What command line options did you use with PerlApp?

One thing you might try is the --trim command line option: --trim Errno;File::Glob (these two modules are loaded by default and can be trimmed provided that you don't use globs or the magic %! hash) as well as removing any unnecessary modules from your script.

You might also try using the --xclude command line option as well and including the perl5x.dll with your app. (Check the documentation to see if this is legal for your particular application.)

Other considerations that may or not be relevant: when is the last time you did a a) virus scan, b) disk scan, c) defragmentation?