Software solutions Archives - PERUZA https://peruza.com/topic/software-solutions/ Wed, 16 Apr 2025 14:45:15 +0000 en-US hourly 1 https://wordpress.org/?v=6.8.2 https://peruza.com/wp-content/uploads/2021/03/Peruza-favicon-1-100x100.jpg Software solutions Archives - PERUZA https://peruza.com/topic/software-solutions/ 32 32 Why Smart Packing Isn’t Just About Speed Anymore https://peruza.com/blog/software-solutions/the-digital-transformation-of-packing/ Wed, 16 Apr 2025 14:28:42 +0000 https://peruza.com/?p=10219 In this blog post you will understand what is giveaway in production and how the giveaway is big problem for manufacturers.

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In today’s fast-paced manufacturing environment, particularly within the food industry, the focus of smart packaging has evolved beyond mere speed. Modern operations now prioritize traceability, sustainability and data-driven decision-making. Manufacturing Execution Systems (MES) have become essential tools in achieving these goals, offering real-time insights and control over production processes.

The Evolving Role of MES in Packaging

MES platforms serve as the bridge between enterprise-level planning and shop-floor execution. They provide real-time monitoring and control of manufacturing processes, ensuring that each step, from raw material intake to final packaging, is optimized for efficiency and compliance. While fast packing remains important, it’s no longer enough in a landscape where accuracy, traceability and quality are equally critical. High-speed lines that produce overweight, underweight or mislabeled products can lead to financial losses, customer complaints or regulatory issues. By integrating MES into packaging operations, manufacturers gain the tools to move beyond speed- achieving precise control over product weights, minimizing waste, improving labeling accuracy and maintaining full traceability with confidence.

Reducing Giveaway and Controlling Product Weight

Product giveaway- the excess amount of product packed over the target weight- remains a hidden cost in many operations. While a few grams may seem minor, over time and across thousands of units, it results in significant loss (see the blog post with a real case study of lost money because of the overweight). MES systems installed at packing stations offer precise, real-time weighing data that alert operators or supervisors when weights consistently exceed or fall short of specification. Overweight packages trigger opportunities to fine-tune filling processes, while underweight detections help catch potential compliance issues before they reach customers- who today have little tolerance for inconsistency. With an MES in place, manufacturers make smarter decisions based on trends, avoid fines or returns and reduce unnecessary product loss.

Strengthen Traceability and Compliance

Traceability has become a non-negotiable aspect of food manufacturing, driven by stringent regulations and consumer demand for transparency. MES systems enable comprehensive tracking of products throughout the production cycle. This capability ensures that, in the event of a recall or quality issue, specific batches can be quickly identified and addressed- without needing to pause or cancel the entire production line. Instead of blanket shutdowns, operators can isolate only the affected time window or batch, minimizing downtime, reducing product loss and maintaining smooth operations. This level of granularity not only protects brand integrity but also strengthens customer trust through responsible, data-backed decision-making.

Sustainability Through Data-Driven Decisions

Sustainability is no longer just a corporate social responsibility buzzword; it’s a critical component of operational efficiency. MES platforms provide the data necessary to identify areas of waste, optimize resource utilization and implement continuous improvement initiatives. By analyzing production data, manufacturers can make informed decisions that align with both environmental goals and bottom-line objectives.

Spotlight on ScanPlant NG

ScanPlant NG, developed by Accuratech, exemplifies the capabilities of a modern MES tailored for the food industry. Its modular design allows for customization to specific production needs, ensuring seamless integration with existing systems. The platform offers real-time management of packing, weighing and labeling processes, supporting unique item numbering for full traceability. It can automatically detect weight deviations, interface with a wide range of equipment- from basic scales to advanced industrial terminals- and provide intuitive dashboards to keep operators and managers informed. ScanPlant NG doesn’t just collect data- it transforms it into actionable insights for better quality control and operational precision.

Conclusion​

The paradigm of smart packaging has shifted to encompass more than just speed. With the integration of MES systems like ScanPlant NG, manufacturers can achieve enhanced traceability, sustainability and operational efficiency- while also significantly reducing product giveaway and packaging errors. Embracing these technologies is not merely an option but a strategic imperative for staying competitive in today’s increasingly data-driven and quality-focused manufacturing landscape.

