In today’s competitive food industry, every gram counts. Yet for many producers, the hidden cost of overweight packing quietly eats into profits- batch after batch, day after day. Whether caused by outdated automation or imprecise manual work, even the smallest overfill adds up fast across high-volume operations.

Why Overweight is a Problem

Conventional packing lines, whether manual or semi-automated, simply weren’t built for the speed, precision and adaptability today’s processors demand. Many rely on static workflows, basic scales or fixed-weight assumptions that fail to account for real-time product variation. As a result, operators are left making manual estimations or overfilling to stay safe, leading to product waste and rising labour inefficiencies. These systems also struggle to adapt to different product types, portion sizes or packaging formats without costly reconfiguration or downtime. As production volumes scale up, so do the losses- turning what seems like minor inefficiency into a major operational drain.

And when you consider that raw product accounts for around 75% of total manufacturing costs, the impact of even small packing inefficiencies becomes crystal clear. Unlike administrative expenses- which typically make up just 25%- raw materials are where the bulk of your investment lies. That means every gram of giveaway in packing process is not just wasted product, but wasted profit. In high-volume operations, consistent overpacking can quietly drain tens and even hundreds of thousands in lost yield over time. Minimizing that waste isn’t just a matter of operational excellence- it’s a direct path to stronger margins and long-term competitiveness.

How We Would Like the Packing Process to Look Like?

Imagine automated packing line that thinks before it packs. One that doesn’t rely on rough estimates or fixed weights, but instead calculates in real time the most efficient product combinations to stay just at the target weight, not over. Picture a process where the machine does the math for you, weighing, analyzing and deciding the perfect product match faster and more precise than any human ever could. A system smart enough to adapt to different products and packing formats, yet precise enough to ensure quality in every pack. In a world where margins are tight and volumes are high, this kind of intelligence isn’t just nice to have- it’s real reason to be ahead of the competitors.

PERUZA Reduced Giveaway Line- Next-gen Packing Line

It’s not an imagination anymore, we have made a solution, which is truly like that. PERUZA Reduced Giveaway Line is not just another packing machine- it’s a smart, high-speed system built to reduce giveaway, increase yield and adapt to your production in real time. 

Why we have made PERUZA Reduced Giveaway Line:

• To eliminate costly overweight by using intelligent algorithms that calculate the most efficient product combinations.
• To meet high-volume demands with a modular design that can reach up to 210 pieces per minute.
• To replicate manual care through product-specific grippers that handle items with human-like precision.
• To ensure long-term reliability with IP69K delta robots that withstand the toughest environments.
• To adapt with different needs with flexible outfeed options- trays, boxes, bins or thermoforms.

 

Watch the video to see PERUZA Reduced Giveaway Line in action:

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As industries increasingly embrace automation, palletizing has emerged as a critical area for improving efficiency and productivity. Automatic palletizers offer a seamless solution to stacking and organizing products, eliminating the need for time-consuming and labour-intensive manual processes. By enhancing speed, accuracy, and load stability, these machines have revolutionized the end-of-line operations for businesses across various industries. In this blog, we’ll delve into five compelling reasons why investing in an automatic palletizer can elevate your production process, reduce costs, and create a safer, more efficient workplace.

Prioritized Employee Well-Being

One of the most significant advantages of investing in an automatic palletizer is its ability to prioritize employee health and safety by eliminating the physically demanding tasks associated with manual palletizing. Repeated heavy lifting, bending, and stacking can lead to long-term injuries, fatigue, and workplace accidents, all of which negatively impact employee morale and productivity. Automatic palletizers take over these heavy tasks, creating a safer and more ergonomic work environment for your team.

Reduced Labour Costs and Enhanced Efficiency

Automatic palletizers are a game-changer when it comes to reducing labour requirements while maintaining high productivity. By automating the palletizing process, businesses can achieve significant cost savings by reallocating or minimizing the need for manual labour. This reduction in manual intervention not only cuts labour expenses but also minimizes errors, ensures consistent pallet quality, and allows remaining staff to focus on higher-value tasks. With less dependency on manual labour, companies can optimize operations and improve overall production efficiency without compromising output quality.

