I'd say introducing an intermediate tarball is just a waste of resources. I presume you're working in a team - how does your boss envision working in a team, and each member making tarballs? Do you handmerge?

At $WORK, we use git (no doubt a dozen or more other source control systems would work as well). Each developer checks out the source, goes to whatever branch (s)he's working in, and uses an environment variable (PERL5LIB!) to point to the sources. Production machines checkout from git as well; then use rsync to sync between machines that play identical roles. CPAN modules are distributed using yum and rpms; the handful of house-written XS modules are distributed using yum and rpms as well, to avoid having to compile C on production machines, which would slow down the deployment process.