Learn more about the digitalization in the webinar!

We want to share our knowledge and experience on how to unlock the full potential of these machines through smart digitalization.

Join us for an exclusive webinar where we’ll explore how  digitalization helps manufacturers connect their end-of-line equipment to improve efficiency, reduce product giveaways and ensure full traceability.

Join our free online webinar:

📅 Date: 24. April
🕒 Time: 10:00 Baltic time (EET)
🌐 Language: English
🎤 Speakers:

  • Guntis Dlohi, Head of Sales at Peruza
  • Stuart McBride, Sales Director at Accuratech

In this session, we’ll focus specifically on end of line equipment- weighing units, labeling systems, packing lines- and demonstrate, through real-world case studies, how manufacturers are gaining actionable insights and operational improvements by digitalizing even stand-alone assets.

You’ll learn how to:
✅ Connect and collect data from your packing, weighing and labelling machines
✅ Reduce product waste and improve giveaway control
✅ Achieve compliance and traceability with ease
✅ Make smarter decisions with real-time production data

👉 Register Now: register here

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]]> The Digital Transformation of Dairy Processing https://peruza.com/blog/software-solutions/digitalization-dairy/ Tue, 18 Feb 2025 12:54:21 +0000 https://peruza.com/?p=10130 In this blog post you will understand what is giveaway in production and how the giveaway is big problem for manufacturers.

The post The Digital Transformation of Dairy Processing appeared first on PERUZA.

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The dairy industry has long been a cornerstone of food production, providing essential products such as milk, cheese, and yogurt to global markets. However, traditional dairy processing methods often struggle with inefficiencies, traceability issues, and compliance challenges. With the rise of digitalization, Manufacturing Execution Systems (MES) are transforming dairy production, enabling better control, automation, and data-driven decision-making. This blog explores how MES integrates with dairy processing, improving efficiency and compliance while providing real-world examples of its impact on dairy plants.

The Shift from Traditional to Digital Dairy Processing

For decades, dairy processing has relied on manual monitoring, paper-based record-keeping, and isolated automation systems. These methods, while functional, often lead to inefficiencies, human errors, and compliance challenges. The growing demand for higher-quality dairy products, coupled with strict food safety regulations, has made digital transformation a necessity.

Modern MES solutions bridge the gap between enterprise resource planning (ERP) systems and plant-floor operations, providing real-time visibility into production processes. By implementing MES, dairy plants can track raw materials, monitor processing conditions, and ensure consistent product quality, all while minimizing waste and improving operational efficiency.

How MES Integrates with Equipment to Improve Efficiency

One of the most significant advantages of MES is its ability to seamlessly integrate with production equipment. Dairy processing involves multiple stages, including milk reception, pasteurization, fermentation, and packaging. An MES system collects real-time data from these processes, providing operators with insights to optimize performance.

Key integrations include:

  • Automated Milk Reception. MES ensures accurate tracking of milk volumes, quality parameters, and supplier details, reducing errors in inventory management.
  • Process Monitoring. Sensors and IoT devices connected to MES provide real-time data on temperature, pressure, and humidity, ensuring optimal processing conditions.
  • Packaging and Labeling. MES ensures accurate labeling, weight control, and compliance with traceability regulations, reducing human intervention and errors.

By integrating MES with smart manufacturing technologies, dairy plants can achieve increased efficiency, reduced downtime, and improved compliance with industry standards.

Boosting Traceability and Compliance in Dairy Production

Food safety and traceability have become top priorities in the dairy industry. Regulations such as the FDA’s Food Safety Modernization Act (FSMA) and EU food safety laws require producers to maintain detailed records of ingredient sources, processing conditions, and distribution channels. Traditional record-keeping methods make compliance cumbersome and prone to errors.

