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plastic technologies & art

BPLAS

FSS

Corporate

ABOUT US

"As an innovative company and a leader in our field, we see our role assatisfying international customer demands in a professional and ethical manner."

Celal GökçenChairman, Founder, Partner and Fifth Generation Industrialist

BPLas, which forms part of the Gökçen family business, was founded in 1987 with CelalGökçen as Managing Director.Its parent company can boast 150 years of experience in industrial production.

The main focus of BPlas is plastic injection moulding. The company has 103 injectionmachines at its disposal with a total clamping force of 40 – 5,000 tons.

Thanks to the state-of-the-art technology employed by BPlas along with its expertise in thefields of construction, development, thermoplastic moulding, tool manufacture and surfacedecoration, BPlas is Turkey`s largest supplier of automotive parts.

BPlas carries out every stage of production in-house, from construction through to thefinished product. As a Full Service Supplier (FSS) it is able to produce plastic componentsweighing anything from 2 grams to 64 kilograms.

The total injection and extrusion capacity of the company amounts to 65,000 tons / year.With six separate factories and a total workforce of 1.720, the company manufacturesparts for the automobile industry at home and abroad.

Alongside the automobile industry the company also supplies manufacturers of electricaldomestic appliances and the construction industry (ECOGROUP).

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BPLAS

FSS

Corporate

COMPANY HISTORYCOMPANY HISTORY

2014 BPlas Energy Institute, İTÜ ARI (Advanced Research and Innovation) Teknokent

2013 BPlas In-Mould Decoration (IMD) Plant2012 BPlas Electroplating and PVD Plating Plant2012 Plastic Production for Tilter™ – Electric car2011 BPlas Research and Development Center,

Bursa (HQ) 2006 BPlas factory in Adapazarı2006 BPlas Research and Development Center

Uludağ University, Bursa2005 BPlas factory in Bursa free zone2004 BPlas Tool Manufacturing Plant, Bursa (HQ)2001 BPlas Ford Otosan assembly plant, Gölcük1996 ECOGROUP (Construction, insulation and

padding material, pipes, roof insulation etc.)1994 BPlas & Plastic Omnium JV : BPO1987 BPlas Bursa (Company headquarters)1980 Buriş (Textile dyeing works and printer)1974 Bemsa (Plastic blow moulding, varnishing and

thermoform moulding)1952 Textile market and cold storage unit1929 Turkish – Japanese silk factory1858 Textile factory Osman Fevzi

A SUCCESS STORY ‘’MADE İN TURKEY”

2012 Plastic production for Tilter™ – Electric car2010 High performance heat insulation material

Ecofoam Plus™2009 PVD coating using sputtering process

(Automobile industry)2008 Producer of the largest XPS heat isulation

material to date2007 Production of the largest injection mould to date

in Turkey (Bumper for the Fiat 225)2005 Production of the flooring coating material,

Ecowood™2004 Production of the waterproof isulation material,

Ecodren™2003 Two-tone varnish for the bumper / IP for the Fiat

Palio/Albea models2002 IP Sequence delivery (V227)2001 Use of waterbased colour on IP2000 5-axle processing (6m): Milling, cutting and

production of models1999 Pre-varnishing flame treatment (Robots) 1998 Laboratory for plastics technology1994 Production of Woodstock composite material1993 Varnishing of bumpers with UV application1993 5,000 ton injection machine1992 Production of 3D door cladding1987 Production of plastic bumpers

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BPLAS Corporate

• 68.000 m² total area • Research and Development

Center• Injection moulding• Paint shop• Mould manufacturing• Blow moulding• Thermoform moulding

PRODUCTION PLANTS

• 35.500 m² total area

• Injection moulding

• Extrusion• Warehouse• Laboratory • Raw material

production

• Rapid prototyping• Laboratory and testing• Technical offices• Sales offices• Purchasing offices• Human resources• Data processing

• 4.600 m² total area

• Blow moulding

• Assembly • Laboratory

• 23.000 m² total area

• Injection moulding

• Paint shop• Laboratory

• 37.500 m² total area

• Electroplating• PVD• Extrusion• Laboratory

Gemlik Gölcük Adapazarı 5.Km BPO

BPlas carries out its production activities in its own manufacturing plants. Theseare in various different locations and have a total factory floor area of around168,600 square meters.

