1. 2013
ECO HEALTH CENTER- A
SUCCESS STORY
AMAL.K
ECO HEALTH CENTRE
amalkrd@gmail.com
+91-8147575141

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Eco Health Centre (EHC) is a successful model of
managing Municipal Solid waste. Joy.K.B, a grass root
inventor and practical intellect, invented a machine-
Automated Plastic Separation Machine (APSM) - that
successfully separated Plastic from mixed Municipal
Waste, and crushed the bio degradable particles, thus
making it possible to extract the hidden value in waste
and finding a permanent solution for the menace of
waste management for the Municipality of Kodungallur.
Economic growth and changing consumption and production patterns are resulting into rapid
increase in generation of waste plastics in the world. The world’s annual consumption of plastic
materials has increased from around 5 million tons in the 1950s to nearly 100 million tonnes;
thus, 20 times more plastic is produced today than 50 years ago. This implies that on one hand,
more resources are being used to meet the increased demand of plastic, and on the other hand,
more plastic waste is being generated. In Asia and the Pacific, as well as many other developing
regions, plastic consumption has increased much more than the world average due to rapid
urbanization and economic development. Due to the increase in generation, waste plastics are
becoming a major stream in solid waste. After food waste and paper waste, plastic waste is the
third major constitute at municipal and industrial waste in cities. Even the cities with low
economic growth have started producing more plastic waste due to increased use of plastic
packaging, plastic shopping bags, PET bottles and other goods/appliances using plastic as the
major component. This increase has turned into a major challenge for local authorities,
responsible for solid waste management and sanitat ion. Due to lack of integrated solid waste
management, most of the plastic waste is neither collected properly nor disposed of in
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PREFACE:
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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appropriate manner to avoid its negative impacts on environment and public health and waste
plastics are causing littering and choking of sewerage system. Due to extremely long periods
required for natural decomposition, waste plastic is often the most visible component in waste
dumps and open landfills.
Plastic waste recycling can provide an opportunity to collect and dispose o f plastic waste in the
most environmental friendly way and it can be converted into a resource
Source: United Nations Environment Programme, 2009.
In most of the situations, plastic waste recycling could also be economically viable, as it
generates resources, which are in high demand. Recycling plastic waste also has a great potential
for resource conservation and reduction of GHG emissions. This resource conservation goal is
very important for most of the national and local governments, where rapid indus trialization and
economic development is putting a lot of pressure on natural resources. Some of the developed
countries have already established commercial level resource recovery from waste plastics.
Therefore, having a “latecomer’s advantage,” developing countries can learn from these
experiences and technologies available to them.
An asset can be defined as something that is of value to the holder of it. It ceases to be an
asset at the point when the holder of it feels it no more valuable and when it so ceases to
be an asset, he hurries to dispose it considering it a waste. An individual strives to protect
We can now analyze this notion in the context of municipal waste. Human settlements,
dumps a huge bulk of waste which is detrimental to the public health. To protect the
public health, the very learned law makers all over the world defined the waste as the
asset of Municipalities (refer Sec 330 of Municipal Act, India). This makes the
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Dumping of waste is an economic transaction
his assets while he throws away the waste. This is the natural course of any transaction.
Waste for someone is Asset for another
Municipalities feel responsible to protect the waste because waste is their asset.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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The primary responsibility of the Municipality is to recycle the waste and maintain public
health. Inc apability of urban bodies in ‘Managing’ waste in the most appropriate manner
is cited as the prime reason for the resent outbreak of epidemics in many cities in India.
The country had witnessed many non-political people ’s mo vements also in the recent past
1.1. Aerobic Composting
Most of the Indian cities are using aerobic composting to treat municipal solid waste.
But this process has not proved to be quite ideal for Kerala-thanks to high humidity,
higher moisture content in typical garbage received and longer rainy days in the State.
All these factors combined generate more leachate, which add to the woes of
municipal authorities.
Besides, in this technology plastic cannot be separated for commercial use. In
addition to their the EM bacteria which is generally use in the technology will
remain alive in compost and landfill which is learned to be not advisable.
Practically, close to 15% of the MSW is converted into useful compost and all
remaining has to be discarded as landfill.
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Asset becomes waste if managed by obsolete technology
demanding proper management of Municipal waste.
1. PROCESSES AVAILABLE TO TREAT MSW:
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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The present biogas technology used in Kerala and all over India for MSW
processing have become obsolete. This technology is not efficient as in the
thermophilic bacteria based processing.
