Mohd Suhail, a Delhi-based entrepreneur, founded Athar Packaging Solutions with a mission to combat plastic waste by transforming it into compostable packaging. With a strong commitment to environmental responsibility, his business now rakes in Rs 1.3 crore a year.
India tops the global list in plastic waste generation, producing a staggering 10.2 million tonnes annually. This figure is more than double that of the next biggest polluters, including Pakistan, Bangladesh, and Russia. And tackling this head on is Mohd Suhail, a 32-year-old entrepreneur from Delhi, who has managed to stop 200 tons of industrial plastic waste from reaching landfills in the last three years.
“By recycling 200 tons, we’ve reduced 300 tons of CO2 emissions, an important step in reducing our carbon footprint and contributing to a more sustainable future,” he tells The Better India.
Sohail grew up in the narrow lanes of Old Delhi, where his father worked as a labourer. His early memories of seeing his father craft packaging materials from discarded polyester and paper had always led him to question if discarded items could play a better role in everyday lives.
“It taught me the importance of making the most of what was available,” he says.
‘I wanted to do more’
With a master’s degree in social work, Suhail’s early career was deeply rooted in the social development sector. “I dedicated over 12 years to working on women’s empowerment, child development, and environmental causes,” he says.
In 2020, as the world grappled with the COVID-19 pandemic, Suhail observed a new environmental crisis in his community.
“I saw firsthand the devastating effects of industrial pollution on the environment. We found it difficult to breathe. It made me realise that pollution isn’t just a problem in Delhi, it’s a widespread crisis affecting people everywhere,” he recalls. “That experience made me realise that I wanted to do more than just talk about environmental issues. I wanted to find a solution to reduce environmental degradation.”
Realising there was no effective solution to the escalating plastic waste around us, Suhail thought it was the right moment to come up with something that could make a real difference.
Recycling industrial plastic
In 2020, Suhail founded ‘Athar Packaging Solutions’, hoping to address the mounting waste problem by providing sustainable alternatives. Drawing inspiration from his father’s innovation in repurposing materials, the 32-year-old focused on the potential of recycling plastic.
The first step was understanding the types of plastic that could be recycled and repurposed into new materials.
“After six months of research, we identified that only three types of plastics, that is LDPE, BOPP, and LD plastics, could be recycled into sustainable packaging,” he says.
“The next step involved conducting further research to determine the most effective methods for converting plastic waste into sustainable packaging solutions,” he adds.
One of the biggest hurdles was finding the right machinery to convert plastic waste into a usable form. The startup worked closely with ML Polymers, a manufacturer that possessed a long-unused machine, which they decided to modify for their project.
“To transform waste plastic into high-quality, reusable products like pouches and zippers, several key modifications were made,” the Athar founder says.
“First, specialised blending tools were added to mix recycled plastic waste with biodegradable additives, ensuring the final products would be durable. Next, the temperature controls were adjusted to allow for precise melting of the waste plastic, preventing degradation and ensuring a smooth processing of the material.
“Multi-layer filters were installed to remove impurities and contaminants from the industrial plastic waste, guaranteeing a cleaner, higher-quality output. Finally, industry-specific molds were developed to shape the plastic into premium packaging products, such as pouches, tailored to the specific needs of customers,” he explains.
These careful steps allowed the team to successfully convert plastic waste into useful packaging products.
‘We prevent 1.5 tonnes of CO2 emissions for every tonne of recycled waste’
Over the past three years, Athar Packaging Solutions claims to have successfully recycled 200 tons of industrial plastic waste, diverting it from landfills, rivers, and oceans. “For every ton of plastic we recycle, we prevent 1.5 tons of CO2 emissions,” Suhail says with pride.
But expanding a sustainable business is never easy, and the young founder had to fight several obstacles before Athar Packaging Solutions could take off. One of the major challenges was building trust with the plastic industries that generate the waste. “Initially, these companies were hesitant to share their plastic waste data with me and they preferred the easier route of sending their waste to landfills,” shares the entrepreneur.
“We had to convince them that our solution was viable and eco-friendly. We spent almost a year building relationships with companies like Akash Plastic, Deepa polymers and Krishna plastic suppliers, assuring them that their waste could be put to better use,” he adds.
Currently, the startup sources waste plastic exclusively from industries due to financial constraints and limited manpower. “As we grow, we aim to diversify our sourcing streams to maximise our environmental impact,” Suhail says.