BURSA (HEADQUARTERS)

• 43.000 m² total area

• Injection moulding

• Paint shop• Blow

moulding• Laboratory

and testing

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FSS

Gemlik Gölcük Adapazarı 5.Km BPO

FULLSERVICESUPPLIER

BPLAS Corporate

CAPACITY

90 % toAutomotive Parts

• Instrument Panels• IP Components• Bumpers ( Rear & Front)• Bumper Components• Fuel Tanks• Fenders• Door Panels• Interior Roof Parts• Other Automotive Parts

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DOSAB-BURSA

SOSAB-ADAPAZARI

BUSEB -GEMLİK

5.KM

GÖLCÜK

BPO

134

765

149

68

594

10

TOTAL

172010 % toOther Productions

• Airway & Helicopter Parts• Packaging Goods

(Containers, boxes, etc.)• Construction Goods

(Isolation sheets, pipes,siding goods, etc.)

• Raw-material productionfrom re-graining of scraps

• white goods

BPLAS

Blue Collar : 941White Collar : 185TOTAL : 1126

BPO

Blue Collar : 485White Collar : 109TOTAL : 594

Turnover Total (m€)

2009 100

2010 110

2011 125

2012 110

2013 110 MARCH 2014

BPLAS

FSS

Technologies

Injection Moulding Chrome Plating Painting Blow Moulding Thermoforming Research Mould Manufacturing Extrusion

/IMD /PVD & Development

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BPLAS

FSS

Technologies

INJECTION MOULDING

The main activity of BPlas is plastic injection moulding. The equipmentused comprises 103 injection machines with a total clamping force of 40to 5,000 tons. The company also uses other techniques and processessuch as hybrid, gas injection, bi-injection and injection onto textiles andin-mould decoration (IMD technologies).

At BPlas, several automotive parts including torpedo, bumper, door panelare being produced, with customized surface properties such asvarnishing or coating.

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BPLAS

FSS

Technologies

IN-MOULD-DECORATION (IMD)With PVD and varnishing techniques, BPlas can create various coatingson a wide range of products in the form of:

DECORATIVE COATINGSDecorative PVD Coatings, metallic effects at different gloss levels andfunctionalities. Nearly all kind of plastics are suitable for PVD process.

DECORATIVE HARD COATINGSColored PVD layers on plastic and metal in different gloss levels.

FUNCTIONAL HARD COATINGSMulti-layer coating systems on components, tools and industrial knives tominimize abrasion etc.

Decorative coatings : Cr, Ni, Cu, AlTribological coatings : TiN, TiAlN, CrN, TiCrN

As it does not contain chromium (VI) and does not produce any toxicwaste, the PVD coating process is very environmentally friendly.

Assembly sequence Control Panel X98 ULC Careg

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BPLAS

FSS

Technologies

ELECTROPLATING / PVDBy using various alternatives such as metal derivatives, alloys and ceramics,BPlas can improve or refine the surface finish of any material at will.

Capability of our Electroplating Line

Substrates :ABS, PC-ABSPlating types :Cr+6 , Cr+3 trivalent, Pearl Bright, Cu, Ni

(Semi Bright, Bright, Microporous, Micro Crack)Line Dimension :3x45mMaximum Platable Area :2200mmx1000mmx350mm (LxDxW)Capasity of the Line :20 million dm² / yearSystem :Enthone / AtotechWaste Water Teatment :OVIVA Company

Capability of our Vakuum Plating Line

Substrates :Plastics (PP,ABS,PVC etc.) Glass, ceramics, metalsand the other materials that can be suitable for Vacuumenvironment.