The outlet slurry contains bacteria causing contagious diseases, which pollute
water and surrounding. Separation of plastic makes bio gas feeding also
impractical.
This technology is not suitable for non-vegetarian components. In this case also
1.4. Waste pelletization for fuel
Two small scale experimental projects were undertaken in the State to dry and
pelletize municipal waste. Both failed for the simple reason that the calorific value of
mixed Indian waste is barely 800 to 1000 Kcal/kg of waste. Sun-drying becomes
impossible in monsoon rains. Covered storage of sufficient area is prohibitively costly
and artificial drying is energy-negative. Issues of PVC waste generating dioxins from
burning of Refuse Derived Fuel (RDF) have not been addressed yet.
1.5. Other Thermal Processes: (Incineration , Pyrolysis, Catalytic Thermal
conversions to fuels etc.)
As India has signed in the CDM (Clean Development Mechanism) under
Kyoto protocol, thermal processing of organic waste matters has limitations.
As the moisture content of our MSW is 50-70% the plants will not be
commercially viable. It also needed heavy investment and maintenance cost,
which is sufficient to consume a considerably high percentage of the revenue
of the municipal bodies.
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1.2. Bio gas plants- present technologies.
1.3. Vermin Composting;
Plastic mixed with biodegradable waste proves to a bottleneck.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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The composition of urban waste and the very fact that plastic components remain
mixed with bio degradable particles makes the process of managing urban waste a
complex task. Practically all the Solid Waste Management (SWM) plant in India
follows the method of composting in one way or other, as the operations of SWM
plants are governed by Municipal Solid Waste Management Act 2000, which suggests
Practitioners across the globe finds mixed waste highly difficult to treat; hence
attempts are made across to educate citizen regarding the need to segregate the waste
The very nature of demography and the sheer volume of urban waste in India make
most of the efforts made at source segregation impractical till date-although there are
isolated cases of partial success-.It is in this peculiar state of affairs ‘Kodungallur
Mr. Joy K.B, an industrial consultant and CEO of M/S SUNTECH INDUSTRIAL
STEEL CO. introduced a mechanical model for separating Plastic particles from
mixed urban solid waste with an impressive 99.91 accuracy. This model was
introduced as a pilot project in the Kodungallur municipality, Trichur district, Kerala.
First developed as a machine to separated seeds and pericarp in red chillies way back in
1995, Joy realized that with certain improvisations, this machine can be used to
separate plastic from mixed urban waste. The pilot project worked wonders for Joy,
and the result was a critical problem solved for the Municipality of Kodungallur- the
Mr. Joy calls his model Eco Health Centre (EHC). When asked about the rationale
behind this name he elaborated- “I consider waste gener ation of waste by any ur ban
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2. CORE OF THE PROBLEM:
composting as the ideal method for Indian cities to treat urban waste.
at source.
model of waste management’ stands apart as a model worth emulating.
problem related to the disposal of Solid waste from the growing municipality.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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settlement as a health issue which needs to be treated. My plant treats this issue
successfully and what come out from my plant are products that are treated and
The machine GREEN APSM (Automatic Plastic Separation Module) can
automatically separate the mixed city garbage into bio-degradable and non-bio
degradable.
GREEN APSM is capable of separating the plastic, rubber, etc. instantaneously
on feeding and can process the organic matter to the aerobic /anaerobic compost.
 This is the only system available in India to process the municipal solid waste
 The municipal solid waste being collected is not a homogenous mixture. The
machines make it homogenous to be fit enough for anaerobic digestion, aerobic
composting or vermin-composting.
 In anaerobic process, the products are biogas and 99.5% plastic free bio
manure and segregated plastic which carry commercial value. The fuel
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healthy. Those products are healthy and can be further used for productive purposes.”
3. ECO HEALTH CENTRE
3.1. SALIENT FEATURES OF ENVIRONMENTAL HEALTH CENTRE
TECHNOLOGY
 No Foul smell, No water pollution, No discharge of leachate. No Fly’s
on day to day basis. Processing capacity of each module is 1- 3 tons/Hr.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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extracted from this process can be utilized for running the plant and the
remaining fuel can be sold directly or can convert it into electricity.
 Due to higher rate of oxygenation /aeration in enclosed chamber up to the 10
meter height, the pollutants are minimized in this plant hence reducing the
chance of spread of contagious viral diseases.
