KOUVIDIS Smart Factory

Welcome to the new “smart” factory of KOUVIDIS

Our recent rewards

FACTORY OF THE YEAR

GOLD

R&D AND PRODUCT INNOVATION

GOLD

BEST FACTORY TO WORK IN

GOLD

BEST IN PRODUCTIVITY & PERFORMANCE

Shaping a new work culture

SMART ECOSYSTEM

In 2023, we completed a multi-year investment plan for the construction of our new smart factory and the installation of state-of-the-art production lines. Following the path of the 4^th Industrial Revolution, we have transformed our new facilities into an intelligent ecosystem that continuously saves energy, ensures ideal working conditions, and constantly optimizes our environmental footprint.

By leveraging digital tools such as big data analytics, artificial intelligence (AI), and the Internet of Things (IoT), we continuously improve our efficiency and the quality of our products. We reduce operational costs, create a dynamic working environment, significantly enhance our customers’ experience, and continue our journey towards a carbon-neutral footprint.

Digitalization

REAL-TIME DATA ANALYSIS

Real-time data analysis is the key prerequisite for transforming our new facility into a truly “smart” and productive building. Our real-time monitoring is based on Schneider Electric’s open-architecture energy platform, EcoStruxure Power, which integrates IoT, cloud connectivity, mobility, sensing, analytics, and network security. This system enables us to collect and store all energy consumption data, allowing for improved cost management, energy savings and optimization (WAGES), enhanced protection, supervision and control, as well as efficient resource management.

Sustainability and autonomy aligned

SMART TECHNOLOGIES FOR A HEALTHIER BUILDING

For the management of all electromechanical installations, we have selected the Desigo CC application by SIEMENS. Through the Building Management System (BMS), we perform automatic control of more than 2,100 points related to production cooling, domestic hot water, air conditioning and office heating, as well as building ventilation — ensuring optimal energy efficiency. At the same time, we maintain full control over the rest of our equipment, including pumping systems, elevators, UPS units, generators, fire-fighting tanks, and the building’s fire detection system.

CONTROL AT THE TOUCH OF A BUTTON

We have implemented a dynamic energy management system based on the KNX platform, allowing us to monitor the building’s energy performance in real time. Elements such as lighting, cooling, heating, air conditioning, shading, security, and access control have been customized to our specific needs and are operated at the touch of a button through the elegant and user-friendly Comfort Click application. In this way, we have created a unique ecosystem of automation, management, monitoring, and data recording that ensures comfort and convenience in our daily operations.

The Shift Towards a “Green” Industry

ENERGY SHIELDING

Renewable Sources

We have replaced up to 100% (Net Zero) of the energy consumed by our production machinery with clean and sustainable energy from renewable sources. Specifically, we have installed a comprehensive net metering system on the roof of our building, featuring photovoltaic panels with a total capacity of 400 kW.

CO₂ Savings

The energy generated during periods of low power demand is fed back into the Greek electricity grid. In this way, we save approximately 550 tons of carbon dioxide (CO₂) and other gases per year, thereby contributing to the global effort to combat climate change.

Photovoltaic Energy Output

GREENHOUSE GASES
avoided through the use of renewable energy sources over a 10-month period

CO₂

Carbon Dioxide

870.041,30 kg

NO₂

Nitrogen Oxide

160,88 kg

SO₂

Sulfur Dioxide

57,58 kg

ENVIRONMENTAL BENEFITS
in 10 months

GREENHOUSE GASES EQUIVALENT TO 191,81 CARS PER YEAR

ENERGY EQUIVALENT TO 3.925,57 COMPUTERS PER YEAR

ENERGY FOR CONTINUOUS OPERATION OF 3.546.751,74 HOURS

FREE SOURCE OF ENERGY

Perhaps the most environmentally friendly way to heat or cool a building using the earth. By installing climate-neutral geothermal pumps, we fully utilize the geothermal potential from the underground or groundwater, achieving up to 25% energy savings compared to conventional heat pumps.
This approach ensures heating, cooling, and domestic hot water in the most economical and efficient way, while minimizing our environmental footprint.

ENERGY SAVINGS EVERYWHERE

We have installed variable speed drives (VSD) on all production machinery motors, allowing them to operate according to the amount of electrical energy required by their load. This approach ensures that only the necessary energy is used for motor operation, reducing energy consumption by up to 30% compared to traditional pumps.

Smart logistics

ULTRA-CONNECTIVITY

Instant delivery within 24 hours

By establishing new loading and unloading stations, we supply our distribution centers in Athens, Thessaloniki, and Cyprus on a daily basis, while remote locations are served through an authorized network of partner transport companies.
A large portion of our products is transferred immediately after production directly into trucks for fast and secure delivery to the distribution points. This approach significantly reduces storage space requirements and strengthens the company’s competitive advantage of guaranteed delivery within 24 hours. All transportation is carried out by our subsidiary, KLS KOUVIDIS LOGISTICS, using a dedicated fleet of 60+ vehicles.

