Turnkey MRF lines — 5 to 100 TPD.
Dry-waste sorting facilities with manual + mechanical separation, K-BPM 25 / 50 baling presses, and EPR-aligned operations. Built for ULBs, private brands, recycling consolidators and PPP operators.
Standard MRF line scope
- Receiving belt + manual picking station
- Bag opener (auto or manual depending on TPD)
- Trommel screen (60 mm + 200 mm decks)
- Magnetic separator (overband)
- Eddy current separator (non-ferrous, > 50 TPD)
- Air density separator (light/heavy split)
- Optical sorter for PET/HDPE colour separation (> 80 TPD)
- Quality control conveyor
- K-BPM 25 baling press (small MRFs)
- K-BPM 50 baling press (large MRFs / export-grade bales)
- Bale storage shed with weighbridge
- PLC + SCADA control system
Typical output streams
- PET / HDPE bales (~10–15%)
- Paper / cardboard bales (~15–20%)
- Aluminium / metals (~3–5%)
- Plastic film & multi-layer (~5–8%)
- Organics fraction routed to compost (~30–40%)
- Inerts & rejects to SLF (~15–25%)
Compliance
- SWM Rules 2016
- PWM Rules 2016 (2022 amendment)
- EPR registration on CPCB portal
- State PCB CTE / CTO
- GST classification 3915 for recycled scrap
Three typical configurations
Small MRF · 5–25 TPD
Manual sort + magnetic + air density + K-BPM 25. Footprint ~0.3 ac. CapEx ~₹2–6 Cr.
Mid MRF · 25–50 TPD
Adds eddy-current + ballistic separator + K-BPM 50. Footprint ~0.6 ac. CapEx ~₹5–12 Cr.
Large MRF · 50–100 TPD
Optical sorter + multi-line + automated bale handling. Footprint ~1.2 ac. CapEx ~₹14–30 Cr.
Building a tender for an MRF?
We supply BOQ-ready spec sheets for every component.
From DPR to commissioning — typically 14–22 weeks
MRF projects move faster than waste-treatment plants because there's no CPCB SOP-mandated trial run. Below is a typical schedule for a 25 TPD K-Recover MRF.
DPR & site survey
Material flow study · land area · electrical load · 1-2 weeks
State PCB CTE
Consent-to-Establish · 4-6 weeks (parallel to design)
Civil & foundation
Concrete pad · sheds · wash bay · weighbridge · 6 weeks
Manufacturing
Trommel + separator + balers + conveyors at Manesar · 10 weeks
Erection & install
On-site assembly + electrical + automation · 3 weeks
CTO + handover
Consent-to-Operate · staff training · 1 week
Common MRF buyer questions
K-BPM 25 vs 50 — which baler for my MRF?
K-BPM 25 (25-ton vertical hydraulic) is the right pick for MRFs processing <5 TPD dry-waste with PET / paper / cardboard / HDPE; bale density 300-500 kg/m³. K-BPM 50 (50-ton heavy-duty) for >5 TPD throughput, dense scrap (e-waste, mixed metal), or export-grade bale density (400-600 kg/m³, 4-strap binding). See K-BPM 25 vs K-BPM 50.
What's the revenue picture?
Indicative dry-waste recyclate prices (2026): PET ₹35-45/kg · HDPE ₹40-55/kg · cardboard ₹15-20/kg · paper ₹12-18/kg · mixed metal ₹35-90/kg. A 25 TPD MRF processing 60% recyclables typically generates ₹3-5 lakh / month gross recyclate revenue, plus EPR plastic-credit revenue from registered offtake.
How does this work with EPR registration?
An MRF registered under the CPCB EPR portal can issue plastic credits to brand owners (FMCG, e-commerce, packaging companies) under PWM 2016 (am. 2022) — adding ₹3-8 / kg revenue on plastic offtake. We help structure the EPR registration and brand-owner offtake agreements at DPR stage.
What's the manpower requirement?
25 TPD MRF: 18-24 sorters (mostly women SHGs in ULB context) + 1 supervisor + 2 baling-press operators + 2 trommel/conveyor operators + 1 maintenance + 1 dispatch coordinator. Manual sorting at the picking belt is the labour-intensive piece; mechanical separation via trommel + magnetic separator + ballistic separator handles 60-70% of volume.
Land area required?
5 TPD: ~1,000 sq m · 25 TPD: ~3,500 sq m · 50 TPD: ~5,500 sq m · 100 TPD: ~9,000 sq m. Add 30-40% for parking, weighbridge, fire pit, office. The exact figure depends on covered shed vs open yard split — finalised at DPR.
Lead time and AMC?
Manufacturing 10 weeks ex-Manesar. Total project (DPR to commissioning) 14-22 weeks. 1-year comprehensive warranty + AMC from year 2. Engineer on-site within 24-48 hr. Spare parts same-day ex-Manesar.