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Growth Story

Our Story

Since inception in 1984, we have grown from a small single-line facility at Khatima in the foothills of the Himalayas in India, into more than half a billion-dollar multinational presence with manufacturing and distribution facilities in India, South-East Asia, Europe and the Americas.

The Polyplex model of expansion moves us closer to our regional markets to deliver more efficiently and cost-effectively to our customers. Our fully integrated green-field film lines with upstream resin plants and downstream metallizers and other offline coating capabilities ensure cost-competitiveness, environmental friendly besides bringing the advantages of a single-point supply for a portfolio of film products to our customers. We have a unique model of on-shore, off-shore and near-shore business locations which complement our focus on customer relationship, access & intimacy.

POLYESTER (PET) FILM

Having begun with a single PET thin film line of 4,000 tons per annum in India, Polyplex now has the Fifth largest capacity of polyester (PET) film globally.

India

By 1996, Polyplex was producing 20,000 tons per annum in India and had backward integrated with capabilities to produce PET resin to feed captive requirements. In 2009, to meet the growing domestic demand for PET film, Polyplex added a state-of-the-art 8.70 meter wide thin PET film line, a PET resin plant and a metallizer at its new manufacturing facility in Bazpur, near Khatima. The present capacity of the two Indian operations is 55,000 tons per annum of base PET film including the capability to produce intermediate thickness up to 150 microns.

Thailand

In 2003, with the strategic objective of adding capacity closer to one of its main regional markets in South-East Asia, Polyplex set up a new plant with a capacity of 21,000 tons per annum at Rayong, Thailand through its subsidiary Polyplex (Thailand) Plc (PTL). In the same year, PTL added a second thin PET film line with a similar capacity and followed it up in 2004/2005 with the commissioning of a batch-process resin plant and a continuous-process resin plant, thereby making it completely self-sufficient in PET resin. In 2013, PTL has set up a Thick PET film line and batch resin plant in Rayong, Thailand adjacent to its existing facility with an annual capacity of 28,800 MT for the film plant and 28,000 MT for the resin plant.

Turkey

In 2005, Polyplex extended its manufacturing footprint into Turkey, moving closer to the European and Mediterranean markets and firmly establishing Polyplex as a global company. Through its subsidiary Polyplex Europa (PE), a facility was set up in the European Free Zone at Çorlu, Turkey.

PE began with a thin PET film line with a capacity of 29,000 tons per annum and in 2006, a continuous process PET resin plant was added for meeting its captive requirements. Two co-generation power plants of 4 megawatts each were installed to provide greater power security for the facility. In 2008, a second thin PET film line with a capacity of 29,000 tons per annum was commissioned, taking the total capacity to 58,000 tons per annum of base thin PET film.

In September 2013, PE incorporated a 100% owned distribution subsidiary in Turkey by the name of POLYPLEX PAKETLEME ÇÖZÜMLERİ SANAYİ VE TİCARET ANONİM ŞİRKETİ to facilitate better market reach in the local Turkish market.

USA

Americas account for about 12% of the world's consumption of thin PET film and has, since the 90's, been a significant market for Polyplex. In 1996, Polyplex moved closer to its North American customers through Spectrum Marketing, Inc., a joint venture based in Fort Worth, Texas, for warehousing and distributing Polyplex products. This entity was acquired in 2006 and renamed as Polyplex (Americas), Inc. In view of the growing American market demand and the absence of new PET film capacity, Polyplex decided to invest in the USA in 2011. Polyplex USA LLC, a wholly owned subsidiary of PTL, was incorporated and a green-field facility comprising a thin PET film line was started in April 2013 in Decatur, Alabama followed by the PET Resin plant in July 2014. In July 2012, Polyplex has acquired some metallizing assets located at Austell, Georgia and have relocated most of these assets to Decatur, Alabama while some had been shifted to other group locations. With effect from January 31st, 2013, Polyplex (Americas) Inc. has been merged with Polyplex USA LLC, Alabama.

Indonesia

In October 2017, a new Company has been incorporated in Indonesia by the name of "PT Polyplex Films Indonesia" as a wholly-owned subsidiary of Polyplex (Thailand) Public Company Limited. The Company has started its manufacturing operations in Q3 2019-20 catering mainly to the domestic market in Indonesia and also the regional / other export markets.

POLYPROPYLENE (PP) FILMS

India

In the backdrop of rapid demand growth rates in India and the need for a single-point supplier of a wider range of packaging films, in 2010, Polyplex diversified its product portfolio to include a range of Biaxially Oriented Polypropylene (BOPP) film products by commissioning a line with a capacity of 35,000 metric tons per annum at the Bazpur facility.

