Kolios is one of Greece’s most established dairy producers, known for its commitment to authentic production methods and high-quality ingredients. With decades of experience in crafting traditional Greek yogurt, feta, and specialty cheeses, the company has grown from a regional producer into an international brand with a strong presence across Europe, North America, and other global markets.

Operating in the highly competitive dairy sector, Kolios must maintain strict quality standards while responding to fluctuating demand and increasing export volumes. Central to this is a robust cold chain, where precise temperature control and efficient product handling are critical to preserving freshness, ensuring compliance, and protecting brand reputation.

As global demand for Greek yogurt surged, Kolios reached a tipping point where its existing storage infrastructure could no longer support operational requirements, prompting the need for a scalable, future-ready solution.

Kolios faced a combination of operational and physical constraints that made traditional expansion unviable:

1. Rapid Demand Growth
   Increasing international demand placed sustained pressure on storage capacity and throughput. The existing system struggled to keep pace with production output, leading to inefficiencies and potential bottlenecks.
2. Chilled Environment Requirements
   All products needed to be stored in controlled, low-temperature conditions. Any fluctuation in temperature risked compromising product quality, shelf life, and regulatory compliance. This made efficiency not just a cost concern, but a quality imperative.
3. Landlocked Facility
   The warehouse footprint could not be expanded due to surrounding infrastructure. This eliminated the possibility of conventional warehouse extensions, forcing Kolios to rethink how to maximize capacity within the same space.
4. Energy Efficiency Pressures
   Maintaining chilled environments is energy-intensive. Frequent door openings and inefficient handling processes were contributing to unnecessary energy loss, increasing operational costs.

Kolios needed a solution that could simultaneously increase capacity, maintain strict temperature control, and improve operational efficiency, all within a fixed footprint.

The implementation of the Moffett Automation AS/RS system delivered significant, measurable improvements across all key performance areas:3x Increase in Storage Capacity
Kolios tripled its storage capacity within the same physical space, eliminating the need for expansion while future-proofing operations.

High Throughput Performance
The system achieves a throughput of up to 100 pallets per hour, ensuring that storage and retrieval processes keep pace with production and distribution demands.

Enhanced Energy Efficiency
The airlock system dramatically reduces cold air loss, lowering energy consumption and contributing to more sustainable operations.

Improved Operational Flow
Automation eliminates manual handling bottlenecks, reduces errors, and ensures consistent, reliable performance across all shifts.

Optimized Space Utilization
By leveraging high-density storage and vertical design, Kolios maximizes every available square metre of its facility.

With the implementation of Moffett Automation’s AS/RS solution, Kolios has successfully transformed its chilled storage operation into a high-performance, future-ready logistics hub.

The company can now:

• Scale operations in line with growing global demand
• Maintain strict temperature control and product quality
• Operate more efficiently with reduced energy costs
• Achieve high throughput without increasing labour dependency

This project demonstrates how advanced automation can unlock significant gains in capacity, efficiency, and sustainability, even in highly constrained environments.

For food and beverage manufacturers operating in temperature-sensitive supply chains, the Kolios project stands as a clear example of how innovation in intralogistics can deliver both immediate impact and long-term strategic value.