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MAIN FIGURES
Pilenpak is one of the Top 3
converters in Turkey
Total Employes: 420
Direct: 317 people
Undirect: 103 people
Total Area: 50,000 m2
Warehouse area: 13,000 m2
Dispatch Quantity: 540 Mln (m²)
PILENPAK,
is a privately owned Turkish Manufacturing Company in the
market since the 1988, operating in the Flexible Packaging
Market and located in the main industrial zone of Manisa, Aegean
region.
PILENPAK INTEGRATED COMPANY
2 Printing Technologies
Rotogravure
Flexographic
In House Processes:
Cylinder Engraving
Artwork Operations
PE Film Manufacturing
In House Laboratory Tests
INKA EXPORT ORG.
12 Export Sales Executives
Multi language Sales Team
Marketing Activities Dept.
Logistic, Warehouse, Customs
OUR COMPANIES
PILENPAK
Producer(Converter)
PolyGraphic
Graphics (Pre-press) & Cylinder Production
Flexpack
Multilayer PE Production
INKA
Export & Marketing
CONTINGENCY PLAN
3 Manufacturing Locations in the
same Industrial Area
Centralized MRP system
High Production Flexibility
Total Rotogravure Converting
Capacity 720,000,000 m²
Total Flexo Printing Capacity
100,000,000 m²
High Speed Printing up to
500m/min
OUR FACTORIES
PilenPak 1 - 1988
3 Printing Machines
3 Laminators
3 Slitters
Cylinders Production
Ink Dispensing
Laser Perforation
PilenPak 2 - 2008
2 Printing Machines
1 Laminator
2 Slitters
2 PE Blown Film Lines
3 Layers & 5 Layers
PilenPak 3 - 2012
2 Printing Machines
1 Laminator
2 Slitters
Cylinder Ware-House
EXPORT MARKET
• PilenPak’s target is to increase
market share in Europe with the aim
of becoming a leading Company in
Food, Confectionery, Pet Food and
other niches Markets
DOMESTIC MARKET
• PilenPak is considered to be one of
the major integrated Turkish
manufacturer.
NEXT THREE YEARS BUSINESS PLAN
Growth will be supported by the up to date Technology investments (New Roto and new Flexo Machines) and the possibility to work with 3 shifts 7 days week
0
20
40
60
80
100
120
140
160
2014 2015 2016 2017 2018 2019 2020
3 YEAR FORECAST (MLN €)
EXPORT MARKET
Export Business represent the wider
part of the total Turn Over. The
Mission of PilenPak for the next 3
years is to have an important growth
rate in the European Markets.
The policy of PilenPak is not to
exceed the Export share more than
70% of the total T.O. to protect the
domestic market share.
DOMESTIC MARKET
PilenPak is considered to be one of
the major manufacturers of Flexible
Printing in the Turkish market.
REVENUES 2015
34%
66%
DOMESTIC T.O.
EXPORT T.O.
Export is the 66% of the T.O.
Domestic is the 34% of the T.O.
EXPORT MARKET PRESENCE:
66% of the Total Production
belongs to Export
3 Years Target is to keep the
export/domestic sales balance
at the same level
Export Sales activities in 22
Countries
Consolidate presence in the
North European food Market
Germany 7%
Belgium 3%
Bulgaria 7%
Denmark 2%
France 17%
Netherland 29%
UK 11%
Poland 17%
Russia 1%
Others 6%
Revenues by Country
Germany
Belgium
Bulgaria
Denmark
France
Netherland
UK
Poland
Russia
Others
MAIN MARKETS:
Confectionary
Coffee
Crisps & Snacks
Icecream
Pet Food
Powdered Products
Hygenic Products
Bottle Labels
Wet Wipes & Soaps
INTERNATIONAL MARKET REFERENCES
CYLINDERS PRODUCTION
• The In-house Cylinders production
permit a stronger flexibility and
shorter new product start up time.
• We are able to produce 100
Cylinders per day
MANUFACTURING EQUIPMENTS:
- 7 Engraver Machines
- 2 Polishing Machines
- 7 Copper Plating Machines
- 3 Chrome Plating Machines
- Over 13.000 Cylinders in Stock
ROTOGRAVURE – CYLINDERS PRODUCTION
IN HOUSE PE PRODUCTION
In house PE-EVOH and PA Film
manufacturing allows wider flexibility,
customized solutions and cost
competitiveness
3 and 5 layer films
2 blown machines
Barrier Films with EVOH or PA
Special Peelable Films
Easy Tear Films
Stand-up Pouch Films
Special formulations upon
customer request
PE – EVOH – PA FILM MANUFACTURING
ROTOGRAVURE PRINTING PROCESS
Flexibility Up to 60 different Jobs
per day
6 Rotogravure presses up to 12
colors
4 Lamination Machines
Cold Seal Application
Laser Perf.: Laser
scribing/perforation
Uni-Coding: 9 Ink-jet Uni-Code
Printers
In-Line Corona Treatment
Slitting: 6 Slittings
Ink Dispensing: 32 heads
100% Full Web Inspection
ROTOGRAVURE MANUFACTURING
FLEXO PRINTING PROCESS
Flexo Printing German (Windmöller)
fast machine (500 mt per minute) up to
10 colors with Fully Automatized camera
and process control
1 Lamination Machine
Off line Cold Seal Application
Laser Perforation: Laser
scribing/perforation
Uni-Coding: 9 ink-jet Uni-Code
Printers
Slitting: 1 Slitter
100% Full Web Inspection
FLEXO MANUFACTURING
2015 INVESTMENTS
A new PE Extrusion Lamination
Line
Cylinder steel body manufacturing
A new Ink dispensing system for
PilenPak sites 2 & 3
2016 INVESTMENTS
Construction of a new Flexo
machine
2017 INVESTMENTS
A new Rotogravure printing
machine with 10 colors
New PE film production line
INVESTMENTS
1 1
2 2
5
4 4 4 4 4
5
6 6 6 6
2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014
TREND (MLN €)
MANUFACTURING CAPACITY
PilenPak Rotogravure Capacity as
had a linear growth during the last
years thanks to a continue
machines park renovation and
technology developments.
