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IONA Engineering Partners with Carbon Masters and SAFE for Bengaluru’s First Integrated Waste-to-Value Park

Turkey-based IONA Engineering has joined the Kannahalli Integrated Waste-to-Value Park in Bengaluru as the waste-to-energy technology partner. The project is being developed under a public–private partnership led by the Bruhat Bengaluru Mahanagara Palike (BBMP), with Saatarem Alternative Fuel and Energy (SAFE) serving as the concessionaire and Carbon Masters acting as the biomethane and circular organics platform partner.

The collaboration aims to establish a first-of-its-kind integrated waste-to-value facility at Kannahalli, combining large-scale compressed biogas (CBG) production with India’s first single-use plastic-to-pyrolysis-to-power system. The initiative is designed to address multiple waste streams while maximising resource recovery and energy generation.

As part of its role, IONA Engineering is designing and operating a dedicated waste-to-energy system capable of processing 25 to 35 tonnes per day of non-recyclable plastic waste. Through controlled pyrolysis technology, the plastic waste is converted into energy-rich fuels that generate around 1 MW of renewable electricity. The electricity will be used entirely within the waste-to-value park, reducing reliance on the grid and improving the project’s overall economic efficiency.

Unlike conventional incineration or open burning, the pyrolysis process significantly lowers emissions and enables safer disposal of difficult-to-recycle plastics. This approach supports the project’s broader environmental objectives while addressing one of the most persistent urban waste challenges.

The foundation stone for the Kannahalli project was laid in December 2025 at the Bengaluru West Municipal Waste Plant, with Karnataka’s Deputy Chief Minister, D.K. Shivakumar, presiding over the ceremony. The BBMP-owned facility currently processes about 350 tonnes per day of source-segregated waste into compost, against an installed capacity of 1,000 tonnes per day.

Under the public–private partnership framework, BBMP and its concessionaire SAFE, along with Carbon Masters and other technology partners, are transforming the site into an integrated waste-to-value park. Once fully developed, the facility is expected to handle nearly 900 tonnes per day of source-separated organic waste, producing approximately 30 tonnes per day of Carbonlites biomethane and around 750 tonnes per day of organic fertiliser.

In the first phase, a biomethane plant will process 300 tonnes per day of organic waste, generating about 10 tonnes per day of compressed biogas and 250 tonnes per day of organic fertiliser. These outputs are expected to significantly reduce landfill dependency and methane emissions while supporting cleaner energy use.

IONA Engineering contributes global expertise in waste-to-energy systems, plant optimisation, and waste preprocessing tailored to Indian waste conditions. Combined with Carbon Masters’ experience in biomethane production and SAFE’s capabilities in executing urban waste infrastructure projects, the partnership demonstrates how international technology can be effectively adapted to local requirements.

Once operational, the Kannahalli Integrated Waste-to-Value Park will convert large volumes of municipal waste into renewable gas, clean power, and organic fertiliser. More importantly, it offers a scalable and financially viable model for Indian cities, showing that even complex waste streams such as single-use plastics can be transformed into valuable energy resources through the right combination of technology and collaboration.