MES addresses these challenges by providing end-to-end traceability, allowing dairy producers to:

  • Track Ingredients. Monitor milk batches from farm to final product, ensuring product authenticity and quality.
  • Automate Compliance Documentation. Generate real-time reports for audits, reducing administrative workload.
  • Improve Recall Management. In the event of a contamination issue, MES enables rapid identification and removal of affected batches, minimizing losses and protecting consumers.

 

Case Study- Dairy's Processing Company’s Digital Transformation with MES

About the Company

To maintain confidentiality, we won’t mention the name, but it is a case study of well-established Danish dairy cooperative, founded over 100 years ago, specializes in producing high-quality cheese and dairy products. Faced with rising market demand and strict food safety regulations, the company aimed to modernize its production processes and enhance traceability to stay ahead in the industry with ScanPlant NG MES system.

 

Objectives of the Project

The key goals of MES implementation included:

  • Improving real-time operational visibility and data-driven decision-making.
  • Enhancing traceability and compliance with European food safety regulations.
  • Automating processes to minimize manual errors and reduce product giveaway.
  • Integrating a digital weighing and labeling system to optimize packaging accuracy.

 

Technical Solution

To achieve these objectives, was integrated an MES platform capable of:

  • Real-Time Process Monitoring. Tracking milk reception, pasteurization, and cheese maturation parameters.
  • Inventory management. Making sure to have all the ingredients and stock in place.
  • Automated Packing and Labeling. Ensuring precision in packaging weight and compliance with food labeling laws.
  • Advanced Data Analytics. Providing insights into process efficiency, ingredient usage, and quality control.

 

Results and Impact

Following the ScanPlant NG MES implementation, the company experienced significant improvements:

  • Up to 2 % reduction in Product Giveaway. Optimized ingredients use and minimized production waste.
  • Enhanced Traceability. Full product lifecycle tracking ensured better quality control and faster recall response. Reduced traceability audits down to 30 minutes.
  • Increased Production Efficiency. Improved production yields by up to 1 %.

 

This transformation enabled company to scale its operations efficiently while maintaining its commitment to high-quality dairy products and sustainability.

Conclusion

The digital transformation of dairy processing is no longer a future trend—it is a necessity for modern production facilities. By implementing MES, dairy manufacturers can optimize efficiency, enhance traceability, and ensure regulatory compliance. As technology continues to evolve, the integration of MES with IoT, AI, and data analytics will further revolutionize the industry, paving the way for smarter, more sustainable dairy production.

Ready to Unlock Your Potential?

As we’ve seen, reducing giveaways isn’t just about cutting costs—it’s about optimizing operations and maximizing profitability. With the right tools and strategies, businesses can achieve significant savings while maintaining product quality and customer satisfaction.

Want to learn better how to minimize giveaways and streamline your production? Join our free online webinar:

📌 Topic: Digitalization in Manufacturing- How to Optimize Production and Reduce Product Giveaways
📅 Date: February 28
⏰ Time: 10:00 (EET)

In this webinar, we’ll dive deeper into real case studies and practical methods to improve processes and reduce giveaways in manufacturing, with a special focus on dairy product processing.

👉 Register here:  Webinar Link

The post The Digital Transformation of Dairy Processing appeared first on PERUZA.

]]> Unlocking the Potential to Reduce Giveaways and Overproduction https://peruza.com/blog/software-solutions/unlocking-the-potential-to-reduce-giveaways-and-overproduction/ Wed, 05 Feb 2025 15:29:26 +0000 https://peruza.com/?p=9977 In this blog post you will understand what is giveaway in production and how the giveaway is big problem for manufacturers.

The post Unlocking the Potential to Reduce Giveaways and Overproduction appeared first on PERUZA.

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In today’s food processing industry, achieving operational efficiency and maximizing earnings depend on managing key factors like product giveaways and overproduction. With raw food accounting for approximately 75% of manufacturing costs—compared to just 25% for administration— minimizing waste can lead to significant savings. But what exactly does product “giveaway” mean, how much can be saved, and how can businesses capitalize on this opportunity?

What Is Giveaway?

The term “giveaway” refers to the extra product included in a package beyond the labeled weight or volume. For instance, if a package is labeled to contain 500 grams but actually contains 525 grams, those additional 25 grams constitute the giveaway. While this might seem like a small difference, over time and large production volumes, it translates to significant losses in potential revenue.

