processing level (level of processing)
Also known as: processing stage · treatment level recycling
The degree to which a material has been processed in a recycling or biogas plant — ranging from initial collection and sorting to full mechanical or chemical processing and final product conversion.
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What is processing level?
Processing level describes the degree to which a feedstock material has been transformed through a recycling or biogas plant — ranging from minimal pre-treatment (segregation, sizing) to deep chemical or thermal conversion (pyrolysis, gasification, depolymerisation). The level of processing applied determines product value, capex per tonne of installed capacity, opex intensity, and regulatory pathway under SPCB and CPCB rules.
For organic waste in CBG plants, processing levels are well-defined. Level 1 — raw collection and storage: aggregating cattle dung or food waste with minimal pre-processing, sold directly as organic input to farmers. Lowest capex, lowest revenue per tonne. Level 2 — sorting and shredding: removal of plastics, glass, and metals; size reduction. Required upstream of any digester. Level 3 — anaerobic digestion to biogas: capture and use of biogas; digestate as by-product. The basic SATAT-scheme value chain. Level 4 — biogas upgrading to CBG plus digestate separation: addition of upgrading train (water scrubbing, PSA, membrane, amine) and screw press or centrifuge for digestate; PESO-compliant cascade. Premium products, higher capex. Level 5 — digestate value-addition: composting, pelletising, blending with rock phosphate (PROM), branded packaging, FCO-registered fertiliser sale. Level 6 — full nutrient recovery: ammonia stripping, struvite recovery, mineral concentration; speciality fertiliser products. Highest capex, highest product value.
The same hierarchy applies to plastic and e-waste recycling. Level 1: collection, manual segregation, baling, sale to consolidators. Level 2: shredding, density separation. Level 3: washing, hot-air drying, granulating into recycled flake or pellets. Level 4: extrusion, compounding with stabilisers, sale as engineering-grade material. Level 5: chemical recycling (pyrolysis, depolymerisation, solvolysis) producing monomer or oil. The processing level decision is fundamentally a capex-versus-margin trade-off. Higher levels need larger capex (Level 1–2 at ₹0.5–2 crore per TPD versus Level 4–6 at ₹5–15 crore per TPD) but earn higher product margin and stronger EPR-credit value. Indian markets currently show clearest profitability at Levels 3 and 4 for both biogas (CBG plus separated digestate) and plastic recycling (washed and pelletised material). Level 5 chemical recycling is emerging but faces regulatory and feedstock-quality challenges.
Common questions about processing level
Plain-English answers to what people most often ask.
Should a new biogas plant start at full processing level 5, or build up incrementally?
Does processing level affect the environmental permit requirements?
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