Target :Cr, Cu, Al, Ni and 54 different types of metals can be plated withunlimited combination

Platible Part dimensions :900x450x300 mm (LxWxD)Capacity :20 million dm² / year

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BPLAS

FSS

Technologies

PAINTING

BPlas has amassed 30 years of experience in creating varnish finishes forplastics. This enables it to comply easily with the quality and testrequirements laid down by the manufacturers.

Both external parts (bumpers, door sill covers etc.) and internal parts (IP, IPcomponents, linings etc.) are produced in a variety of different finishes.

Water-based and solvent-based colours are both used.

All process steps are carried out by robots.The variety of its decorative coatings and soft-touch applications put BPlasone step ahead of the competition.

I. Paint Line II. Paint Line III. Paint Line IV. Paint Line V. Paint Line

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BPLAS

FSS

Technologies

BLOW MOULDING

With its 5 blow mouldingmachines, up to 1,000,000 fueltanks can be produced each year.

Tanks for Ford, Fiat and Renaultare manufactured in the factoriesat Bursa and Gölcük.

Ford Transit Connect Ford Transit Ford Transit Hyundai Starex Fiat New Doblo

55 lt 80 lt Low & High Floor 103 lt 65 lt 60 lt

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BPLAS

FSS

Technologies

Three machines and two milling machines are used for thethermoforming processes.

The total production capacity is 250,000 parts per year.

Components are produced for Fiat-Tofaş, TAI (Turkish AerospaceIndustries).

THERMOFORMING

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BPLAS

FSS

Technologies

RESEARCH AND DEVELOPMENTR&D studies are being carried out as part of the «Research & Development Center»which has been approved by Ministry of Science, Industry and Technology ofTurkey, by the end of 2011.BPlas attaches great importance to its activities in the field of Research &Development. Alongside its leading role in production the company has set itself thegoal of developing new processes and technologies and creating new products.

ModellingA 5-axle, high-speed milling machine with an operating volume of 34 cubic metres makes itpossible to build models out of a diverse range of materials – from polystyrene to aluminium.

Rapid PrototypingThe existing FDM machines are used for faster production of smaller industrial designs. Anypart, which has a 3D mathematical model, can be produced via this machines at short notice,using ABS or PC material.

Vacuum CastingFor the testing of desired mechanical & physical properties, usually one sample would not besufficient. In this case, a silicon mould is produced by using the prototype at first. Then byusing this mould and appropriate raw materials (in 90% accordance with mass productionmaterials), 15-20 parts can be produced rapidly without any problem. (Materials: PP/PPE,HDPE, PE, PS, RUBBER, PS/ABS, PA6, ABS, PMMA, PC, filled ABS)

3D Measurement and DigitalisationThanks to reverse-engineering equipment and the corresponding software, BPlas is able tobuild the digitalised model of any particular technical part on the computer and also tocalculate the measurements of both the parts and the moulds.

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BPLAS

FSS

Technologies

RESEARCH AND DEVELOPMENTProduct Development and Mould Design (CAD & CAM)Part and mould analysis are carried out with cutting edge hardwares and latest versions of thesoftwares.

PROGRAMMES:CATIA V5R20 (CCV, MD1, RM2, YM2, HD2, RE2, MTD2, DP2), Unigraphics NX7.5, IDEAS C3P CAD-CAM,Moldflow SINERGY, Tebis V3.5 R4, ALIAS DESIGN STUDIO (Industrial Design, Reverse Engineering), AUTOCADMECHANICAL & INVENTOR, CATALIST (For “Dimension” Prototyping Machine), INSIGHT (For “Titan”Prototyping Machine)

LaboratoryBesides the central laboratory which operates within R&D Center, individual laboratories are presentin five different production plants.Comprehensive test and measurements are carried out by recognised analysis methods (FTIR,DSC, TGA) for different research and development purposes.