Let’s take a closer look at how this affects your bottom line. If you’re selling products at a fixed weight basis and the package consistently contains more than promised, your company is effectively giving away extra product for free, reducing overall profitability.

Why Focus on Reducing Giveaways?

Reducing giveaways can lead to significant cost savings, improved operational efficiency, and enhanced profitability. Here are some key ways to achieve this:

  1. Automated and Advanced Batching Equipment. Precision batching systems ensure accurate measurements during production, reducing overproduction and minimizing giveaways.
  2. Automated Check Weighing Devices. These systems continuously monitor the weight of packages, allowing for real-time adjustments to maintain accuracy.
  3. Packing and Labeling Solutions. Both manual and automated systems can streamline processes and improve consistency in packaging.
  4. Software Solutions. Implementing software to monitor and manage packing operations provides actionable insights and enables tighter control over production processes.

How to Calculate Giveaways

Understanding your giveaways begins with measurement. Below are examples of how giveaways are calculated across different food processing sectors:

Industry

Labeled Weight/Volume

Actual Weight/Volume

Giveaway Weight

Giveaway Percentage

Meat Processing

500 grams

525 grams

25 grams

5%

Dairy Processing

1 liter

1.05 liters

0.05 liters

5%

Snack Food Processing

200 grams

210 grams

10 grams

5%

These examples show how even small differences can add up, significantly affecting costs over time. For instance, just 10 grams of overweight can result in a 5% giveaway.

Now, let’s take a look at how much you could lose annually with a 5% giveaway and how reducing it by 3% could lead to significant cost savings.

A Business Case Study

Let’s consider a hypothetical scenario to demonstrate the potential savings:

Scenario:

  • Daily Production: 10 tonnes of product A
  • Production Days: 250 annually
  • Sales Price: €1.50 per kilogram
  • Current Giveaway: 5%
 

Calculation:

Category

Weight

Percentage

€

Annual Production of Product A

2,500,000 kg

  

Average Sales Price

  

1.50 €/kg

Current Giveaway

125,000 kg

5%

187,500 €

Reduced Giveaway

50,000 kg

2%

75,000 €

Profit Gain

  

112,500 €

In this case study reducing the giveaway by just 3% saved a company over €112,000 annually. While the numbers are hypothetical, they are realistic and reflective of actual industry scenarios.

Other examples

Dairy products manufacturing example

Imagine a dairy company producing yogurt in 1-liter bottles. By using advanced check weighing devices and monitoring software, they notice a consistent 0.05-liter overfill in each bottle. Over a year, this small overfill results in a substantial loss. With optimized equipment and monitoring, they bring the overfill down to 0.01 liters, saving thousands of euros annually.

Snack Food manufacturing example

Or consider a snack food manufacturer that reduces its giveaway percentage from 5% to 3% by implementing precision packaging technology. Over time, the financial and resource savings dramatically improve the company’s profitabilit

ScanPlant Solution

Here is an example of a Scanplant NG packing station allow to weight various type of products, and managing the give aways through upper and lower limits on the product being weighed and labelled (see in the photo inside the red square).

Later with this control it is possible to move the products, which are outside the weight range, to the reject and make the production and business decisions better. 

Ready to Unlock Your Potential?

As we’ve seen, reducing giveaways isn’t just about cutting costs—it’s about optimizing operations and maximizing profitability. With the right tools and strategies, businesses can achieve significant savings while maintaining product quality and customer satisfaction.

Want to learn better how to minimize giveaways and streamline your production? Join our free online webinar:

📌 Topic: Digitalization in Manufacturing- How to Optimize Production and Reduce Product Giveaways
📅 Date: February 28
⏰ Time: 10:00 (EET)

In this webinar, we’ll dive deeper into real case studies and practical methods to improve processes and reduce giveaways in manufacturing, with a special focus on dairy product processing.

👉 Register here:  Webinar Link

The post Unlocking the Potential to Reduce Giveaways and Overproduction appeared first on PERUZA.

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