Case Study: FAGE USA achieves 40% storage capacity increase with Westfalia Tech. Inc.'s High-Density AS/RS and Savanna.NET WMS

FAGE USA Dairy expands into the US, its 28th country

FAGE (FAGE USA Dairy) expanded into the U.S. with a new Johnstown, NY plant and faced the challenge of designing for growth in a 33‑foot‑high, 40°F warehouse that needed to handle buffer product from manufacturing, full‑pallet movement, case picking, variable pallet sizes/heights, and ongoing SKU growth. To meet these requirements FAGE selected Westfalia Tech. Inc. to provide a High Density Automated Storage & Retrieval System (AS/RS) and the Savanna.NET® Warehouse Management System (WMS).

Westfalia Tech. Inc. installed a modular high‑density AS/RS with a Satellite® entry vehicle, conveyors, gravity flow pick lanes, barcode scanning, stretch wrapping and Savanna.NET® WMS to control pallet flow and picking. The system scaled from an initial 1,600 pallet design to over 4,100 pallet positions (including a 509‑location deep‑lane extension), delivered roughly a 40% increase in storage capacity, reduced energy costs by about 30%, improved picking efficiency and traceability, and avoided a larger building expansion by enabling deeper rack storage.

FAGE