Castrol, one of the world's leading mineral oil brands, accelerated its filling line by 5,5 times with an investment of 2,2 million dollars in its Gemlik production facility. In this filling line, for the first time in Europe, packages that are 20 times more durable will be used, although the amount of plastic is 2 percent less.
Castrol, one of the world's leading mineral oil brands, with its sustainability strategy; It focuses on 3 goals: reducing carbon footprint, reducing operational waste and making people's lives better. In order to achieve these goals, it invests in many projects in Turkey and around the world.
Castrol designed the most efficient packaging it has ever used, as a result of 2 years of research and development studies carried out in line with these goals and the examination of global logistics criteria. In the first stage, 1, 3 and 4 liter plastic product packages are being replaced. As part of the project, a $24 million fast filling line investment was made at the Gemlik facility, which is one of Castrol's eight production facilities in Europe and where the products produced are exported to 5,5 countries. As a result of this investment, the Gemlik production facility became the first factory in Europe to use new packaging. With the new line established, the amount of plastic waste generated during production is reduced and a smooth transition between different product weights is ensured. By filling more packages in a shorter time zamtime saving and energy efficiency are provided.
While packaging uses approximately 300 tons of less plastic, carbon emissions will also decrease.
Castrol Turkey, Ukraine and Central Asia (TUCA) Director Ayhan Köksal, stating that they have established a new filling line at the Gemlik facility with this project, states that the new fast filling line is 2,2 times faster than the previous one and is suitable for filling packages of different sizes. Stating that the first robotic palletizer of the facility is also located on this line, Köksal said, “Our new packaging is also produced on this line. Therefore, these two projects are co-located in Gemlik. zamWe implemented it instantly. This line will also help us to increase our production capacity in the coming period” and underlines that their goal is to produce over 120 million liters of mineral oil.
Although 20 percent less plastic is used in their production, the packages, which are 2 times stronger, also allow 50 percent more efficient shelf use thanks to its new design. Castrol TUCA Director Ayhan Köksal, who said that they reduce the amount of waste generated during production and reduce carbon emissions, as well as providing logistics advantages by reducing the plastic used, said, “The amount of plastic used in the production of new packaging is approximately 300 tons and carbon emission is approximately 12 tons less. We've also improved durability, thanks to a new design and smoother edges of the sharp corners from previous packaging. Again, thanks to this new design, we can fit much more products in a pallet. As a result, we will use approximately 2023 thousand less pallets in 7. This means that 300 less trees will be used in pallet production. As a result of this investment we made in the Gemlik facility, we both reduced the plastic waste used during production and created less environmental impact by reducing our carbon footprint.”
Regular investments are made in the Gemlik facility every year.
85% of the products produced in the Gemlik production facility are offered to the domestic market and 15% to the foreign market. In the Gemlik production facility, which realizes approximately 700 percent of the 14 million liters production volume of the Europe and Africa region, which includes Turkey, a tank investment of more than 2023 million dollars will be made in 1 and a warehouse investment of 2024 million dollars will be made in 5,5.