 This plant can process any solid waste containing heavy fibers, like tender
 Solid waste includes born from fish/meat markets can also be processed in this
1. The Green Automated Plastic Separation Module (APSM) separates the fresh
2. The Bio degradable materials are crushed to make slurry of it, which is further
allowed to degenerate in natural way. This process ensures that no foul smell is
generated in the whole process.
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 No chemicals or genetically modified bacteria are involved in this process.
coconut husks, elephant dung, branches of trees, etc.
plant.
 The average power consumption of the plant is 15kw/Hr/ton.
 Doesn’t cause water, air or sound pollution
 Follows MSW rules 2000 of India.
 The plant can be of stainless steel Built
3.2. HOW DOES EHC OPERATE:
garbage into Bio-Degradable and non-bio degradable.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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3. Non bio-degradable particles-Mainly plastic- is separated by APSM. This allows
4. Since the rejects are 100% free of biological particles, the chances of generation
5. The leachate generated at the feeding point is reused in the process. By this it is
ensured that no leachate is released out of the plant. This approach solves the
issue of leachate generation which the gravest issue in the present process.
6. The bio degradable slurry is ideal to be fed into bio gas plants. This allows
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recovery of plastic in reusable form.
of leachate at landfill is practically nil.
generation of electricity out of waste.
4. DETAILS OF TECHNOLOGY USED IN EHC
4.1 PLANT STRUCTURE
EHC is consists of a bunch of different modules:
4.1.1. APSM module –
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE
Fresh garbage feeding
point
Plastic collection
tank
Leachate
collection
tank

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Existing plant at Kodungalloor
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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The core APSM ensure that the basic separation of Bio-degradable and Non Bio-degradable
are achieved without using any chemicals and emulated bacteria which
The bio-degradable wastes are crushed to form slurry inside the machine itself and
the slurry is further composted. Leachate generated from the fresh garbage along
with water is used in the process of making slurry and dipping garbage in the
water. In this way, it is ensured that leachate is reused and as a result, no leachate
goes out of the plant. This process is bundled to give a solution of foul odor in the
site and control of flies and other insects.
b. A range of Products from crushed plastic, which require optional
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are harmful to the environments.
By-products:
The end products of eco-health center will be
a. Bio manure (From 3rd month onwards)-which will be produced
with the core module and
modules as given below:
4.1.2. Optional Modules- Details:
a. Plastic Film Crunching Module
This module is mandatory for processing the waste plastic from MSW. It is
used for size reduction of plastic bags separated from the MSW for further
processing like using them for re-in forcing the Cement & Bitumen tar for
laying roads.
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ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE
The plant in
Kodungalloor has
the core APSM
module only.
Municipality cited
financial crunch as
the reason for not
paying for the
optional modules.
The APSM separate
the entire garbage
collected and
brought to the site
in less than 2 hours
every day
b Solid Strip - Casting Module
This module is for converting the separated plastic in to
Hard Bars in appropriate size for industrial & domestic
use as per the commercial requirement.
c. Tar- Mixing Module
This is to mix this plastic with Bitumen Tar for laying
road and the municipality/corporation can use as much as
30% of plastic (form the waste) into the tar mix and it is
experienced that it improves the life of the roads by near
to 80%.
d. For Brick Making - Mixing Module
Plastic Waste is used for making Mix for Bricks /Floor tiles/Fencing pole etc.
4.2. Euro standard Bio Reactor (Bio gas plant) – Dome type.
The organic slurry which comes
out of the APSM module is fed
in the dome shaped biogas plant
which has a heat exchanger unit
(gas firing).
After composting, the out
flowing slurry is sterilized at
90-1000C and heat is exchanged
to the system for maintaining

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1. Electricity generator
A set of generators for generating electricity using the biogas.
2. Solid manure module-
Here vibrator mesh is used for separating solid manure from outflow of slurry,
3. composting yard for rejected mass,
4. Compost sieving machines etc.
This is a storage-area for the collected dry plastics, glass, metals, e waste etc.
from the collection source.
The aerobic compost yard is the open area where the fresh slurry is kept covered
for a period of 90 days so that the slurry turn into compost in aerobic manner. No
concentrated or emulated bacterial solution is added to the slurry so collected. This
ensures that the composting happens purely in natural way thus reducing the foul
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system temperature at 60-700C.
Sub modules
4.3. STORAGE REGION.
4.4. Aerobic Compost Yard:
order to the least.
