Case Study

How Wootz.work Automated & Scaled Meal Prep from 250K to 1M Meals per Month

Industry

Beverage

Constraint

High SKU complexity, manual operations, and lack of process traceability

Objective

Design and deliver a fully automated, eco-friendly, traceable meal preparation and packaging line for 40+ SKUs across 2,000+ unique daily combinations.

The Challenge

Wootz.work’s client, a leading UK F&B brand, faced growing operational constraints when scaling its chilled meal production

01 Process Inefficiency

Manual case packing and portioning led to inconsistent weights, low throughput, and frequent escalations from customers. And this led to errors, slowed production, and increased manpower requirements.

02 High Mix Complexity

Managing 40+ SKUs and 2,000+ unique daily combinations demanded precise portion control and flexible line setups, something manual processes couldn’t sustain.

03 Lack of Traceability

Without digital tracking, it was nearly impossible to trace product genealogy or identify process deviations, risking compliance failures and loss of customer trust.

Result

Declining productivity, inconsistent quality, and mounting regulatory risk.

The Approach

Wootz.work’s engineering and automation teams developed a turnkey solution — a CE-certified, ergonomic meal preparation line — designed for high throughput, sustainable, plastic-free packaging, and full digital traceability.

01 Smart Portion Control

Delivered a fully automated prep line equipped with automated scales, metal detectors, and check weighers for consistent, compliant portion control.

02 Sustainable Packaging

Implemented a Pick-to-Light automated case packing system with eco-friendly, moulded-fiber bowls, enabling high-mix packaging accuracy while doubling operator productivity.

03 Traceable Production

Integrated PackML-compliant printing and labelling, powered by Wootz.work’s proprietary software for real-time traceability across SKUs and production batches.

04 End-to-End Ownership

Managed coordination across 25+ vendors in India and Southeast Asia, ensuring the system was delivered ready-to-run with complete supply chain ownership.

The Outcome

The F&B manufacturing unit rapidly automated its meal prep operations with better portion control and replaced plastic with biodegradable, moulded-fiber bowls.

250K to 1M meals/month

expanded production capacity

2x increase

In workforce efficiency

100% digital traceability

across SKUs and batches

Fully CE-certified system

to ensure process reliability

Wootz.work’s automated solution transformed the client’s meal preparation and packaging process, delivering faster rollouts, stronger compliance, and consistent quality across thousands of product variations with precise portion control.

Want to stop losing hours to manual packing and portion errors and automate your production?