Integrated Quality Control for Enhanced Accuracy

Automatic palletizing systems can be seamlessly equipped with advanced quality control mechanisms to ensure only the best products are processed and shipped. These systems can quickly detect issues such as broken boxes, improperly sealed cartons, or incomplete packaging before they are palletized. By integrating sensors, vision systems, and automated rejection mechanisms, the palletizer becomes a dual-purpose tool—optimizing both product stacking and quality assurance. This real-time inspection not only prevents defective products from reaching customers but also reduces rework and waste, saving both time and resources. With the added capability of fast quality control, automated lines ensure consistent product standards while maintaining high-speed operation, ultimately boosting customer satisfaction and protecting brand reputation.

Integration with Smart Factory Systems

Automatic palletizers can integrate seamlessly with Industry 4.0 solutions, such as Manufacturing Execution Systems (MES), warehouse management systems (WMS), and Internet of Things (IoT) technology, providing a smarter and more connected production environment. These integrations enable automatic palletizers to communicate with other systems in real time, allowing for continuous data gathering, monitoring, and analysis of production processes. By collecting information on factors such as cycle times, machine performance, and product throughput, businesses gain valuable insights into operational efficiency, equipment utilization, and potential bottlenecks. The ability to analyze this data empowers companies to make data-driven decisions that enhance productivity, reduce downtime, and optimize resource allocation.

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Reduced Giveaway Line

The PERUZA Reduced Giveaway Line is designed for automatic, precise packing of raw products into trays, boxes, or thermoformed packages, ensuring minimal product overweight. This system utilizes 3D dimension recognition and weight calculation to reduce giveaway, enhancing line capacity and profitability. With an intuitive user interface, it offers fast changeovers for different product types, from fresh or frozen meat to vegetables, and can connect seamlessly with traysealers or thermoformers, making it efficient for different production lines.

ScanPlant NG

The ScanPlant NG system is an advanced Manufacturing Execution System (MES) that provides full traceability and production management for the food industry. It enables precise real-time monitoring of quality, weight, and yield data, ensuring that every product can be tracked from raw material to finished goods. This system optimizes efficiency by automating key tasks like quality control, sorting, and data synchronization, leading to significant time savings and better product traceability, ultimately boosting profitability.

KPI real time monitoring and reporting

The combination of the PERUZA Reduced Giveaway Line and the ScanPlant NG system can offer significant benefits for the facility by providing real-time performance indicators such as capacity, yield, and quality. For line operators, this instant data will allow quick adjustments to maintain efficiency and product standards, minimizing waste and errors. Meanwhile, managers will gain valuable insights through detailed KPI reports, enabling them to track overall performance, identify trends, and make informed decisions. This powerful combination ensures a more efficient, streamlined production process and supports both short-term and strategic goals.

Reduced giveaway in a next level

The collaboration of PERUZA processing lines and Accuratech ScanPlant NG revolutionizes giveaway calculations by monitoring entire processing lines and factories not just stand-alone equipment, providing real-time oversight of product weight and data. The system continuously tracks the whole line’s overweight, offering managers detailed insights into the production process and profitability. It provides a clear view of the entire operation, helping to pinpoint inefficiencies and areas where product loss or excess occurs. This transparency allows manufacturers to make informed decisions and optimize profits without compromising process control.

Clear traceability

Solutions together significantly enhance traceability throughout the production process. By tracking each product in real-time, from raw materials to finished goods, it ensures complete transparency and accountability. The data is captured and logged at every stage of production, enabling full product traceability, which can be crucial for quality control, regulatory compliance, and customer assurance. This streamlined traceability helps manufacturers maintain high standards, quickly identify and resolve issues, and improve overall operational efficiency.

PERUZA and ScanPlant go hand in hand

The ScanPlant NG technology can be seamlessly integrated with various PERUZA processing solutions to enhance whole lines performance and traceability. For instance, when paired with the Full Speed Batcher, ScanPlant NG monitors the batching process in real time, improving lines efficiency and reducing errors. With the Flow Weight Grader, it tracks grading success rates, helping to optimize recipes and reduce whole lines waste. But in combination with the High-Speed Palletizer, ScanPlant NG automates labeling and ensures full traceability for each client’s batch, streamlining both the packaging and tracking processes across multiple applications.

