Silafrica Leads the Transformation of East Africa’s Packaging Industry

Interview with Muthu Ravi, Country CEO of Silafrica KENYA

In 2022, you mentioned Silafrica Kenya’s ambition to lead the circular economy and sustainable packaging movement in East Africa. How has the company advanced toward becoming a regional leader in circular manufacturing and eco-friendly packaging solutions since then?

Since 2022, Silafrica has made significant strides in embedding circular economy principles across our operations. Today, 100% of our product portfolio is designed and comply with recyclability, and we have expanded regional recycling partnerships in Kenya, Tanzania, Ethiopia and Mozambique.

It operates in 2 ways.

Open loop system – What this means?

Through open loop system, we source back post consumer plastic waste in the form of reprocessed polymers from local Recycling plants and use to manufacture crates for applications in Industrial and Agriculture sector.

Second model is a closed-loop systems that operates between our own customers like Coco-Cola, Pepsi, Heineken, AB InBev and Diageo.  Post-industrial plastic wastes are collected, reprocessed, and reused within our production streams.

Our ambition to lead the regional circular economy is no longer aspirational — it is operational and measurable.

Silafrica committed to powering 30–35% of operations with renewable energy by 2025. Could you share what progress has been made in green energy adoption and how renewable power is transforming your sustainable manufacturing processes today?

We are proud to report that as of 2025, approximately 12% of our total energy consumption is sourced from renewable sources, primarily solar power installations at our Nairobi plant. We remain firmly on track to achieve our 25% renewable energy target by end of 2030. This transition not only reduces our carbon footprint but also enhances operational resilience by stabilising long-term energy costs. Equally important to note that our new generation injection moulding machines consumes 40% lesser energy than standard machines making our operations more greener than earlier.

Increasing the use of post-consumer recycled (PCR) plastics was a major goal for Silafrica. Which of your key packaging products or innovations now incorporate recycled materials, and how has this contributed to the growth of circular packaging in Africa?

Increasing the use of PCR plastics has been a central focus of our sustainability agenda. Currently, over 31% of our rigid and flexible packaging lines incorporate PCR content. We use right-quality recycled resins without compromising product performance. We collaborate closely with certified recyclers to maintain traceability and compliance with ISO standards.

Silafrica’s foldable returnable crates (FRCs) won “Packaging Innovation of the Year.” What makes this award-winning product a game changer for supply chain efficiency, sustainability, and cost optimization across the region?

Our Foldable Returnable Crate, which won Packaging Innovation of the Year, transforms logistics efficiency across East Africa’s supply chains. The design allows up to 70% volume reduction during reverse logistics, dramatically cutting transport emissions and storage costs. It also supports reusability over 15–20 cycles, reducing single-use waste. This innovation represents Silafrica’s ability to merge design thinking, sustainability, and cost efficiency in one solution — a true reflection of our technological leadership.

How is Silafrica leveraging Industry 4.0 technologies, such as automation, data analytics, and smart factories, to enhance sustainability, operational efficiency, and innovation in packaging manufacturing?

Silafrica has progressively integrated Industry 4.0 technologies across all major plants. Through automation, real-time data monitoring, and predictive maintenance systems, we’ve achieved greater precision, waste reduction, and energy efficiency. Our Smart Factory Dashboard, launched in 2021, connects production lines digitally, allowing instant visibility on quality metrics and energy consumption. These technologies have improved operational efficiency by over 25% and strengthened our sustainability reporting through accurate data analytics.

As you work with leading FMCG and multinational brands in Africa, how have customer expectations evolved around eco-friendly design, recyclability, and cost-effective sustainable packaging in the past few years?

In the past three years, customer expectations have shifted dramatically toward sustainability, circularity, and total cost efficiency. FMCG clients are now demanding packaging solutions that reduce environmental impact while enhancing brand differentiation. There’s a strong push for design for recyclability, lightweighting, and carbon footprint transparency. Silafrica’s ability to co-create sustainable solutions with clients combining innovation with affordability has positioned us as a trusted partner rather than just a packaging supplier.

Building a circular economy for plastics depends on strong recycling, collection, and waste management systems. What kind of strategic partnerships or public-private collaborations is Silafrica leading to strengthen recycling infrastructure and post-consumer plastic recovery in East Africa?

We believe the circular economy cannot thrive without a strong recycling ecosystem. Silafrica played a proactive contribution in Kenya’s Circular economy through BU’s like EMF, KEPRO, EPR, KPP and PETCO, We also collaborate with community-based collection networks and NGOs to enhance post-consumer waste recovery. We’re in the process of piloting “Recycle for Tomorrow” programs that incentivize local collectors and processors, strengthening value chains from waste to manufacturing.

The packaging industry in East Africa is becoming increasingly competitive. What differentiates Silafrica as a leader in sustainable, innovative, and high-quality packaging manufacturing across the region?

What sets Silafrica apart is our end-to-end sustainability integration — from design and material innovation to production and recycling partnerships. Unlike many players, we are not merely reacting to sustainability trends; we are shaping them. Our focus on circular product design, renewable energy adoption, and data-driven manufacturing ensures clients receive solutions that are compliant, cost-effective, and environmentally sound. We also invest heavily in local talent and R&D, ensuring regional expertise with global standards.

 Kenya is emerging as a hub for eco-friendly and high-performance packaging solutions. How is Silafrica positioning itself to expand exports and establish Kenya as the regional center for sustainable packaging production in Africa?

Kenya is at the heart of our regional growth strategy. Our Nairobi facility serves as the innovation and export hub for East and Central Africa, supplying eco-friendly packaging to markets across East, Southern and West African markets. We leverage Kenya’s advanced infrastructure, regulatory leadership, and renewable energy availability to produce high-quality, sustainable products. This strategic positioning supports the African Continental Free Trade Area (AfCFTA) vision by making Kenya a benchmark for green industrial exports.

 Looking ahead to 2030, what is your vision for Silafrica’s growth, sustainability leadership, and long-term impact on the future of green manufacturing and circular packaging in Africa?

By 2030, Silafrica aims to become Africa’s most sustainable and innovative packaging manufacturer, achieving carbon-neutral operations, 100% recyclable product design, and full integration of renewable energy across all facilities. Beyond environmental goals, our vision includes empowering local livelihoods through recycling and circular value chains. We see our role not only as an industry leader but as a catalyst for responsible manufacturing, creating a legacy of innovation and sustainability for future generations.

Closing Remarks:

“Sustainability is no longer a department or a target — it’s the way Silafrica operates. We see every tonne of plastic not as waste, but as an opportunity to build a circular, resilient African economy.”