Growth Story
OUR STORY

Since inception in 2002, PTL has grown from a single-line facility into a 300 million dollar turnover multinational, with manufacturing in Europe and the Americas and distribution in China and Netherlands.

The Company’s model of expansion has helped move closer to its regional markets to deliver more efficiently and cost-effectively to its customers. Our fully integrated green-field film lines with upstream resin plants and downstream metallizers and other offline coating capabilities ensure cost-competitiveness, minimized environmental impact besides bringing the advantages of a single-point supply for a portfolio of film products to our customers.

POLYESTER (PET) FILM

Having begun with a single PET thin film line in 2003, PTL doubled its capacity in the same year by adding the 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 its first foray into the thick PET film segment, PTL has set up a new 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, PTL 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.

USA accounts for about 14% of the world’s consumption of thin PET film and has, since the 90’s, been a significant market for Polyplex group. In 2006, PTL acquired a distribution company in USA and renamed it as Polyplex (Americas), Inc. (PA). In view of the growing American market demand and the absence of new PET film capacity, PTL decided to invest in a manufacturing facility in USA in 2011. Polyplex USA LLC (PUL) has been 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 have been shifted to other group locations.

In 2009, addressing the strategic need to establish a long-term presence in the fast growing Chinese market, PTL incorporated Polyplex Trading (Shenzhen) Co. Ltd. as a distribution entity in China.

In 2012, PTL has set up a representative office in Malaysia to service the customers in Malaysia and Singapore in a more effective manner.

In April 2013, PTL has set up a distribution company in Netherlands, Polyplex Europe B.V, which will help in servicing the European markets for its value added products such as Silicone coated film and Thermal Lamination film.

POLYPROPYLENE (PP) FILMS

In an effort to promote PTL to be a single-point supplier of a wider range of packaging films, in 2010, we diversified our product portfolio to include Cast Polypropylene (CPP) film line with a capacity of 10,000 tons per annum, at the Rayong facility in Thailand.

To provide a key substrate for release liners and customized film, a Blown PP film line with a capacity of 4,645 tons per annum was commenced in October 2013 at Rayong, Thailand.

VALUE ADDED PRODUCTS

Innovating to simplify product sourcing, improve services and reduce costs for our customers, PTL has continuously added downstream facilities to offer an expanded product portfolio that includes Metallized films, Siliconized Release Liners and Extrusion Coated films.

PTL and its subsidiaries have a metallizing capacity of about 39,700 MT pa, with multiple metallizers at all its manufacturing locations.

To deliver similar benefits to the Pressure Sensitive Adhesive industry, a state-of-the-art silicone coating line with an annual capacity of 500 million sq. meters for the production of sophisticated Siliconised Polyester Release Liners/ PP Liners was commissioned at Rayong in 2011. This was followed by adding 3 metallizers at Rayong, 2 at Corlu, 2 at Bazpur and some metallizing assets in USA through acquisition. In order to augment the capacity as well as portfolio of Metallized films, the Company has added two new metallizers at Thailand & Turkey . With these installations, the total capacity of metallized film stands at 71,500 tons per annum.

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. The second extrusion coating line in Rayong with an annual capacity of 215 million sq. meters has started operations in June 2013.

In April 2013, Polyplex expanded its market presence in EU by setting up a wholly owned distribution company in Netherlands named Polyplex Europe B.V. The distribution entity is fully owned by Polyplex (Thailand) Public Company Limited (PTL). This new entity is strategically formed to address the need for additional business for value added products.

OFFLINE COATING

With the objective of enhancing its Product Portfolio, Company commissioned an offline coating line in Turkey in Q4 FY 2013-14 with another line in India started in Q2 2014-15.

PET RESINS

Polyplex has divested it's 100% stake in the brown field Bottle Grade PET Resin plant in favour of Indorama Netherlands B.V., a wholly owned subsidiary of Indorama Ventures Public Company Limited in Q4 2014-15. This plant was set up in Turkey in the entity named Polyplex Resins (PR) with a capacity of 210,000 tons per annum. Bottle Grade PET Resin is being used in fast growing consumer products like Mineral water bottles, Carbonated Soft drinks, etc with potential for continued growth as more products like beer shift from traditional forms of packaging to Pet bottles.

RECLYCING

Polyplex has set up a recycling unit in Thailand with a capacity of 3000 MT per annum in order to provide sustainable solution for film based process waste.

 It’s been an exciting journey, and Polyplex has come a long way, moving swiftly and dynamically in step with the needs of a new and changing world.