Our client, a national foods manufacturer, produced fresh salads for national retailers in standard tubs ranging from 200g through to 1.5kg. As production staff had no access to real time data on fill weights there was limited ability to react to instances of significant overfill on the production line resulting in significant losses for client. Furthermore, management had limited reporting to drive systematic overfill improvement.

Our Solution

  • PCG's Pulse solution was implemented across all lines with electronic check-weighers
  • Line staff were given a tailored dashboard which enabled them to immediately address overfill issues
  • PCG Solutions worked with management to develop a customised reporting suite that enabled them to target problem areas and develop ongoing performance improvement plans


  • After three months our client reduced its overfill by over 32%