- Category Group:
- Company/Organization Categories
- Category:
- Award for Excellence in Innovation in Manufacturing Industries - Organizations with 100 or More Employees
- Organization Name:
- pladis, Istanbul, Uskudar
- Organization Description:
pladis places its employees at the forefront of all the practices it develops and attaches great importance to both white-collar and blue-collar training in its factories. In addition to legally required training in all factories at specific intervals, we also offer orientation, technical, product, and competency training to improve employees' skills.
In a world where the future of manufacturing is defined by agility, intelligence, and automation, digitalization has become not just a competitive advantage, but a necessity. According to McKinsey, companies that adopt Industry 4.0 technologies see productivity gains of up to 30%, while in Turkey, only 24% of manufacturers are considered digitally mature. As part of its commitment to reimagining production in the digital age, pladis Türkiye launched "Digitalization - The Future of Manufacturing" strategy rooting to 2021. This initiative marks a bold step in smart manufacturing, integrating IoT, CIMS, AGV, MES, SCADA, and predictive analytics across biscuit, chocolate, and cake production lines with a goal of creating fully traceable, automated, and sustainable production ecosystems.
Smart Factory Infrastructure transformed operational management. pladis deployed SCADA, MES, IoT, and Data Collector systems across all factories. Environmental sensors now provide real-time data on temperature, humidity, and air quality, while digital tablets deliver on-the-spot specification access, eliminating paperwork and enabling instant quality validations. Operational Excellence through Automation & AI was achieved through inline weight control, Brix and moisture sensors, color/size detectors, optical readers, and AI-driven cameras that monitor defects, topping accuracy, labeling, and expiry dates. Predictive maintenance minimized downtime and helped ensure consistent product quality. Sustainability & Resource Optimization reinforced management impact.
Digital energy and steam monitoring systems ensured real-time efficiency. Automatic alerts and process automation helped detect anomalies early, preventing energy waste. IoT-connected X-ray and metal detectors secured food safety while generating actionable logs supporting compliance and sustainability audits. Human-Centric Digital Culture ensured that employees used digital dashboards for transparency and rapid response, making technology an enabler of engagement rather than a replacement. What sets this journey apart is the comprehensive, interconnected transformation of Ülker's entire production ecosystem. QR-coded material tracking, inline quality sensors, IoT-based alerts, AI-powered inspection, and SCADA-integrated batch management operate within a unified digital backbone enabling real-time control, predictive analytics, and proactive decision-making. Instead of upgrading isolated lines, Ülker built a cohesive data infrastructure where insights generated at one stage automatically inform others. This dynamic flow allows continuous optimization in quality, safety, energy, maintenance, and logistics. The success of the transformation is evidenced by measurable outcomes. AGVs and MES systems eliminated 72,000 manual labor hours annually. Overall Equipment Effectiveness improved by 15%. The program delivered £18 million in cost savings. Quality improvements included 100% inline monitoring with AI-driven control systems. Workplace safety and compliance were enhanced via VisitPro and IoT tracking, while the Digital Training Center empowered employees with VR and gamified learning. These achievements illustrate a scalable model for modern manufacturing transformation driven by technology, management excellence, and product innovation.
Entry Sources & Additional Supporting Information
The "Digitalization - The Future of Manufacturing" strategy marks a major shift toward connected, automated, and intelligence-driven production. pladis Türkiye deployed SCADA, MES, IoT, and Data Collector systems across biscuit, chocolate, and cake factories, enabling real-time visibility on temperature, humidity, air quality, and material movements. Digital tablets removed paperwork and allowed instant access to specifications and quality validations. Inline weight control, Brix and moisture sensors, color/size detectors, optical readers, and AI-driven cameras provided continuous monitoring of defects, topping accuracy, labeling, and expiry dates. Predictive maintenance reduced downtime and improved product consistency. Sustainability gains were achieved through digital energy and steam monitoring systems that flagged anomalies early and prevented waste.
IoT-connected X-ray and metal detectors increased food safety and generated traceable data for compliance. A human-centric culture supported the transformation as employees used digital dashboards and the Digital Training Center strengthened learning through VR and gamification. System-wide interoperability ensured that QR-coded tracking, IoT alerts, AI inspection, and SCADA-integrated batch management operated as one digital ecosystem. Operational and financial results validated the model: 72,000 manual labor hours were eliminated, OEE improved by 15%, and £18 million in savings were generated. These outcomes demonstrate a scalable and future-ready manufacturing transformation.