Batch-driven optimization streamlines costs in pet food manufacturing

Managing the complexities of raw material batches presents a constant challenge for pet food companies. You need to balance content, shelf life, and quality while upholding product standards and complying with production regulations.

Addressing the challenge

This issue is especially acute in meat-rich wet foods, where raw material availability and prices shift rapidly. Each batch comes with its own unique characteristics and complexities to meet standard formulation requirements.

Traditionally, manufacturers have relied on standard formulations and averages with large safety margins. However, this approach requires constant manual adjustments and monitoring, leading to inflated costs and squeezed profit margins.

Optimizing by the batch: reducing waste and costs

Software solutions help wet food manufacturers optimize production at the batch level. Rather than relying on averages, it’s based on what’s actually on their shelves and in their machines.

By continually factoring in the quality, price and batch parameters (like shelf life) of current stock in individual lots and production orders, you can deliver products that precisely meet specifications.

Consistent quality

What if nutrient values in your raw-material lots show high variability? Optimization software adjusts each production order and proposes a better composition based on the exact inventory on hand.

This ensures that the end product maintains consistent quality, meeting both customer expectations and regulatory requirements.

Adapting to production constraints

Optimization tools also take into account production rules and logistical constraints.

By considering factors such as shelf life, production line capacities and stock management priorities like ‘first in, first out’, manufacturers can eliminate the need for manual interventions that often disrupt production schedules and impact costs.

Enhanced traceability

With compositions varying by batch, traceability is key. Advanced systems track each optimized order, ensuring producers have a clear record of material lots used, as well as quality and pricing data.

This transparency supports both quality control and regulatory compliance efforts.

Agility and competitiveness

Pet food manufacturers adopting real-time optimization tools are finding that a data-driven approach to batch management can significantly reduce costs, increase efficiency and enhance product quality in an ever-changing market.

And with constantly fluctuating raw material prices and quality, batch optimization allows manufacturers to stay agile and maintain a competitive edge while keeping costs in check.