In a world grappling with mounting waste, ceramic debris poses a unique challenge. Durable and non-biodegradable, discarded ceramics can linger in landfills for centuries. Shashank Nimkar, a National Institute of Design (NID) graduate, saw this problem as an opportunity. Through his startup, Earth Tatva, he has pioneered a process to recycle ceramic waste into a versatile, eco-friendly material used by artists, architects, and designers. This article explores how Earth Tatva is reshaping ceramic waste into sustainable products, diverting tonnes of waste from landfills and reducing environmental impact.
The Genesis of Earth Tatva
Shashank Nimkar’s journey began with a visit to Khurja, Uttar Pradesh, a ceramic manufacturing hub, in 2017. Witnessing piles of discarded ceramics cluttering the streets, he was struck by their permanence. “Ceramics don’t biodegrade,” Shashank recalls. “This waste was here to stay, long after we were gone.” This realization, coupled with his training in industrial design at NID, Ahmedabad, sparked the idea for Earth Tatva.
During his master’s program, Shashank researched global efforts to recycle ceramics. Inspired by a Japanese project that incorporated 50% recycled ceramic content, he set out to create a scalable solution. His goal was to develop a material that was not only sustainable but also practical for real-world applications.
The Innovation: Recycling Ceramic Waste
Earth Tatva’s process transforms post-industrial ceramic waste into a reusable material called Tatva Mix. The method begins with sourcing waste from factories in Gujarat’s Morbi and Thangadh regions. The waste is pulverized into a fine powder and mixed with a proprietary clay binder—60% recycled ceramic and 40% clay. This mixture is processed using a ball mill for uniformity.
For products like mugs and architectural partitions, the mixture undergoes slip casting, where the liquid blend is poured into molds and solidified. For pottery, the mixture is dewatered using a filter press and processed through a pug mill to create a dough-like consistency. After extensive testing, Earth Tatva achieved a breakthrough: a mix containing up to 70% recycled ceramic, surpassing the Japanese benchmark.
The choice of clay as a binder was deliberate. Unlike cement or resin, which are difficult to separate during recycling, clay is natural and allows the material to remain recyclable. This innovation ensures that Earth Tatva’s products are both durable and circular, capable of being repurposed at the end of their lifecycle.
Overcoming Challenges
Developing Tatva Mix was not without hurdles. Early experiments resulted in cracked molds, requiring nearly a year of tweaking to perfect the composition and manufacturing process. The COVID-19 pandemic further delayed progress, but it gave Shashank time to secure funding. In 2020, Earth Tatva received a Rs 20 lakh grant from the Government of Gujarat, enabling commercial operations to begin in 2021.
Another challenge was consumer education. Many assume ceramics are inherently eco-friendly due to their natural origins, but Shashank emphasizes that their production is energy-intensive. Firing ceramics at high temperatures consumes significant resources, making recycling critical to reducing environmental impact.
Sustainable Operations and Impact
Earth Tatva operates at a studio level, prioritizing handmade craftsmanship over large-scale machinery. Each piece is carefully crafted, minimizing energy consumption compared to mass-produced ceramics. The company fires products at 1200°C using natural gas, balancing durability with energy efficiency. This approach has diverted approximately eight tonnes of ceramic waste from landfills, saving an estimated 450-500 kg of carbon emissions.
Tatva Mix is now used by studio potters, artists, and architects to create products ranging from food-safe bowls to mosaic tiles and partitions. These partitions, designed to be dismantled and reused, exemplify circular design. Kanzariya Ankit, Earth Tatva’s Technical Material Manager, notes, “By recycling up to 60% of ceramic waste, we’re reducing the need for raw material extraction, conserving natural resources.”
Real-World Applications and Partnerships
Earth Tatva’s products have garnered attention for their functionality and sustainability. Dhruva Patel, founder of Studio WildFlower, has sourced Tatva Mix for two years. “The idea of reducing landfill waste while maintaining the elegance and durability of ceramics stood out,” she says. Her hand-painted ceramic products, made with Earth Tatva’s material, reflect a commitment to environmental responsibility.
Architects are also embracing Tatva Mix for sustainable construction. The material’s versatility allows it to be molded into intricate designs, making it ideal for both artistic and structural applications. From tiles to partitions, Earth Tatva’s products are proving that recycled materials can be both beautiful and practical.
A Vision for the Future
Shashank’s mission extends beyond creating recycled products. He aims to redefine waste as a resource, inspiring a shift in how society views discarded materials. “I always knew I wanted to create something meaningful through design,” he reflects. “Through Earth Tatva, I’m contributing to a future where waste is a solution, not a problem.”
Earth Tatva’s success highlights the power of design-driven innovation in addressing environmental challenges. By combining creativity, technical expertise, and a commitment to sustainability, Shashank Nimkar has turned ceramic waste into a symbol of hope—a testament to what’s possible when waste is reimagined as opportunity.
