The Stergiou Family’s new facility in Avlona, Attica, is far more than a typical industrial site. It represents a dynamic fusion of advanced Industry 4.0 technologies with a strong focus on sustainability and exceptional quality standards.

Frigo Stahl played a crucial role throughout the project, from initial planning to execution and commissioning, ensuring timely delivery, adherence to budget, and alignment with all technical specifications.

Seamless Transition from Concept to Reality

1. Collaborative Design Process:
   In close collaboration with the client, Frigo Stahl developed the optimal layout for production lines within the existing building, emphasizing ergonomics, streamlined maintenance, and future scalability. The project also included extensions for a deep-freeze robotic warehouse, flour silos, a robotic pallet control system (woodpecker), and auxiliary facilities. The design ensured integration between existing and new structures, allowing for coordinated future expansions.

2. Construction and Infrastructure Development:
Frigo Stahl oversaw all aspects of construction and upgrades, from renovating existing facilities to building new ones and enhancing site infrastructure. The company also delivered all supporting systems for the production lines, including electrical installations, steam-water-air networks, and IT infrastructure, ensuring seamless connectivity with production equipment.

3. State-of-the-Art Refrigeration Systems:
The project included a unified four-stage refrigeration system designed and implemented by Frigo Stahl. Featuring environmentally friendly refrigerants and innovative airflow distribution, the system ensures consistent cooling and low-noise operation.

Cutting-Edge Innovations

1. Deep-Freeze Robotic Warehouse (-22°C): One of the most notable aspects of the factory is its pioneering robotic warehouse. Frigo Stahl customized the structural elements to support an advanced robotic handling system, delivering fully automated storage and logistics operations. This system guarantees an uninterrupted cold chain from production to delivery, preserving product quality for food service professionals.
2. Energy Efficiency and Sustainability:
   The facility incorporates advanced energy management systems and energy-saving technologies. With 35% of its energy sourced from renewables, the factory minimizes its carbon footprint while significantly lowering operating costs.

Leading the Way in Production Excellence

1. Exceptional Production Capacity: Capable of producing 96 tons of dough and 40,000 liters of sourdough daily, the factory sets new benchmarks in its sector. The production lines ensure maximum efficiency, with sourdough undergoing a fermentation process exceeding 24 hours—a rare practice in Greece that enhances flavor and texture. All systems are managed by fully automated, computer-controlled networks.
2. Harnessing Technology for Optimization:
   Incorporating advanced technology into every aspect of the factory posed a significant challenge.
   Frigo Stahl leveraged Industry 4.0 principles to:
   • Ensure smooth communication between systems and machinery.
   • Enable real-time data analysis for process improvements.
   • Automate key processes to boost efficiency and minimize errors.

Remarkable Efficiency

The project’s timeline—from the start of construction to the factory’s operational launch—was completed in under 12 months. This impressive achievement for such a complex project underscores the efficiency of Frigo Stahl’s “turnkey” approach.