To Sum up

In conclusion, the combination of the PERUZA Reduced Giveaway Line and ScanPlant NG technology represents a powerful solution for optimizing processing and packaging lines. With real-time monitoring, traceability, and KPI reports, this integration significantly helps to reduce giveaway, enhances product quality, and improves efficiency across the whole production line. As well whether it’s batching with PERUZA Full Speed Batcher, grading with the Flow Weight Grader, or ensuring traceability with the High Speed Palletizer, ScanPlant NG technology can be integrated with various PERUZA solutions to elevate productivity and profitability for manufacturers in a highly competitive market.

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In the world of automated packaging, efficiency and precision are crucial, especially when dealing with fragile or uniquely shaped products. As we seen in the previous blog post, in the market there are few different solutions for packaging. Here in this blog post we will see how the side loading case packer stands out as an innovative solution that handles products from the side reducing the damage of the products.

Understanding Side Loader Packaging Machines

Side loader packaging machines are specialized systems designed to automate the process of loading products into packaging from the side, ensuring precise placement and secure packaging. The PERUZA Side Loader is a prime example, capable of handling a wide range of products, including delicate items that require careful handling, such as in the food, pharmaceutical, and consumer goods industries. These machines excel in applications where high-speed, precise alignment is essential, such as packaging irregularly shaped products or those that are prone to damage during handling. By automating the entire process, from box creation to product insertion and sealing, side loaders enhance efficiency while maintaining product integrity.

Key Advantages of Side Loaders

Secure and Smooth Packaging

The main feature of the PERUZA Side Loader is its ability to ensure that the lid remains securely in place as products are smoothly inserted into the box from the side. This is particularly crucial for products that cannot be accessed from the top, such as glass jars, narrow-necked containers, and aerosol cans. The smooth side-loading process minimizes the risk of the lid coming off, maintaining the integrity of the packaging and protecting the product during transportation. All that leads to PERUZA Side Loader is specifically designed to handle delicate products with care, reducing the risk of damage during packaging.

Efficiency and Speed

Side loaders, like the PERUZA Side Loader, are engineered for high-speed operations, significantly boosting throughput. Compared to top loaders or wrap-around machines, side loaders offer faster processes for products that require precise alignment and gentle handling.

Side Loader vs Top Loader vs Wrap-Around Packers

Side load case packers, top load case packers, and wrap-around case packers each offer unique advantages tailored to specific packaging needs. The side load case packaging excels in handling delicate or irregularly shaped products, placing them gently into packaging from the side, which is ideal for items like glass jars or aerosol cans. In contrast, top loaders are designed for high-volume operations, efficiently dropping or placing products into cases from above, which ensures even weight distribution but can be harsher on fragile items. Wrap-around packaging machines, meanwhile, wrap the packaging material around the product, providing a tight and secure fit, making them suitable for more uniform, sturdy products. The side loader stands out for its ability to protect product integrity, while top load case packers and wrap-around case packers are favoured for their speed and efficiency with less delicate items.

Conclusion

In conclusion, the side loader presents clear advantages in automated packaging, particularly for industries dealing with delicate or uniquely shaped products. Its precision, efficiency, and compact design make it an ideal solution for maintaining product integrity while boosting productivity. For businesses seeking the best packaging solutions tailored to their specific needs, it’s crucial to consult with our specialists. Our team can provide expert advice and help determine which type of case packers can optimize your packaging processes. Contact us to explore the perfect solution for your packaging challenges.

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Choosing the right case packer for your business is a crucial decision that can significantly influence your operations. An efficient case packing system is essential for maximizing productivity, reducing costs, and enhancing overall operational efficiency. The right equipment ensures smooth workflows, minimizes downtime, and can adapt to the specific needs of your production line. In this blog post, we will explore the key factors you should consider when selecting a case packer and compare different case packer types to help you find the best fit for your business. Understanding these elements will empower you to make an informed decision that aligns with your company’s goals and operational requirements.

