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.

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.

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.

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.

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 has also added third Blown PP line with the annual capacity of 4,800 MT in Jan’2021.

The Company has 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 later part of 2021.

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 Q3 FY 2021-22

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.

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.

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 Q3 FY 2021-22.

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

Polyplex has successfully commissioned six holography lines in India, two in Thailand and one in Turkey which will further enhance the product basket.

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.