4.5. PRECAUTION DUMPING YARD.
A safely covered dumping yard to meet contingencies.
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The rough diagram of the system and the process layout gives an idea about the
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5. PROCESS DESCRIPTION OF THE PROJECT
process.
5.1. Proces diagram
Bio Degradable slurry
collection point
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The carrier vehicles dump the fresh garbage on the hydraulic tipper of the APSM module.
On rising, this slowly discharges the items towards the water pit. Meanwhile the waste
packets, if any, present in the garbage are cut by automatic cutting machine and the waste
fall scattered in to the water. The high density material will sink in water and those with
low density like plastic and organic substances will float. The elevator forklifts collect the
floating material at a rate 3 ton/ hr. these materials are sent to the APSM machine.
The plastic present is the feed will be separated and dropped in the water tank. The
organic matter is fed into a vibrator mesh where it is sieved and collected in a tank. It is
Once the APSM separate the plastic, the plastic if fed into shredding machine. The
Shredder cuts the plastic into near powder form. Plastic at this form is dried, packed and
The organic slurry from bio-reactor is drained to a tank and sterilized.
If there is any rejection of the organic slurry is there on the process control tank that can
be transferred to aerobic composting yard for producing compost.
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diluted, and the accepted slurry will be fed to the bioreactor.
It takes about 15-30 days for the bio reactor to produce biogas regularly.
sent out of the plant for making value added products.
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5.2. Process Layout
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1. Biomedical waste, industrial waste and e waste cannot be process through this
2. As the system is dynamic machineries based, failure in critical machines may
1. Bio medical waste and Industrial waste need separate system for collection
2. Sufficient spare machines should be installed and regular maintenance
should be carried out. This should be ensured in contract sign between the
technology provider and stake holders.
3. Regular scientific monitoring of organic slurry and the installation of a
proper discard system should be included in the process layout of
bioreactor feed system.
4. Insure the properties and proper maintenance for all systems should be
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6. LIMITATIONS OF THE EHC TECHNOLOGY
technology.
affect the regular functioning of the system.
3. The presence chemicals and certain pathogen may upset the bioreactor system.
SUGGESTIONS FOR OVERCOMING THE LIMITATIONS.
and processing
incorporated.
5. Precautionary Dumping yard be constructed for meeting contingencies.
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Comparison between EHC model and Windrow composting model- the most widely used MSW
treatment model in India is worth comparing-
The following drawbacks are attributed to all the Windrow composting plants across the
country-
The Draft Municipal Solid Waste
(Management and Handling) rules 2013
states-
“Landfill shall only be permitted for non-usable,
non-recyclable, non-biodegradable,
non-reactive inert waste and other waste such
as residues of waste processing facilities as
well as pre-processing rejects from waste
processing facilities and the like nature
provided that effort shall be done by the
municipal authority or operators to utilize
inert waste for making bricks, pavement
blocks, construction blocks, non-recyclable
plastics and other incinerable waste for co-incineration
in cement kilns or any high
temperature furnaces or manufacture of door
panels, and the like nature so that the burden
on landfill is reduced and the landfill sites
shall meet the specifications as given in
Schedule”
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7. EHC VS WINDROW COMPOSTING MODEL
1. Leachate generation: Owing to the very
nature of the process being, leachate is
generated as a natural by-product. Leachate
is generated both from windrow platform as
well as from the sanitary landfills. This
causes great inconvenience for people
living nearby the plants and causes severe
damage for the ecology and ground water of
the area.
2. Odor: The accelerated bio digestion causes
bad odor, making it impossible for people
to live anywhere near these plants.
3. Rejects/Landfill: More than 70 % of the
garbage (By volume) what is received
everyday goes into landfills. (The operators
may object this argument, but the author is
confident while making this statement and
making this statement out of his personal
experience)
4. Minimal recovery of reusable plastic:
There is no clear mechanism to recover
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plastic from segregated waste in windrow composting model. A very minimal
amount recovery happens manually- the manual recovery is indeed cannot be seen
from much different from annual scavenging. People segregate plastic in highly
unhygienic and hostile working conditions, posing serious threat to their health.
This is a major cause for the high volume of net reject after processing which
ultimately goes in to the landfill.
 The Bio degradable materials are crushed to make slurry of it, which is further
allowed to degenerate in natural way. This process ensures that no foul smell is
generated in the whole process.