Assessing Your Business Needs

Understanding your specific business requirements is vital before selecting a case packer. The right choice depends heavily on several factors, including your production volume, the types of products you handle, the packaging materials used, and the available space in your facility. High production volumes may necessitate faster, more robust machines, while fragile or uniquely shaped products might require specialized handling. Additionally, it is crucial to consider scalability and flexibility to ensure that the case packer line can accommodate future growth and adapt to changes in production. Essential features to look for in a case packer include speed, accuracy, ease of operation, and ease of maintenance. Furthermore, it is important to determine whether the case packer needs to perform additional tasks beyond just placing products in cases. Many modern case packers can also make cases and seal them, streamlining the packaging process and reducing the need for additional equipment. By thoroughly assessing these factors and understanding your business needs, you can select a case packer that enhances efficiency and supports your operational goals.

Top load case packer

PERUZA Case Packer, designed to place products from the top.

Top-loading case packers are designed to pack products such as cans and boxes from the top into open cases. This technique involves the products being conveyed to a packing station where they are either dropped or placed into cases from above. One of the primary advantages of top- loading case packers is its ability to handle a high volume of products quickly and efficiently, making it ideal for industries with high production rates. This method ensures even distribution of weight within the case, enhancing stability during transportation. However, there are some cons to consider. Top-loading packers can sometimes be less gentle on delicate products, potentially causing damage.

Side load case packer

PERUZA Side-loading case packer for fish cans.

Side-loading case packer is a type of packaging machine that places products into cases from the side. This method is particularly effective for handling a variety of product shapes and sizes, ensuring they are neatly arranged within the case not from the top but from the side. The side-loading process offers precision and efficiency, reducing the risk of product damage during packaging. So, this is the right solution where products are more fragile and cannot be packed from the up by the lid. Also, this solution provides option for different type of placement in the boxes (vertically from the case), which is crucial for some markets and products, where products is in the box at the market shell.

Making the Final Decision

Choosing the right case packer is a multifaceted process that involves evaluating your specific business needs and understanding the capabilities of different packing methods. Top-loading case packers are advantageous for their speed and efficient handling of high volumes, making them ideal for robust products like cans. However, they may not be suitable for products whose lids are fragile. On the other hand, side-loading case packers offer precision and flexibility, reducing the risk of damage and accommodating a variety of product shapes and sizes. They are particularly beneficial for fragile products and specific market requirements. Ultimately, making the final decision involves balancing these factors with your production goals, scalability needs, and budget. Contact PERUZA product specialist Hugo at hugo.grube@peruza.com and we will ensure you select a case packer that aligns with your operational objectives and supports future growth.

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The automation of warehouses is bringing a revolution in the logistics industry, offering advantages such as increased efficiency and productivity as well as cost reductions. However, putting automation into place in a warehouse environment does not come without its share of challenges. There are many that need to be overcome before an implementation can be considered successful. These challenges range from technological complexities to employee adaptation. In this article, we will investigate some of the most significant obstacles that must be overcome in order to successfully implement warehouse automation, and we will discuss potential solutions.

Technological Integration and Complexity

The seamless integration of different technologies is one of the primary challenges that must be overcome in order to implement warehouse automation. Robotics, conveyor belts, automated storage and retrieval systems (also known as AS/RS), and software designed specifically for warehouse management are typically the elements that make automation systems. It is possible that the task of ensuring that these different parts work together efficiently will be difficult.

In order to overcome this challenge, careful planning of the implementation procedure is absolutely necessary. This includes carrying out an in-depth analysis of the infrastructure that is already in place, locating any potential delays, and developing a plan for the implementation of the change in stages. In addition to helping to streamline the integration process and ensure compatibility between various automation components, working together with experienced software developers and technology providers can be of great benefit.

Workforce Adaptation and Training

When automation is implemented in a warehouse, employees frequently express concerns about their ability to adapt to new technologies as well as the security of their jobs. The implementation process can be slowed down by resistance to change, which can affect overall productivity.