Thailand

A Cast Polypropylene (CPP) film line with a capacity of 10,000 tons per annum was added at the Rayong facility in Thailand. This was followed by commissioning of two Blown PP film lines in Oct' 2013 and June’2018 respectively at Rayong, Thailand with the total annual capacity of 8,845 tonnes. The Company is in the process of adding third Blown PP line with the annual capacity of 4,800 MT.

Indonesia

The Company has recently announced a new BOPP line adjacent to the PET film line in Indonesia which would help diversify the product offering and help mitigate challenges posed by concerns surrounding sustainability and provides an opportunity for the Company to grow in a familiar industry. The stated capacity of BOPP film plant is about 60,000 TPA. It is expected to be commissioned in H1 2021-22.

Turkey

To meet the needs of Blown Film for local and export market (Europe), the Company is setting up a new Blown Film line in Turkey with the annual capacity of 4,392 MT expected to be commissioned by Q2 FY 2021-22

VALUE ADDED PRODUCTS

Innovating to simplify product sourcing, improve services and reduce costs for our customers, Polyplex has continuously added downstream facilities to offer an expanded product portfolio that includes Metallized films, Holography, Transfer Metallized Paper, Siliconised Polyester Release Liners, Extrusion Coated films and offline Chemically Coated films.

Metallizer

In 2002, Polyplex restructured the polyester industry value-chain and set a global benchmark for efficiency by commissioning an in-house metallizer at Khatima with a capacity of 4,800 tons per annum. This was followed by adding 4 metallizers at Rayong, 3 at Corlu, 3 at Bazpur, 1 in the USA and some additional metallizing assets in the USA through acquisition, part of which was later shifted to group entities.

In order to cater to the new segments of specialty products, the Company has added another Metallizer in India with the annual capacity of around 7200 MT/annum. A metallizer in Indonesia (green field expansion) was commissioned in Q3 2019-20 and another one is under process.

Silicone Coating

To deliver similar benefits to the Pressure Sensitive Adhesive industry, a state-of-the-art silicone coating line with an annual capacity of 160 million sq. meters for the production of sophisticated Siliconised Polyester Release Liners was commissioned at Khatima in 2007. This was followed by two silicone coating lines with the annual capacity of 550 million sq. meters at Rayong in 2011 & in 2019.

Extrusion Coating

In April 2008, an Extrusion Coating line with an annual capacity of 150 million sq. meters for the production of Thermal Lamination film was commissioned at Rayong, Thailand. Subsequently, a second Extrusion Coating Line with an annual capacity of 215 million sq. meter was commissioned at Rayong, Thailand in June 2013.

Offline Chemical Coating

With the objective to enhance its Product Portfolio, Company commissioned an offline chemical coating line in Turkey in 2013-14 followed by commissioning of two lines in India in FY 2014-15 and FY 2018-19 respectively and one in Thailand in FY 2019-20. Another offline coating line is expected to be commissioned in Turkey in FY 2021-22.

Transfer Metallized Paper

Polyplex has successfully commissioned a laminating machine in India in Q1 FY 2019-20 to facilitate Transfer Metallized Paper business.

Holography

Polyplex has successfully commissioned six holography lines in India and one in Turkey which will further enhance the product basket. Two more holography lines are under implementation in Thailand.

DISTRIBUTION ENTITIES

Netherlands

In April 2013, Polyplex expanded its market presence in the EU by setting up a wholly-owned distribution company in the Netherlands named Polyplex Europe B.V. The distribution entity is fully owned by Polyplex (Thailand) Public Company Limited (PTL).

Turkey

In September 2013, PE incorporated a 100% owned distribution subsidiary in Turkey by the name of POLYPLEX PAKETLEME ÇÖZÜMLERİ SANAYİ VE TİCARET ANONİM ŞİRKETİ to facilitate better market reach in the local Turkish market.

Recycling Initiative promoted by Polyplex

EcoBlue Limited

In 2012, Polyplex set up a recycling unit in Thailand, EcoBlue Limited, in order to provide a sustainable solution for film based process waste.

Over the years, EcoBlue has been working with different post-consumer and industrial wastes to develop and produce high quality rPET & rPP which can replace virgin resin in high end applications.

EcoBlue’s current capacity is 15,000 MT/year for rPET and 5,000 MT/year for recycled Polyolefin. The company is in the process of setting up a new state of the art recycling facility for post-consumer waste. EcoBlue’s product range includes:

  • 3D Pure High IV rPET: For bottle application
  • 3D Pure Amorphous rPET: For Polyester Filament and PET Film application
  • High IV rPET: For strap, sheet, monofilament application
  • Low IV rPET: For fiber application
  • Recycled PP & PE: For extrusion, blow moulding and injection moulding applications

The company is GRS certified and its 3D Pure rPET range has the Letter of No Objection from U.S. FDA.

Learn more at http://ecoblue.co.th/

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