GEBZE PRODUCTION PLANT

Bilim Gebze, which entered operation in 2008, is Turkey’s largest drug manufacturing plant according to production forms. The plant was developed in accordance with standards of the American FDA (Food and Drug Administration), one of the world’s most prestigious healthcare authorities.

Established on an area of 60,000 m2 at the Gebze Organized Industrial Zone, the plant has an indoor area of 51,500 m2. With a manufacturing capacity of 250 million boxes per year, Bilim Gebze was planned to cover any needs for capacity increase. The plant is able to meet 17% of the Turkish Pharmaceutical industry’s need on its own.

The Bilim Gebze Production Plant holds ISO 9001 Quality Management Systems, ISO 14001 Environmental Management Systems and OHSAS 18001 Occupational Health and Safety Management Systems certificates.

Products Manufactured at the Bilim Pharmaceuticals Gebze Production Plant and Their Volumes

Gastrointestinal products, Analgesics-Anti-inflammatory products, Dermatological products, Antibiotics (non Beta-Lactam), Vitamins (Minerals), Respiratory System products, Antiparasitic products, Sweeteners, Central Nervous System products, Cardiovascular products, Iron preparations, Muscle relaxants and Antiflue products.

Pharmaceutical Form    Annual Capacity * *
Tablet   72 million boxes (1.5 billion tablets)
Capsule   18 million boxes (0.5 billion capsules)
Syrup   18 million bottles
Sachet   5 million boxes
Dry Powder Suspension   7 million boxes
Cream/Pomade   5 million boxes
  

Environmentally Friendly Approaches and Practices

Bilim Pharmaceuticals' environmentally friendly approaches and practices are based on the protection of natural resources, both today and in the future. The Bilim Gebze Production Plant is equipped with environmentally friendly infrastructural systems which comply with EU regulations in order to ensure protection of natural resources. The Bilim Gebze Production Plant is the most environmentally friendly drug manufacturing plant, observing the following environmentally friendly practices:

    
  • Automatically controlled functions which reduce energy consumption have been established within the building automation system;
  • Process wastewater is treated with the state-of-the-art Biomembrane system, and in compliance with the wastewater control regulation;
  • No pollutants are allowed in the air exhausted by means of highly impermeable HEPA filters used in the ventilation exhaust systems;
  • In powdered production processes, air sucked from each room is passed through dust separators with an automatically controlled shaking system;
  • Solid waste is collected in accordance with the solid waste management procedure, and then taken by delivery companies approved by the Ministry of Environment and finally treated in authorized incineration plants, with no adverse impact on the environment;
  • Heat loss is prevented through an insulation system that minimizes heat transfer; and
  • Enclosed type towers, using the latest technology, were chosen as the cooling towers. They are more expensive than open towers but enable an 85% reduction in water consumption for cooling when compared to open towers.

 Modern Automation Levels

Planned in accordance with FDA regulations, besides being equipped with the latest technology in safety areas and energy saving, the Bilim Gebze Production Plant performs high quality production that is able to compete in international markets, thanks to the level of automation provided through computer systems in the production process, and fully equipped building automation with smart building features. Systems, which allow the Bilim Gebze Production Plant to be defined as a smart factory, are as follows:

  • Controlling all areas 24 hours a day and 365 days a year through the Building Management System (BMS)
  • Employee recognition and safety through the card pass system used for all areas
  • Automatic fire detection, alarm and extinguishing system
  • Automatic data collection and reporting from the production field through the Manufacturing Execution System (MES)
  • Lighting automation
  • Full-automatic unmanned warehouse management system (WMS)
  • Chromatographic Data System / Scientific Data Management System (CDS/SDMS)
    

Full-Automatic Unmanned Warehouse Management System (WMS)

     

Our fully automatic unmanned warehouse is 38 meters high and has a capacity of 11,400 pallets. It is the highest warehouse in Turkey to operate with this technology. All pallets are managed with robots, cranes and conveyors. Thanks to this system,

  • An increase was realized in the efficiency and speed of warehousing and transportation activities;
  • The risk of loss of goods was prevented;
  • Occupational accidents, which are frequently encountered in conventional warehouses, were eliminated.

 

“Occupational Health and Safety” and “Social Facilities”

The Bilim Gebze Production Plant was designed from a “human-friendly” point of view so as to enhance our employees’ living standards. Thus, the Bilim Gebze Production Plant offers the following to its employees within the framework of “Occupational Health and Safety” and “Social Facilities”:

  • OHSAS 18001 Occupational Health and Safety Management Systems and respective practices,
  • A building security system operated with CCTV,
  • Workplace practitioner, resting room, psychological consultancy services,
  • A cafeteria, resting rooms, library and internet rooms for employees,
  • A gymnasium,
  • Outer environment walking areas