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 Whether caused by outdated automation or imprecise manual work, even the smallest overfill adds up fast across high-volume operations.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.
- 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.
Case Study
One of our clients- a high-volume poultry processor- faced a common challenge in drumstick packing: manual labor, high giveaway and inconsistent results. Their process relied on 9 workers manually weighing and packing each portion. While functional, this setup led to an average overweight of 7%, eating directly into profits with every batch.
After installing PERUZA Reduced Giveaway Line, the transformation was immediate. The system was fully integrated with minimal disruption to existing workflows and adapted quickly to the specific geometry and handling needs of drumsticks. Now in the packing process only 3 people is needed and from 7 % giveaway dropped to just 1%, saving significant product volume daily. Not only did the system pay off in reduced waste, but it also delivered greater consistency, hygiene, and reliability- setting a new benchmark in their packing line performance.
Metric | Before (Manual Packing) | After (PERUZA Reduced Giveaway Line) |
Number of Operators | 9 people | 3 people |
Average Giveaway | 7% | 1% |
Packing Method | Manual | Automated |
Consistency of Packing | Variable | High precision |
Conclusion
In modern food production, precision isn’t a luxury- it’s a necessity. Every gram given away is margin lost, and relying on manual processes or outdated systems only multiplies the damage over time. With rising production demands and tightening profit margins, the smartest move a business can make is to automate with purpose.
PERUZA Reduced Giveaway Line is built for that purpose. It does what humans can’t: calculates, weighs, and optimizes with relentless accuracy and consistency. No guesswork. No excess. Just intelligent packing that pays for itself—batch after batch.
Let the machine do the math—so you don’t have to.
PERUZA Demo Days 2025
We’re inviting forward-thinking professionals to experience PERUZA Reduced Giveaway Line live in our Demo Days 2025.
PERUZA Demo Days 2025:
Location: PERUZA Showroom, Lejasrandoti, Mucenieki, Latvia
Dates: August 19 and 20, 2025 (you can choose which date suits you better)
Register for the Demo Days 2025 here to reserve your spot and experience the future of raw product packing up close.
Join us to see the equipment in action with your product, ask questions live and explore how it can fit your production line.