Development of raw materialsRaw material improvement studies which answer the quality requirements of extrusion and injecitonprocesses are being carried out within BPlas facilities.These studies are mainly focused on recycling raw material formulations.The company has 4 certifi ed raw materials with brand of «Ecoplen»

(ECOPLEN PPC R 10T 05 B, ECOPLENPPCR 10T20B, ECOPLENPPCR 12T07B,ECOPLENPPCR 12T 20 B)

PVD thin film coatingsBy using various alternatives such as metal derivatives, alloys and ceramics, BPlas can improve orrefine the surface finish of any material at will.Research and development activities in the field of thin film coatings are being carried out ascooperative projects with universities and scientists.

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BPLAS

FSS

Technologies

The Mould Production Workshop is capable of producing moulds up to 50 tons in weightand 8000x1700x1250 mm in dimension. Our workshop has 9 high speed milling machines withdifferent capacities:

• 3+2 axis with loading capacity up to 8000x1700x1250 mm and 25 tons,• 5 axis simultaneous machines with loading capacity up to 4000x2500x1500 mm and 50 tons,• Deep drilling machine with a load capacity of 15 tons (1200 mm d x 40 mm Ø).

Following services are provided to the clients of BPlas:

Plastic PartsEngineering StudiesCo-Design StudyTechnical SupportTrack Scanning and ModelingReverse Engineering Studies

Fuel TankPart ModelingBlow Mold DesignBlow Mold ManufacturingCooling Mould Manufacturing

Design and Production of Fixtures.

MOULD MANUFACTURING

Plastic Injection MoldsMold designFlow analysisMold manufacturingMold changes

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BPLAS

FSS

Technologies

3D, 5 axis, high-speed cutting, drilling, boring and modeli ng

Size in millimeters: 6000x4800x1200

MOULD SAMPLES

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2150mm Extruder Head Fiat New Doblo Luggage Compartment Euro Pallet Ford Transit 103lt Fuel Tank Lower Grill for Honda Sun Visor for Ford Truck H566 Moulds for Renault X10 and X98

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BPLAS

FSS

Technologies

BUMPERS

DASHBOARDS

DOOR PANELS

PRODUCT SAMPLES

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FORD TRANSIT FORD RHD CONNECT FORD LHD CONNECT FIAT FIORINO

FIAT-LINEA RENAULT CLIO UPPER PART RENAULT CLIO LOWER PART HONDA CIVIC

RENAULT DOOR PANELS

FIAT- NEW DOBLO FRONT AND REAR BUMPER

225 MCV FIORINO FRONT BUMBER PANORAMA

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FORD

BPLAS

FSS

Technologies

INTERIOR PARTS

PRODUCT SAMPLES

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D200 LINEA CENTRAL AIR VENT - FIAT / TOFAŞ 223 DOBLO GLOVE BOX –FIAT / TOFAŞ D200 LINEA BREAK COVER BASE - FIAT / TOFAŞ

L35 PH1' CENTRAL CASQUETTEDECORATIVE TRIM – RENAULT 223 DOBLO MALIBU BEVERAGE HOLDER - FIAT / TOFAŞ TRANSIT BEVERAGE HOLDER - FORD

225 MCV FIORINO AIRBAG COVER - FIAT/TOFAŞ 223R DOBLO IP SPEAKER COVER - FIAT/TOFAŞ 223R DOBLO FUSE BOX DOOR – FIAT/TOFAŞ 225 PANORAMA HEATING - FIAT/TOFAŞ L35 CENTRAL 3 SWITCHES - RENAULT L35 CENTRAL 3 SWITCHES - RENAULT

223 DOBLO EMOTION & MALIBU CONSOLE SUPPORT - FIAT/TOFAŞ

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BPLAS

FSS

Technologies

PAINTED / PLATED PARTS

PRODUCT SAMPLES

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L65 PH4 TAILGATE HANDLE

- RENAULT

L35 MIRROR COVER - RENUALT K85 BANDEAU ECLAIREUR – RENAULT DOOR HANDLE - RENAULT

B460 GRILL FRAME – FIAT/TofaşL35 MIRROR COVER - RENAULT

X10 / X98 FRAME AND TRIM – RENAULT

K85 BANDEAU ECLAIREUR - RENAULT

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BPLAS Technologies

EXTRUSION

BPLAS is producing various products for construction industry suchas heat isolation panel, waste water pipes, water isolation cover.BPLAS has 24 production extruder and 5 raw material developmentextruder.

