ESENYURT
PRODUCTION COMPLEX

Spreading across an 173,700 m2 site in the Esenyurt district of Istanbul, the Esenyurt Production Complex became operational in 2000 with a state-of-the-art infrastructure. The Esenyurt Production Complex, which stands out with its design, bears the signature of architect Dante Benini, who is renowned for his designs of industrial buildings and pharmaceutical production facilities.

Setting a global benchmark with an annual production capacity of 700 million units, the production facilities, which fulfill GMP and GLP requirements, utilize modern and eco-friendly technologies. The processes in all production facilities within the complex are continuously improved through new investments in technology, as well as automation systems enhancing traceability and productivity.

The production facilities are inspected and accredited by Europe’s and the world’s leading pharmaceutical producers and authorities and are equipped with the most advanced, high-speed production and packaging machinery. In addition to its own products, Abdi İbrahim also produces for many other national and international companies in its own facilities.

Abdi İbrahim’s production facilities, certified by European Healthcare Authorities, boasts ISO 9001 certification for quality management systems, OHSAS 18001 certification for occupational health and safety, and ISO 14001 certification for environmental awareness and environmentally friendly technologies.

Electronic Systems Used in Production Facilities

All processes in our Esenyurt Production Complex are monitored with the following electronic control systems:

SAP

All procurement, production and logistics operations are managed through SAP software.

BYS (Building Management System)

All HVAC and support systems are managed with the Building Management System (BYS).

BIS

Critical quality parameters in production areas such as temperature, humidity and pressure difference are monitored and recorded.

Calibration Management

Tracking, management and documenting of calibration procedures are performed with the Calibration Management system. 

KEDI (Quality Document Inventory)

KEDI (Quality Document Inventory) indexes and reports quality training.

2D QR Code System

All products launched bear a 2D QR Code System, allowing tracking of each individual product from the warehouse to the pharmacy, and to the user.

Warehouse Management System

Warehouse Management System enables continuous stock and location tracking of all items stored in the automated warehouse, and automatic transfer of necessary material to the desired destination (e.g., production, quality control, shipping). 

The PAS-WD (Computer Assisted Weighting System)

The PAS-WD (Computer Assisted Weighting System) integrates with SAP software to enable accurate weighing of raw material used in production.

The Qmex Quality Management System

The Qmex Quality Management System manages change, deviation, supplier evaluation, supplier audit, customer complaint, internal-external audit, pharmacovigilance and new product declarations.

The Equipment Efficiency Measurement

The Equipment Efficiency Measurement (PROMANAGE) enables real-time monitoring and retrospective reporting of operating performance of all production lines.

CSG PRO (The Environment, Health & Safety Information System)

The Environment, Health & Safety Information System (CSG PRO) tracks and records Environmental and Occupational Health & Safety processes in software.

IRONIC (Workplace Physician Information System)

Workplace Physician Information System (IRONIC) enables tracking of employee health checks through a software.

EMPOWER 3 ( The Analytical Device Management System )

The Analytical Device Management System (EMPOWER 3) offers analytical and workflow-related improvements to boost laboratory efficiency.

NARSOFT (Personnel Attendance Control System )

Personnel Attendance Control System (NARSOFT) is a software for tracking and reporting personnel attendance, visitors and warehouse vehicles within the production facility.

The Pharmaceutical Track and Trace System

The Pharmaceutical Track and Trace System (VPP) is a software that enables the printing, tracking of the data matrix on the drugs and their declaration to government agencies. 

Chemical Production Facility

Boasting a total indoor area of 33,300m2 and a production capacity of 700 million units, our Chemical Production Facility consists of solid, liquid, semi-solid, hormone, special production (High Potent), DPI, Effervescent and Sterile Ophthalmology and Sterile Inhalation production areas and Quality Control Laboratories.

Quality Control Department

With an area of 1,830 m2, the Quality Control Laboratory provides services for pre-production inspection of raw materials and packaging materials, as well as during production inspection with state-of-the-art tools in accordance with up-to-date specifications and test methods.