GREEN TRANSPORTATION

Free Charging Stations for Electric Vehicles

With the smart energy planning we implemented, we went beyond just meeting the building’s electricity needs and addressed electric vehicle charging as well. As part of our commitment to raising awareness about the green transition, we have equipped our new facility with six parking spaces featuring free charging stations for electric cars and bicycles.

Comprehensive Quality Control

ARTIFICIAL INTELLIGENCE AS AN “ASSISTANT”

Using state-of-the-art laboratory equipment, we conduct multiple tests with precision, fully aligned with international and European standards. Tests are performed either through live inspection by AI-powered cameras installed on each production line, or in our quality control laboratory, which carries out scheduled checks covering 20 different technical fields. This approach minimizes potential product failures, ensures full compliance with European legislation, and drastically reduces scrap generated during production. Our goal is the reliable and scientific operation of our laboratory, which is in the process of accreditation by ESYD (Hellenic Accreditation System) according to ELOT EN ISO/IEC 17025.

Corporate Culture

THE IMPORTANCE OF WELLBEING

The company’s sustainability must be closely linked to corporate wellbeing. To achieve this, we have created functional, comfortable, airy, and bright spaces with clean lines that promote both concentration and collaboration. The facility includes lounges, meeting rooms, locker rooms, a gym, and dining areas, all designed to ensure a pleasant and productive working environment. All cooling, heating, ventilation, lighting, and shading functions are fully automated and controlled via a smart KNX platform at the touch of a button.

Accessibility

The concept of contactless is one of the key pillars in the architectural design of our new bioclimatic factory. Contactless technology has been implemented throughout the building to allow employees to move safely and easily. This has been achieved through the use of personal RFID cards, touchless entry sensors, motion detectors, and lighting controls, which also contribute to energy savings.

Τeam building

Employee health translates into increased energy and creativity. Taking into account the importance of occupational health and team building, dedicated dining and exercise areas have been designed for shared use by all employees throughout their time at work. Our state-of-the-art gym provides exercise opportunities for everyone.

Catering

Our kitchen is fully equipped, meets the highest hygiene standards, and is HACCP certified. This allows us to provide over 120 high-quality, nutritionally balanced meals daily, ensuring the proper nourishment of all our employees.

Flexibility

Great ideas rarely come while sitting on a computer. A conversation with colleagues during meals or exercise can often be far more productive.

Production

Continuous Investment

The transition to our new smart factory has accelerated our strategy of continuous modernization of our mechanical equipment. Through significant, ongoing multi-million investments, we continuously upgrade our production lines, develop new manufacturing methods, and adopt cutting-edge plastic technologies that contribute to the production of innovative multilayer pipe systems. In this way, we actively participate in the growth and strengthening of Greek industry.

Production Speeds of Up to 70 Meters per Minute

Selecting the right mechanical equipment is a key criterion for achieving high quality. For this reason, we choose top-tier machinery, ensuring precise forming, consistent performance, superior production quality, and high speeds of up to 70 meters per minute. Combined with the advanced plastic processing expertise of our team and quality control using artificial intelligence, we maintain complete oversight of the production quality of our pipes.

Integration of Robotic Technology

Full automation of our production lines requires continuous investment in robotic technology. This ensures high production speeds, flexibility in handling multiple products, full compliance with European legislation, precision in the manufacturing process, and improved working conditions for our employees. So far, we have applied this technology in palletizing, packaging, and storage of our products, and we plan to integrate it into other stages of the production process soon, such as feeding and assembly.

Smart packing

One of the goals of our sustainability strategy is to reduce the waste generated by our packaging. To achieve this, we have internally developed a new packaging method that uses up to 75% less plastic, completely replacing all of our packaging machinery. Beyond its environmental benefits, the new packaging design saves up to 45% more storage space, providing multiple advantages in both transportation and warehousing.

Think smart, act smart

KOUVIDIS “SMART” PIPES

In our new smart factory, we have the capability to produce even “smarter” plastic pipes, offering multiple benefits for both installers and the environment. The shift towards multilayer pipes began in 2012 and continues with undiminished intensity, introducing more than 10 new multilayer pipe series that have fundamentally transformed modern electrical and plumbing installations. These multilayer pipes are fully compatible with modern plastic technologies, ensure greater mechanical strength, facilitate installation through their multiple advantages, and provide a better environmental footprint.

Welcome to the new “smart” factory of KOUVIDIS

Renewable Sources

CO₂ Savings