To be able to conquer this obstacle, it is crucial to include employees in the automation launch procedure from the very beginning. Communication that is open and honest about the reasoning behind automation, that emphasizes the benefits that it brings, and that addresses concerns can help alleviate fears. It is also extremely important to provide employees with comprehensive training programs to equip them with the skills necessary to operate and manage automated systems. It is possible to further encourage workforce adaptation by providing opportunities for retraining and highlighting the possibility of positions requiring higher levels of skill.

Source: Pexels

 

Maintenance and Support

Because warehouse automation systems are made up of a wide variety of electronic and mechanical components, it is essential to perform routine maintenance and support in order to ensure smooth operations. Problems with technology, unscheduled downtime, or malfunctioning systems can have a significant negative effect on both productivity and customer satisfaction.

The development of a solid maintenance and support strategy is absolutely necessary if this challenge is to be overcome. This includes performing routine inspections, keeping preventive maintenance schedules, and reacting quickly to problems in order to diagnose and repair them. When it comes to effectively addressing maintenance needs, close collaboration with technology providers or system integrators who offer comprehensive support services can provide the necessary expertise to meet those needs.

PERUZA’s Plastic crate palletizing and depalletizing system

We, the PERUZA’s team, know how difficult it is to implement new technologies. So, we offer full support and our knowledge throughout the process.

One of the popular solutions is PERUZA’s Plastic crate palletizing and depalletizing system. It’s an automated warehouse solution that provides a 2 in1 system for palletizing and depalletizing plastic crates.  It’s possible for crates to hold a wide variety of goods, such as raw produce, glass bottles, or even different types of packages. The one-of-a-kind gripper that we’ve designed can be adapted to meet any requirements you may have.

Forklifts can be used to transport incoming crates to the production line, where they are fed to the pallet conveyor system. They can also be positioned directly in the frame of a pallet as an alternative. The process of depalletizing and palletizing is carried out entirely automatically by product recipes that have been set. Either a person can pick up ready pallets from pallet frames or a conveyor system can deliver them to the appropriate location. An additional available add-on is an automatic wrapping system for pallets.

Main benefits:

• Adaptable to customer needs;
• 2 in 1 system for palletizing and depalletizing;
• Modular system layout for various products.

To sum up

Warehouse automation implementation is not without its challenges, but with a strategic approach and a focus on addressing these challenges, organizations can unlock the full potential of automation. By embracing automation technologies, businesses can enhance efficiency, accuracy, and customer satisfaction while empowering their workforce to embrace new skills and contribute to the evolving landscape of logistics and warehousing.

As robotics, automation, and machinery develop, you must look into the best possible solutions now. If you’re interested in learning more about how PERUZA can help you get the best results with your food processing, feel free to get in touch at info@peruza.com, and we’ll be happy to discuss the possibilities of us creating something great for your fish processing business!

 

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Everyone is familiar with the packaging used for food. Processed foods are a big part of modern life, and packaging technology helps ensure food safety by keeping food products fresh and extending their shelf life. You will notice that almost all processed foods you bring home from the grocery store are packaged if you pay attention to your trip to the store. 

In this blog post, you will learn all there is to know about food packaging types and will compare traysealer and thermoformer.

What are the main functions of food packaging?

The way food is packaged, the materials that are used, and the technology that makes it possible are all referred to as food packaging. Food is packaged for a variety of reasons, including increasing shelf life. So, here are the main functions of any and every kind of food packaging: 

• Food preservation – packaging keeps food items from coming into contact with air or moisture. Food that has been exposed to air can quickly begin to rot. Food that has been properly packaged has a longer shelf life, which is good news for any food manufacturer and consumer as well. 
• Protection from Biological Agents it also shields food from biological agents that could contaminate or render it unsafe to consume, such as rats, insects, bacteria, and germs.
• Information – Everyone reads the food product labels, right? Brands can include crucial information on every food item they sell, such as the brand name, expiration date, and ingredients, thanks to food packaging.
• Better Usage – packaging makes it simpler to use products like milk cartons or canned slices of food. These foods can be kept in storage according to their shelf life and used as needed.