All the products are TSE and TSEK certified.

FSS

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BPLAS Quality

CERTIFICATES

FSS

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1991

A-LEVELSUPPLIER

RENAULT

ISO9002

QS 9000

EAQF 94

ISO16949

ISO 14001

LEAN MANAGEMENT SYSTEM

PI &OD

A-LEVELSUPPLIER

TOFAŞ OTOSANOTOYOL

OHSAS8001:2007

1996 1997 2000 2001

NATIONALMINISTRY OF

DEFENCE

PLANTSECURITY

20042002 20052008 20122010 2013 2014

References

FULLSERVICESUPPLIER

2015

All our production plants are ISO TS 16949, ISO 14001 and OHSAS 18001 certified.Three production plants have been awarded with ‘’Ford Q1 certificate’’

BPLAS

FSS

Quality

ENVIRONMENT

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The company strives to achieve an environmentally friendly approachand low energy consumption:

• Recycling of waste matter such as paper, plastic, glass, metal etc.,at collection centres.

• Disposal of all non-recyclable waste matter through collection atsource or through separation in line with current national guidelines.

• Waste water from the dyeing process enters a closed system andgoes to the company’s own water treatment plant.

• Regular measurement of exhaust gases in our factories, wherenatural gas is used as a fuel source.

• Energy consumption values are measured at every single point ofproduction in order to ensure efficient use of all natural resources.

• Training courses for all employees, so that they develop a greaterawareness of environmental issues.

BPLAS Partners

Design Companies•Edag•Bertrandt•Contechs•Progest•Step’n

Mold Producers•Schneider-Form•Zimmerman•Hoffman•Comau•Sanvito & Somaschini S.P.A.•Simoldes•Yamaguchi-Seiki

Machinery Producers•BMB •Engel•Italtech•Bielomatik•Branson•Cemaselettra•Sonotronic•FI•Phasa

Other Partners•Borealis•Visteon•Inergy•BPO (BPlas and Plastic Omnium JV)•Norm

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BPLAS Contact

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FSSFULLSERVICESUPPLIER

BPLAS BURSA

DOSAB Orkide Sk. No: 1516369 BURSA / TÜRKİYEPhone : +90 224 261 09 00Fax : +90 224 261 09 18URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPLAS BURSA ECOGROUP

Yeni Yalova Yolu 5.km No: 365BURSA / TÜRKİYEPhone : +90 224 211 42 73Fax : +90 224 211 42 70URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPLAS GEML İKHisar Mevkii Liman Yolu Serbest BölgeGemlik / BURSA / TÜRKİYEPhone : +90 224 524 76 10-11 Fax : +90 224 524 76 20 URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPLAS GÖLCÜK

Ford Otosan Yan SanayiiGölcük / KOCAELİ / TÜRKİYEPhone : +90 262 315 68 34Fax : +90 262 315 68 30URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPLAS ADAPAZARI

1. Organize San. Blg. 3. Yol No: 1Hanlı / ADAPAZARI / TÜRKİYEPhone : +90 264 276 98 65-89-90Fax : +90 224 276 98 68URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPLAS COATING TECHNOLOGIES

Yeni Yalova Yolu 5.km No: 365BURSA / TÜRKİYEPhone : +90 224 211 42 73Fax : +90 224 211 42 70URL : www.bplas.com.trE-Mail: bplas@bplas.com.tr

BPO A.Ş.

Yeni Yalova Yolu 8.km Okul Cad. No: 48Panayır / BURSA / TÜRKİYE+ 90 224 211 66 20 (6 lines)+ 90 224 211 66 27

BPLASBURSA PLASTIC, METAL, CONSTRUCTION, ENERGY, MINING,GEOTHERMAL AND TOURISM, AGRICULTURE INDUSTRY AND TRADE CORP.TEL : +90 224 261 09 00 FAX: +90 224 261 09 18 www.bplas.com.tr