The last Advance Machine moved
the Capacity up to 720 Mln (m²),
value necessary to support the
expected growth of the Business.
-
100.000.000
200.000.000
300.000.000
400.000.000
500.000.000
600.000.000
700.000.000
800.000.000
2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Used Capacity (m2) Free Capacity (m2)
ROTOGRAVURE CAPACITY (m2)
35% 25%
MANUFACTURING CAPACITY
Thanks to the brand new German
Top Techology Flexo-Printing
machine, starting from 2013
PilenPak is approaching the Flexo
Packaging market.
Flexo process is considered
strategic in order to provide to
PilenPak customers a complete
Product Offer, strenghtens our
partnerships and opening new
markets
-
50.000.000
100.000.000
150.000.000
200.000.000
250.000.000
2013 2014 2015 2016 2017
Used Capacity (m2) Free Capacity (m2)
FLEXO CAPACITY (m2)
45% 20%
*
* Capacity increasing cause an Investment of a 2nd Flexo machine
LEGISLATIONS:
Approvals in accordance to
Legislation of the exported country
is managed by the System Dept.
DECLARATIONS:
Declaration Documents are
prepared and sent to customers
before the products are dispatched
PRODUCTS QUALITY AND SAFETY DECLARATIONS
82/711/EEC
Migration Testing
1935/2004
Frame Work
Regulation
85/572/EC List of
Simulants
EU 10/2011
European
Legislation
FDA
USA Legislation
2023 Good
Manufacturing
Practice
NORM AUDIT COMP.
CERTIFICATION TYPE YEAR OF
ACHIEVEMENT APPROVALS
ISO 9001:2008 LRQA Quality Management
System Since 2000 √
BRC-IOP.V4 LRQA Packaging Norms Food Safety Since 2008 √
OHSAS 18001:2007 LRQA Safety Since 2010 √
AIB AIB Packaging US Standard Since 2005
HACCP BVQI Food Safety Since 2003
SEDEX INTERTEK Ethical Business - SMETA Since 2011 √
ISO 14001 LRQA Environment Management System 2014 √
IN-HOUSE QUALITY TESTS:
Gas Chromatography and other
Solvent Residue Testers
OTR Test
WVTR Barrier
Hot-Tack Seal Test
Cold-Tack Seal Test
COF Test Equipments
TEST EQP. CALIBRATION:
Colour Spectrophotometers are
calibrated every 3 months
All the others Tests Equip. are
calibrated by International
accredited laboratories once per
year or in case of need.
LABORATORY TEST EQUIPMENTS
CRITICAL CONTROL POINTS
SOLVENT RESIDUE checks are
done with Gas Chromatography (GC-
HS). All the Solvent Residue checks
are recorded into PP MRP software
CURING TIME is digitally controlled
by PP MRP software with Barcoded
Labels between process steps
QUALITY TEST MIGRATION out
sourced tests are made by
accredited laboratories
ODOR TEST are carried out by
experienced and trained odor team
members
LABORATORY TEST EQUIPMENTS
BARCODE TRACEABILITY
INFORMATION:
Fast traceability from PilenPak MRP
software manage below records:
Raw Material Record
Process Records
Storage Records
Supplier Record
Shipping Records
Customer Information
Maintenance Records
PROCESS TRACEABILITY SYSTEM
Unique Barcode
Nr. For every roll
Process Nr. - Mother Roll Nr. / Lane Nr.
New Project
BDG
- Customer Oriented Project
- Tender Specification Analysis
- Cost Reduction Projects
- Tailor Made Structure Study
- Project Price Calculation
- Alternative Film Research
Trial Roll Production
Customer Approval
Specifications System Set-Up
Standard Production
BDG (BUSINESS DEVELOPMENT GROUP) WORKFLOW
SALES PROCESS DEPT.
R&D DEPT.
PURCHASING DEPT.
COST DEPT.
INTEGRATED SOFTWARE SYSTEM
PP Software is operating from the
ORDER to the DELIVERY
Full compatibility with the most
common International Softwares
like SAP, IBM AS400 with direct
Technical File convertions
Production Process is fully
managed from PP software by our
customers specifications
Fast and reliable information
Technology System generating
Statistics
PilenPak 4.0 MRP SOFTWARE
SUSTAINABILITY:
• FINANCIALLY STABLE
• CONTINGENCY PLAN
• WIDE PRODUCT RANGE
• HIGH FLEXIBILITY
• COMPETITIVITY
• STRONG R&D OFFICE
PILENPAK AN INTEGRATED SUPPLIER
CUSTOMER ORIENTED
CUSTOMER DRIVEN R&D ACTIVITIES
FAST GROWTH & CONTINUOUS INVESTMENTS
CUSTOMER ORIENTED INVESTMENTS
CONTINUOUS CAPACITY INCREASING
WE WOULD LIKE TO BE ONE OF YOUR MAJOR
FLEXIBLE PACKAGING SUPPLIER