Source: Freepik

What are the different types of food packaging?

There are many kinds of food packaging. Most of them are used for specific kinds of foods. For example,

• Aseptic packages are suitable for non-refrigerated sterilized food product packaging. Food and drink items like soup, milk, other dairy products, etc. are packaged in aseptic packaging. 
• Trays are used to store products like meat, seeds, fish, and beverage cans. They are typically flat and have high sides to keep the contents from spilling out. Also, it’s possible to vacuum oxygen out of the package and fill it with a gas mixture, so the shelf-life is even longer. 
• Thermoform –  or Thermoforming process is heating a thermoplastic sheet to its softening point and the sheet is stretched across a single-sided mold and then adjusted, in a result, it cools into the desired shape.
• Film bags and boxes are used for snack foods like crackers, chips, cereal, frozen foods, pizza, fast food, and much more.
• Cans are very adaptable and durable, and they are frequently used for beverages or canned food. To prevent corrosion, they are made of thin metal containers coated in the tin.

Traysealer vs. Thermoformer

Tray seal and thermoform are two of the most popular when talking automated packing, but which is better? Let’s start at the beginning, with the question – what is the main difference?

In simpler terms, tray sealers are machines that apply plastic film lids to pre-formed trays of various materials, sizes, and depths. Tray sealers are also known as tray lidding, heat sealers, and top sealers internationally.

A multi-stage process called thermoform can be used to form the tray and produce a sealed pack from plastic. Plastic sheets can be thermoformed into three-dimensional shapes using pressure, vacuum, and heat during manufacturing. The shapes are created using a mold. After the shapes have interacted with the mold, they are cut, examined, and assembled into packaging.

Pros of traysealer:

• The product is kept fresh and it’s leak-proof. 
• Extended shelf-life and recyclable materials can be used. 
• Visually appealing presentation and convenient for customers. 
• Always the same size of packaging. 
• The tray sealer machine is less expensive than a thermoformer.

Pros of thermoformer:

• Design flexibility and it suits different sizes of products.

• This is a cheaper solution in the long-term as this packaging uses way thinner material. 
• Takes less space – as it’s in the size of the product, not the tray. 
• It could  work with gas or without it – just with the vacuum that is created inside of a package.

What to choose – traysealer or thermoformer? There is no simple answer to this question. First, you have to consider your priorities – is it sustainability and flexibility or maybe the constant size of packaging? Second, think about the visual aspect – do you need trays that are all the same and look in specific ways? And last but not least, think about the machinery that is available for you. Yes, the tray sealer machine is less expensive than a thermoformer, but in the long run, the packaging costs are lower.

Source: PERUZA

PERUZA’s Reduced giveaway line

When talking about automated solutions for food packaging, we have to mention PERUZA’s Reduced giveaway line. This solution is designed for raw product automatic insertion into plastic trays or boxes by reaching a specified final weight range in packaging. It will not only pack and seal the product, but its precise calculations reduce the giveaway of the product and increase the line capacity.

 

But how does it work? The products arrive on the main product conveyor one by one in 1, 2, or more lanes. But then, after passing through the 3D dimension recognition and weight calculation unit, the program sends a signal to a robot with an appropriate gripper to pick it up and place it into a tray or box to reach the set final weight range in packaging. The final weight range in packaging and current line setup can be adjusted in a smart user interface.

The main benefits of PERUZA’s Reduced giveaway line :

• Reduced product giveaways;
• Easy-to-use, intuitive user interface;
• Adaptable to various products;
• Precise and fast operation; 
• Products are organized not dropped in the trays.

Final thoughts

When choosing between traysealer or thermoformer you have to consider all the aspects – price, sustainability, and accessibility. And keep in mind that as the product differs the packaging should be different as well.

As robotics, automation, and machinery develop, you must look into the best possible solutions now. If you’re interested in learning more about how PERUZA can help you get the best results with your food processing, feel free to get in touch at info@peruza.com, and we’ll be happy to discuss the possibilities of us creating something great for your fish processing business!

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