Handling fragile and unstable products at the end of the production line is one of the most challenging tasks in manufacturing. Whether it’s delicate food and beverage items, easily deformable products like consumer packaged goods and pharmaceuticals or dangerous chemicals and building materials, traditional packing and palletizing methods often cause product damage, inefficiencies and high labor dependency.
Frozen products demand more from your end-of-line
Ice, weight and shape- a difficult combination
- Variable product geometry.
- Ice-coated surfaces.
- Cold and wet production environment.
- Mixed SKUs and formats on the same line.
- High throughput demands.
- Strict hygiene requirements.
A complete, synchronized end-of-line
–PERUZA approach to frozen product end-of-line automation combines three purpose-built machines into a single, communicating system. Primary packaging with precise target weight for each pack, case packaging with gentleness and palletization with stable, dispatch-ready pallets. Together they eliminate the bottlenecks, product damage and labour dependency that come with manual or partially automated lines.
Step 1 – Primary Product Packing
Before a single case is packed, product weight accuracy at the primary packing stage sets the tone for the entire end-of-line. PERUZA Reduced Giveaway Line is designed for exactly this: automatic, precise packing of raw frozen products- fish, seafood and meat- into trays, boxes or thermoformed packages, with minimal product overweight.
At the core of the system is a 3D dimension recognition and weight calculation unit. Products arrive on the conveyor one by one, are measured and weighed in real time and a signal is sent to the robot with the appropriate gripper to pick and place each product into its target packaging until the set weight range is reached. The result is consistently filled packs with significantly reduced giveaway- meaning less product given away for free and more profitability per unit packed.
The intuitive user interface allows operators to adjust weight ranges and switch between product types quickly, making it well suited to facilities running multiple frozen SKUs on the same line.
Key features:
- 3D dimension recognition and real-time weight calculation.
- Robotic pick-and-place into trays, boxes or thermoforms.
- Minimizes product overweight and giveaway with smart mathematics.
- Adaptable to frozen or fresh fish, seafood and meat.
- Fast changeover via smart operator interface.
- Compatible with traysealers and thermoformers downstream.
- Increases line capacity and profitability.
- Seamless integration with upstream and downstream equipment.
STEP 2 – PERUZA Side Loader
The PERUZA Side Loader is a horizontal case packer that loads products into corrugated boxes from the side. For frozen fish and seafood, this distinction matters enormously. Products that are stacked or dropped from above can shift, crack glazed coatings or compromise seal integrity. Side loading eliminates these risks entirely by guiding products smoothly and precisely into position before the box is sealed. Beyond the loading mechanism, the Side Loader handles the complete packaging sequence- from erecting the blank box, through product placement, to sealing and closing. One machine, one operator, zero compromise on hygiene or format flexibility.
Key features:
- Horizontal side-loading- no top-down product stress.
- Box making, packing and sealing in one machine.
- Adaptable to fish, seafood, meat and mixed formats.
- Handles fresh, frozen and IQF products.
- Multiple pack configurations per box.
- Seamless integration with upstream and downstream equipment.
- Designed for cold and wet production environments.
- Intuitive operator interface for fast format changeover.
STEP 3 – Palletization
Key features:
- Simultaneous palletization of up to 3 pallets.
- Advanced robotic gripper- handles varied case sizes.
- Automatic layer pad insertion between stacks.
- Self-adjustable between predefined product patterns.
- Flexible pallet configurations for export and retail.
- Full-pallet outfeed conveyor logistics included.
- Adapts to available factory floor space.
What the integrated system delivers
Minimized giveaway: The Reduced Giveaway Line uses real-time weight calculation and smart mathematic algorithms to ensure every pack is filled to the target weight- no more, no less. Less product overweight means direct savings on every unit packed.
Consistent case quality: Stable, well-formed cases from the Side Loader give the Robot Palletizer a reliable base for building strong, uniform pallets every time.
Reduced product loss: Gentle handling across both machines minimizes physical damage to frozen product, reducing waste and improving profitability per pallet.
Optimized throughput: Synchronized communication between machines eliminates bottlenecks- the line runs at matched speed without waiting or buffering.
Lower labour dependency: Automation of repetitive end-of-line tasks frees your workforce for higher-value activities while reducing exposure to cold-environment strain.
Format flexibility: Fast changeovers between SKUs, case sizes and pallet patterns mean you can run multiple product lines without reconfiguring hardware.
Scalable by design: The system is engineered to grow with your operation. Add capacity, integrate new lines or adjust pallet patterns as your business evolves.-