Our Quality Control Department has 387 analytical instruments capable of qualitative and quantitative analysis:

  • 58 HPLCs
  • 13 UPLCs
  • 13 HCLASS HPLCs
  • 18 Dissolution tests
  • 11 GCs
Good Laboratory Practices (GLP)

These laboratories, fulfill all the requirements of Good Manufacturing Practices (GMP) and Good Laboratory Practices (GLP), and the tests are performed with high-tech equipment that comply with the requirements of international and local authorities. The data produced by all analytical instruments is stored and recovered in a secure manner.

Job descriptions for the Quality Control Department
fall under the following eight headings:
Quality Control Compliance

Quality Control Compliance is responsible for the preparation and revision of all the documents used in the Quality Control Laboratory through the "Qmex Quality Management" system, and the control of analysis results, and the management of semi-finished products, raw materials and packaging material approvals through SAP.

Microbiological Control Laboratory

In the Microbiological Control Laboratory, microbial limit tests and pathogen detection tests, endotoxin and sterility tests of pure water, water for injection, pure steam, all primary packaging materials, raw materials and auxiliary materials used in production processes are performed and reported by using methods aligned with European and US pharmacopoeias. Similarly, areas, surfaces, equipment and personnel are controlled, and related processes are reported in accordance with European and US pharmacopoeias.

Analytical Method Validation and Transfer Laboratory

Ensures that the chemical control methods of semi-finished products, finished products, active and auxiliary substances are validated and documented in accordance with approved protocols and instructions aligned with cGLP and cGMP regulations as well as the regulations of the Republic of Türkiye Ministry of Health. In addition, it carries out quality control operations (such as analytical method transfer, process validation analysis, stability analysis) during the transfer of technology transfer products of our customers to whom we provide production services or proprietary products of Abdi İbrahim and our licensors to our company. It acts as a bridge connecting the quality control departments, provides the necessary analytical support – from the initial project phase to its submission to the authorities – and is responsible for preparing the relevant documents.

Raw Material Control and Packaging Laboratory

Regularly and accurately carries out the necessary reporting and analysis processes of the raw materials to be used in production in line with approved methods and specifications to check their compliance with the required level of quality and specifications. These activities are performed in accordance with GMP, ISO 27001 and ISO 13485 standards.

Product Analysis Laboratory

Performs the reporting and analysis processes of semi-finished products, finished products, active and auxiliary substances delivered to the laboratory in accordance with approved methods and specifications and in alignment with the regulations of the Republic of Türkiye Ministry of Health, in a timely and accurate manner. These activities are performed in accordance with GMP, ISO 27001 and ISO 13485 standards.

Support Analysis Laboratory

Carries out the long-term, bulk, transport, in use, photostability (light) and tracking stability analyses of all products produced by Abdi İbrahim, in compliance with the cGLP and cGMP regulations and in alignment with the regulations of the Republic of Türkiye Ministry of Health; and performs and reports process validation, R&D transfer, customer complaints and production trial analyses. 

In-Process Control and Sampling Laboratory

Performs the sampling and physical control processes of semi-finished products, finished products, active and auxiliary substances in accordance with approved protocols and instructions aligned with cGLP and cGMP regulations as well as the regulations of the Republic of Türkiye Ministry of Health.  It performs product and packaging material label, document, print, machine and area cleaning checks and keeps a record of said checks before production (including pilot production) launch. If the results are sufficient to start production, it grants the approval to do so. During the production process, it performs the in-process controls of the products and records them according to procedure. It reports all the cases that are detected to be non-compliant with respect to any of the Culp written-approved procedures-instructions-controls and test specifications at any stage of the production process and ensures that appropriate actions are taken.

Stability Operations

Performs the long-term, bulk, transport, in use, photostability (light) and tracking stability analyses of all products produced by Abdi İbrahim, in compliance with the cGMP regulations and in alignment with the regulations of the Republic of Türkiye Ministry of Health. These activities are performed based on the ICH, EMA, WHO, FDA guidelines that are recognized by international authorities.

Solid Production
Liquid and Semi-Solid Production

SPECIAL PRODUCTS PRODUCTION

Boasts an annual production capacity of 800,000 units and 650,000 bottles. This department produces and packages special products in tablet from in a separate production area and in compliance with regulations.