 Non bio-degradable particles-Mainly plastic- is separated by APS.This allows
recovery of plastic in reusable form. This reduces the need of landfill to less than
8% of the present level.
 Since the rejects are 100% free of biological particles, the chances of generation of
 The leachate generated at the feeding point is reused in the process. By this it is
ensured that no leachate is released out of the plant. This approach solves the issue
of leachate generation which the gravest issue in the present process.
 The bio degradable slurry is ideal to be fed into bio gas plants. This allows
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HOW EHC PROPOSE TO ADDRESS THESE ISSUES:
 EHC separates the fresh garbage into Bio-Degradable and non-bio degradable.
leachate at landfill is practically nil.
generation of electricity out of waste.
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE

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8. APSM ON WHEELS- THE MOBILE APSM (AUTO PLASTIC
APSM on wheels-The mobile version of APSM is the latest improvisation of the traditional plant
based plastic separation and slurry composting MSW module. This is effectively a vehicle
mounted version of APSM which further improves the cost effectiveness of the whole process of
treating MSW.
APSM on wheels practically nullifies the very requirement of any larger infrastructure for MSW plants,
by taking the plant to the source of solid waste generation and completes the entire treatment
process without having to transport the garbage to a common plant- which in most cases is located far
from the source.
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SEPARATION MODULE)
Following is the basic composition a Mobile APSM unit:
1. Garbage and Water feeding points
2. Conveyor
3. APSM
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Similar to the Stationary unit, mixed waste (slightly pre-sorted) is fed in to the feeding point (1).
Water is sucked in and the fresh garbage is drained in the water at this very stage itself. The conveyor
(2) carries the fed waste to a height of six meters and transports it into the APSM(3). Separation
of mix waste into bio degradable and non-bio degradable happens at this point and the organic
particles are slurried and stored in the slurry collection tank (4). Plastic is stored in two separate
collection tanks and rest of the components are further sent to their respective collection bins.
One unit can process 10 Tons of mixed waste before the separated waste load gets unloaded. The bio
degradable slurry needs to be fed into decentralized MSW bio gas plants that are to be
established at different parts of the city, depending upon the size and population of the city. Once
unloaded, the unit can further go to the next common collection point and take the waste from there for
processing. APSM on wheel significantly reduces the manpower requirement in the whole rocess.
While a single truck requires 6 persons including a driver to transport 3 tons of garbage to the
dump yard, APSM on wheel can completely process 10 tons with 4 persons, including a driver.
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4. Collection tank- Slurried bio degradable
5. Collection Tanks- Plastic
6. Collection bins for specific waste items.
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The APSM installed in Kodungallur Municipality follows the direction given in the latest act in
its letter and spirit. The model indeed saved the municipality from the menace of managing
urban waste in the traditional way. The dump yard, which got completely filled in with dump by
the year 2005, was a big cause of worry for the municipal authorities. It was at that time Mr. Joy
came out with his prototype machine. The authorities-though skeptical- accepted Joy’s offer to
install the machine as a trial basis. The result was miraculous indeed. The 1.5 acre land, which
was totally filled in with garbage accumulated over decades were cleared almost completely
“O ur municipality is free of the menace of city waste, and other issues related to waste- like bad
odor, flies and epidemics resulting from improper management of waste”- said G.Sudhakaran,
Secretery, Kodungallur Municipality.
A.V.Raveendran, Helath Secretery, Kodungallur municipality said- “99.9 percentage of waste
can be processed with this module. This is a model to be emulated for all the municipalities in
the State”.
EHC, a home grown model of Solid Waste Management has successfully shown that it
can be the solution for one of the glaring issues that the country faces in such a time of
rapid urbanization. The model has grown from initial days of trial and error operations
and the experience that has gained over last 6 years made the team EHC confident of
handling greater tasks.
The team EHC has already given its preliminary proposal to Coimbatore municipality to
treat fresh garbage and the garbage accumulated in their dump yard over last many
decades. The proposal given is a PPP model where the municipality will build the plant
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9. ECO HEALTH CENTRE IN KODUNGALLUR
10. CONCLUSION:
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and the EHC will supply machineries. The project proposes to reclaim close to 600 acres
of land that became useless after the dump yard was set up in its premises.
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Tags: Case studies, Best Practices of SWM, Solid waste Management, Waste Segregation, Mechanical
segregation, Zero landfill
ECO HEALTH CENTRE- A SUCCESS STORY OF MANAGING MUNICIPAL SOLID WASTE