjee, “Most conventional thermoset plastics are strong and
durable but cannot be reshaped or recycled once manufactured, resulting in considerable
waste accumulation. Our work demonstrates that discarded PET bottles can be converted
into high-value engineering materials that combine durability with reprocessability, opening
new opportunities for sustainable materials and advanced manufacturing.”
The technology has promising potential for manufacturing customized plastic components,
reusable consumer products, educational models, and engineering prototypes where repeated
reshaping and repair are desirable. Its ability to soften upon heating and regain its strength
after cooling also makes it a promising candidate for future 3D printing and additive
manufacturing, enabling more sustainable production with reduced material waste.
The innovation aligns with the Government of India’s vision under initiatives such as Swachh
Bharat Mission, Atmanirbhar Bharat, Make in India, and the National Resource Efficiency
Policy, reinforcing the importance of indigenous technologies that address environmental
challenges while creating value-added materials for a more sustainable future.
