Korres: An Exciting Visit To A Greek Natural Cosmetics Factory

📷 Photo: Paris Tavitian/LIFO.

In a fascinating visit to a Greek natural cosmetics factory LIFO toured all stages of product development, from lab to production and packaging.

The first thing you notice as you arrive at Korres headquarters in Oinofyta, 60 kilometers north of Athens, are the earthy colors used externally to refer to the pharmacy lab, the industrial aesthetics of the metal, and of course the signature font that is instantly recognisable for all of the brand's products - it dominates everywhere, from exterior signs to corridors.

At the same time, the interior layout and decoration and the simple vertical lines in the public areas, the exposed details, and even the floor are reminiscent of a photo studio.

This charming masterpiece is the flagship of Korres, where we begin and complete the production of our favorite products and distribute them throughout Greece and abroad, in 30 countries in total. Here is one of the biggest success stories of the last 20 years in Greek entrepreneurship.

We are talking about all the stages of creating more than 400 codes currently in the catalogs of the brand: scientific research and development in laboratories, extracts of herbs coming here from the Greek growers with whom the company collaborates, collection and strict quality controls of raw materials, infinite samples and tests on formulas that last from months to years, preparation and packaging.

During our visit to the Korres factory we had the unique opportunity to be guided by specialists in all departments, following all stages of production of the "Greek Yogurt" series, from research and development to laboratory, to industrial production and the packaging.

LiFO's invitation from Korres came on the occasion of the launch of the new series "Greek Yogurt", which uses one of the most beloved Greek products as a raw material, which is introduced daily in every home.

The practice of using yogurt to pull the burn out of the summer sun is old and widespread, a tradition of ours that inspired Korres several years before, in 2003, to launch the Yoghurt Cooling Gel - the first yogurt product, that was set to become an international best-seller and synonymous with Greek summer.

But now it's a new line of faces that "takes advantage" of the advanced technology of prebiotics and probiotics and links it to trademark, now a component of the company - even releasing better timing, as the Greek yoghurt trend abroad is huge

In addition, the Greek element has always been present in a brand that celebrates at every opportunity its place of origin.

📷 Photo: Paris Tavitian/LIFO.

During our visit to the Korres factory we had the unique opportunity to be guided by specialists in all departments, following all stages of product development, from research and development in the laboratory to industrial production and packaging.

The first stop was at one of Korres's workshops, where we were welcomed by the co-founder and head of innovation and development of brand new products Lena Korres, expressing her enthusiasm for the Greek Yogurt Collection.

📷 Photo: Paris Tavitian/LIFO.

Korres conceded that he "feels immense joy that no one else has done", beginning a brief look at that original idea, whose seeds were laid twenty years ago, to bear fruit all over the world today:

"In 2000 we were just two people in Korres research and we were thinking about how unique the yogurt was, so we ended up making the first after sun with yoghurt, the Yoghurt Cooling Gel.

For three years, until 2003, we released a puzzle because yogurt is not a cosmetic raw material, it has 4,000 microorganisms, it is a living raw material that makes fermentation, changes and is difficult to stabilize, control and control. maintenance.

The way we've been able to stabilize edible yogurt using the same organic acids in our stomachs is unique and has never been done by any company worldwide. "

Research and development

But what does a cosmetic development process mean when the primary research that usually lasts 3-5 years ends?

"Then we know what ingredients to work with," explains Mrs Korres. “We build the formula first on paper. A cream always has two phases, aqueous and oily. So we choose which (vegetable, exclusively) oils to use in the oil, depending on the texture we want.

Most of our active ingredients enter the aqueous phase. Our backbone is the emulsifier that unites the two phases, which in themselves do not mix. Many samples are taken by researchers until the research piece is completed and a formula is closed.

Then the development begins, where we ensure that the product is physically, chemically and microbiologically stable throughout its three-year life cycle, until its expiration date.

European law tells us that we need to control 5 pathogenic micro-organisms. We control 13, our own protocols are much stricter because we are a global brand, we sell in many markets and our property is the protocols we have built to develop safe products, even as difficult as yogurt.

Growth is divided into three production steps: the first takes place in a small ten-ton cauldron, which closely resembles the conditions in a large one-ton cauldron. Following is a series of difficult development tests completed in 13 weeks.

After some months we make the second production of 100kg and then the first industrial production in the final tonne or six tonne cauldron. Then the product development is completed and we are sure we can launch it. "

But before we went on our tour of the production and packaging plants, following the next steps in the production of the "Greek Yogurt" series, our laboratory scientists reserved a great surprise: we had the opportunity to make our own yogurt based body butter.

Of course the expiration date of our design was much shorter, but the satisfaction we got from the lab process and the fun of the case was enormous - and its texture was gorgeous, perfect for after the first spring baths at sea!

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

Clean water unit

The thrill of our fascinating tour was undertaken for the second leg by the plant manager, Theodoris Pantazis, guiding us to the production and packaging units.

Περιηγηθήκαμε αρχικά στη μονάδα νερού, ενός συστατικού ζωτικής σημασίας για όλα τα καλλυντικά, καθώς αποτελεί στις περισσότερες περιπτώσεις το 80-95% της σύστασής τους.

Korres produces its own water for its products, in an impressive water purification plant inside the cosmetics plant. Water is treated to the most stringent specifications, resulting in 'ultra-pure' water - 5 times cleaner than required by European cosmetics legislation.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

Production unit

We left the homeopathic medicine lab (the oldest homeopathic pharmacy in Athens was the starting point for the brand's launch and launch, back in the '90s and early' 00s) for a future visit and, in front of warehouses and scales, we found ourselves in the unit. production with the huge bins of one and six tonnes, 400 and 200 kg, where the production process was at that time in progress. Each year Korres produces 10,000 tons of product.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

Packaging unit

The final stage of the packaging was perhaps the most striking visually. In the state-of-the-art equivalent unit, costing € 5.5 million, 7 power lines pack the various brand codes, depending on production, demand, season and other parameters.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

We were lucky because at the time of our visit we had achieved the packaging for the day cream of the series "Greek Yogurt" and we were able to miss all its stages: from cleaning the jars, putting the cream in them, closing them with airtight lid. , until they are stored in cardboard boxes, accompanied by the leaflet with instructions for use and forwarded to cartons. These are just a few of the 48 million pieces packed here each year to continue their journey on the world map. 

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

📷 Photo: Paris Tavitian/LIFO.

 

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Source: Lifo

 

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