Nayana J C
Daijiworld Media Network – Mangaluru
Mangaluru, Jul 15: In a major step towards scientific waste management and sustainable development, the Dakshina Kannada Zilla Panchayat has commissioned Karnataka's first Refuse Derived Fuel (RDF) pellet manufacturing unit at Kemral near here. The pioneering facility converts non-recyclable dry waste into high-calorific industrial fuel pellets, offering an eco-friendly alternative to coal while significantly reducing the need to transport waste to distant processing centres.
Established under the Swachh Bharat Mission (Gramin) as a pilot project, the unit processes non-recyclable dry waste such as discarded clothes, footwear, single-use plastics, and other low-value waste materials. The processed waste is converted into RDF pellets, which can be used as an alternative fuel in industrial boilers, promoting resource recovery and reducing dependence on fossil fuels.
Dakshina Kannada Zilla Panchayat chief executive officer Vinayak Narwade, IAS, said the project was conceptualised after an exposure visit to a similar RDF pellet unit in Maharashtra. He noted that the initiative is aimed at transforming waste management by converting waste into a valuable resource while encouraging a circular economy and environmentally sustainable practices.
The project has been implemented at a cost of around Rs 50 lac, of which nearly Rs 42 lac was spent on procuring machinery, including a pulveriser and pelletiser, through the tender process. An existing dry waste processing shed at Kemral was renovated and upgraded to accommodate the new facility.
Kemral panchayat development officer (PDO) Arun Pradeep D'Souza said the project was executed by optimally utilising the existing infrastructure, avoiding the need to construct a new building. He added that the unit has been designed to scientifically process non-recyclable dry waste that would otherwise end up in landfills or be transported to cement plants for co-processing.
The pilot unit has the capacity to process two tonnes of RDF waste per day. Operating for 25 days a month, it is expected to produce nearly 50 tonnes of RDF pellets every month. At present, the unit is processing waste collected from the Yedapadavu Material Recovery Facility (MRF), which generates around 45 to 50 tonnes of RDF waste every month.
The pellets produced have a high calorific value and can be used as a cleaner alternative to coal in industrial boilers, helping industries reduce fossil fuel consumption while ensuring scientific disposal of non-recyclable waste.
To ensure a ready market for the pellets, the Zilla Panchayat has entered into a buy-back agreement with the Pune-based company that supplied the machinery. Under the agreement, the company will purchase the pellets at Rs 5 per kg.
As part of the Memorandum of Understanding (MoU) with the self-help group, Re 1 from every kg of pellets sold will be credited to the Zilla Panchayat. The revenue will be utilised for operational expenses, maintenance, and setting up similar units in other locations.
Narwade said self-help groups have also been encouraged to explore tie-ups with other industries to market the pellets at higher prices, enabling them to increase their earnings while generating additional revenue for the local body.
Until now, non-recyclable RDF waste collected at MRF centres had to be transported to cement factories in Belagavi and Kalaburagi for co-processing, at a transportation cost of nearly Rs 48,000 per truckload. With the commissioning of the Kemral unit, the waste can now be processed locally into a value-added product, significantly reducing transportation costs while strengthening scientific waste management and supporting the circular economy.
Dakshina Kannada currently has four Material Recovery Facilities (MRFs) at Yedapadavu, Ujire, Kedambady, and Narikombu, with a combined dry waste processing capacity of 31 tonnes per day. Nearly half of the waste generated at these centres is RDF material.
Narwade said the Kemral unit will function as a pilot project for one year. Based on its performance and operational experience, the Zilla Panchayat plans to establish similar RDF pellet manufacturing units at other MRF centres across the district. He added that the initiative marks a significant milestone in Karnataka's waste management sector by converting non-recyclable waste into a valuable industrial resource, reducing landfill burden, creating employment for rural women, and promoting cleaner energy solutions.