Once the trust with industries was established, the next challenge was convincing customers to buy sustainable packaging, which was significantly more expensive than virgin plastic packaging. “The cost of sustainable packaging is five times higher than regular packaging, and many companies were reluctant to make the switch even though they liked the idea,” he says.
To overcome the initial cost barrier, he made the strategic decision to offer his products at a lower profit margin. “In the beginning, we priced our packaging at cost-effective rates, keeping our profit margin at just 5%. This was to cover logistics and administrative expenses. It was a conscious decision to build trust with customers and make it easier for them to try our sustainable solutions,” the 32-year-old says.
His commitment to providing value quickly earned him the loyalty of clients. Within the first year, the startup had secured 40 companies as customers. As the word spread about his affordable and eco-friendly packaging, the demand grew exponentially. “Currently, we have around 700 companies as customers across 60 cities in India. Our major hubs include Delhi, Bengaluru, Hyderabad, Mumbai, Jaipur, Lucknow, and Noida,” he informs.
Leveraging digital platforms for expansion
To market his company and reach potential buyers, the founder leveraged digital platforms like IndiaMart, Justdial, and Exporter India. These platforms helped him connect with the right customers and expand his reach far beyond the confines of Delhi.
“We made 600-700 calls every month, and sometimes it took up to three months to convert a lead into a customer. But we remained consistent, and that’s what made all the difference,” Suhail says.
After battling the early struggles with a well-planned strategy, Athar Packaging Solutions has been able to cater to a diverse range of clients, including companies like Khadi Natural, Gopala Fresh, and Sai Expo Mart, as well as smaller businesses and self-help groups.
“One of our customers, Khadi Natural, started with 10,000 pouches in the pilot phase, and now they’re ordering over 1,00,000 pouches. It’s a testament to the trust we’ve built,” the entrepreneur shares proudly.
“Switching to sustainable packaging was primarily driven by our commitment to environmental responsibility and the growing consumer demand for eco-friendly products. We believe it’s important to minimise our ecological footprint and contribute positively to the planet. As for the quality of Athar Packaging Solutions, we’ve been very pleased. Their materials are durable and functional, while still being environmentally friendly,” says Bhuwnesh Tiwari, director of Khadi Natural Healthcare.
“They provide a great balance of quality and sustainability, ensuring that our products are well protected during transit without harming the environment. Overall, the transition has been positive, both for our brand and our customers,” he adds.
Catering to diverse clients
Athar Packaging Solutions offers a diverse range of 18 products, including everything from corrugated boxes to kraft paper stand-up zipper pouches. Among these, three products stand out as the highest revenue generators — the stand-up zipper pouch, the centre seal pouch, and the three-side seal pouch.
“The stand-up zipper pouch, which is priced at Rs 300 per kg, is the most popular, closely followed by the centre seal pouch, which ranges between Rs 140 and Rs 180 per kg, and the three-side seal pouch, price starting at Rs 160 per kg. These products account for the bulk of the revenue, owing to their versatility and high demand across industries,” Suhail informs.
He admits that the 15% profit margin on these products is lower than the industry average of 25%, but this lower margin aligns with his business philosophy of offering cost-effective, sustainable solutions.
In addition to product sales, the company has diversified its revenue streams by offering consultancy services. One example is an organisation that reached out to the team to help them reduce their carbon emissions.
While the organisation had successfully tracked its own carbon emissions, they struggled with gathering data from their vendors and integrating it into their own system. “We developed a custom dashboard for them, based on extensive research into the machinery used by their vendors. The type of machinery helps to track the carbon emissions,” the 32-year-old entrepreneur explains.
“While most packaging companies rely on up to 70% virgin plastic in their products, our startup takes a bold step by recycling 95% of plastic waste. This not only helps reduce the strain on landfills but also lowers the environmental impact of their production process,” he adds.
Athar is now focused on securing all necessary government approvals and compliance certifications. “Within the next three months, we aim to obtain the eco-mark as part of our roadmap to establish credibility and demonstrate our commitment to sustainability. Once the required approvals are in place, we will prominently display eco and recycling marks on our pouches,” Suhail adds.
With a current revenue of Rs 1.33 crore and a consistent profit margin of 15%, the founder has proved that sustainability and profitability can indeed coexist. “Without compromising on quality, we are creating solutions that benefit both our customers and the planet,” Suhail smiles.
Source : The Better India
