Hayat Kimya Creates First End-to-End Production System for Hygiene Products in Turkey
Hayat Kimya, one of the largest Turkish consumer goods manufacturers specializing in home care, hygiene and tissue has created the first and only end-to-end production system in the fast-moving consumer goods in Turkey. 2017 two new productions sites on the company’s premises in Kocaeli were opened. They have been specifically designed for manufacturing non-woven fabrics for diapers and product packaging. For the manufacturing of flexible packaging Hayat Kimya preferred W&H technology. The world-class plant includes MIRAFLEX and VISTAFLEX flexographic printing machines and VAREX II blown film extrusion lines, some with MDO.
For the new production Hayat implemented a deep value creation chain. From manufacturing a diverse range of packaging formats to printing its designs on them, all areas of the company are kept under one roof to ensure the processes integrate seamlessly with one another. Its hygiene division was the first area in which Hayat took this end-to-end integration to such depths: It covers every stage from the raw materials for the diapers to manufacturing all of the packaging. Hayat Kimya NW&FA Global Production Director Aytekin Çelikkesen explains: “50% of the non-woven fabrics and packaging we produce is exported. The integration has enabled us to react faster and more flexibly to the different needs of our consumers around the world, thereby increasing the competitiveness of our brands. The production efficiency of the new sites has increased our independency. They are playing a key role in assuring our continued growth.”
When it comes to manufacturing breathable diapers, Hayat chose Windmöller & Hölscher technology for both its flexographic printing machines and its blown film lines. The new plant is home to a world-class technology, machine-to-machine integration systems, which is the first and only example in Turkey. Hayat Kimya sets the benchmark in its sector with this forward looking investment: MIRAFLEX and VISTAFLEX lines, VAREX II - blown film extrusion lines, some with inline MDO. ‘’The W&H machines ensure efficient production and high-quality printing of the breathable diaper film. They are setting new benchmarks in terms of integration, quality and efficiency. All lines are perfectly integrated into the production process at Hayat – beginning at the granulate from the silos and in-house compound manufacturing systems to packed, ready for sale diapers in a range of sizes,” explains Carsten Varney, the W&H representative responsible for Hayat.
By using a blown film manufacturing process for its diaper films, Hayat is taking a step away from conventional cast film extrusion. This is because blown film systems offer clear cost benefits while maintaining or even improving levels of quality. “The neck-in effect you tend to get with cast film production of diaper film doesn’t occur with blown film. Blown film technology also enables the customer to downgauge by up to 25 percent, furthermore they can use more cost-effective materials”, explains Varney. He continues: “We are seeing a clear trend towards producing breathable diaper films with blown film systems. Hayat is a pioneer in this area as the world’s 5th largest branded diaper manufacturer. More projects in this area have followed around the world. We also see an increasing number of Turkish customers manufacturing diaper films on their own blown film machines and processing them further on-site”.
The successful first year has confirmed that Hayat has chosen the right path. Thus the successful partnership between Hayat and W&H is expanding beyond the Turkish market to other countries. Hayats objective as a market leader is to increase the presence in the key markets of the future and so improve flexibility and reduce transport costs. This approach is also helping to achieve considerable reductions in carbon footprint. “In the field of baby care products, GREENOVATION and environmental responsibility are an absolute must; our customers want to do all they can to protect the planet for their children,” concludes Varney.