Automation with purpose
How Danforel and GEA are scaling sustainable seafood production
For more than 80 years, Danforel has been producing premium hot smoked trout in Denmark. With full control over its value chain, from hatching eggs and raising fish to processing, packaging, and distribution, the company has built its reputation on quality, freshness, and traceability.
Today, Danforel processes approximately 30 tons of fish per day and supplies retailers across Europe, with Germany representing a key market. Growing demand has also expanded the company's presence in Australia, the United States, and Asia.
As production volumes increased and labor availability became more challenging, Danforel began looking for new ways to improve efficiency while maintaining the high quality standards expected by its customers.
Customer Profile
Danforel is a Denmark-based seafood processor with more than 80 years of experience in producing premium hot smoked trout.
Located in Jutland, the company manages the entire value chain, from fish farming to processing and packaging, ensuring full traceability and quality control. To further improve efficiency and product handling, Danforel partnered with GEA and implemented an integrated packaging solution consisting of the GEA OptiRobot and the GEA PowerPak 7000.
The investment has delivered significant results, including a 50% reduction in giveaway, improved ergonomics and working conditions for employees, reduced manual handling of delicate fish products, increased flexibility in packaging operations, and enhanced overall production efficiency.
Full ownership from egg to package
Danforel's business model is built on complete control of the production process. Fish are raised on the company's own farms before being processed, packaged, and shipped to customers worldwide.
This approach provides full traceability and consistent product quality while supporting the company's long-term commitment to sustainability and responsible resource management.
"We are owning this fish all the way through"
Steffen Nielsen
CEO of Danforel
Steffen Nielsen, CEO of Danforel
The challenge: handling a delicate product more efficiently
Hot smoked trout fillets require careful handling throughout the packaging process. At the same time, Danforel was working to address two significant operational challenges.
First, the company wanted to reduce giveaway, the practice of overfilling packs to ensure declared weights are met. While common throughout the food industry, giveaway represents a direct and ongoing cost for manufacturers.
Second, like many food producers across Europe, Danforel faced increasing labor shortages. Repetitive manual packaging tasks were becoming more difficult to staff while also creating ergonomic challenges for operators.
The company needed a solution that would improve efficiency and accuracy without compromising product quality or damaging the delicate fish fillets.
GEA OptiRobot
The solution: one integrated packaging line
After evaluating several suppliers, Danforel selected GEA as its automation partner. What began as a collaborative development process evolved into a fully integrated packaging solution combining the GEA OptiRobot loading system and the GEA PowerPak 7000 thermoforming packaging machine.
The GEA OptiRobot automates the loading process by gently picking and placing individual trout portions into the package with high precision and repeatability. This significantly reduces manual handling while ensuring consistent product presentation.
Integrated directly into the line, the GEA PowerPak 7000 forms and seals each pack while providing the flexibility to adapt packaging formats, weights, and materials as customer and retailer requirements evolve.
Together, the two solutions create an efficient end-to-end process from portioning to final packaging, reducing manual touchpoints and improving production consistency.
From skepticism to confidence
Introducing robotic handling for delicate fish products represented a major technological shift. Initially, Danforel questioned whether automation could match the precision and care of manual handling.
Following implementation, however, the results quickly demonstrated the system's capabilities. The automated loading process consistently handled products with the speed, accuracy, and gentleness required for premium smoked trout, helping to build confidence in the new production setup.
GEA Fish-Line
"We see that we have halved our giveaway."
Steffen Nielsen
CEO, Danforel
The results: reducing giveaway and increasing competitiveness
Using GEA's InsightPartner digital performance tools, Danforel was able to monitor and verify these improvements with measurable production data.
Lower giveaway directly improved product yield and reduced unnecessary product loss. At the same time, greater loading accuracy and packaging consistency helped improve overall operational performance.
The benefits extended beyond cost savings. By automating one of the most labor-intensive production steps, Danforel reduced repetitive manual handling and improved workplace ergonomics for employees.
The flexibility of the GEA PowerPak 7000 also allows the company to respond more quickly to changing retailer and consumer demands. Packaging weights, formats, and materials can be adapted more efficiently, helping shorten lead times while supporting evolving sustainability requirements.
Building the future together
For Danforel, the project is more than a single automation investment. It represents an important step in a broader strategy focused on innovation, competitiveness, and long-term growth.
As customer expectations continue to evolve and global competition increases, Danforel sees automation as a key enabler for maintaining product quality, operational efficiency, and sustainable production practices.
"This is not a short-term partnership. This is a long-term partnership because we need to evolve together."
Steffen Nielsen
CEO, Danforel
Our service & support
Partnership that goes beyond equipment
With GEA, you get more than a machine – you get a trusted partner.
- Installation & commissioning support
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