Trends revolutionizing pet food manufacturing equipment

Many manufacturers are discovering that their existing production machinery requires an upgrade if they want to remain competitive in today’s pet food market. This is being driven by 2 main trends: the rising demand for human-grade pet food, and the growing importance of sustainability. We asked a few equipment manufacturers to share their insights into the market developments.

Explosion of interest

As the name suggests, Pennsylvania-based Reading Bakery Systems started out as a bakery equipment supplier; the founders didn’t initially intend to get into the pet food business. But when the company purchased a cookie/cracker equipment manufacturer in the early 2000s, the owners realized the equipment could also be used to make treats for pets. Over the past few years, the firm has seen an explosion of interest from pet food companies looking to make human-grade and human-like baked pet food.

“The machinery is more expensive, but profitable in the longer term. People are willing to pay more for the end products, so you can make a lot more money even though production capacity of the line is lower,” says Dulcie Freymoyer, VP of Marketing.

Equipment upgrades

Animal feed equipment firm KSE Process Technology attributes the trend to the ongoing humanization of pets. Consumers increasingly make decisions based on the perceived healthfulness and quality of pet food, just as they would for other members of the family, according to Martijn van Eijk, the company’s North America Area Sales Manager for the pet food group.

Meanwhile, Todd Olmstead from processing equipment manufacturer Marlen says that this shift – and the demand for human-grade and fresh refrigerated products that has come with it – has brought new companies into the pet food manufacturing equipment segment as well as prompting existing companies to innovate to keep up with the competition.

Higher standards among consumers, the introduction of a wider array of ingredients – including more vitamins and minerals – and the greater diversity of recipes, have all increased the complexity of pet food manufacturing. This is driving manufacturers to upgrade their equipment and software.

Inspiration from human food processing

“With the increase in demand for human-grade pet food, we’ve seen companies looking at new equipment that they previously wouldn’t have needed or even thought of when producing pet food,” Olmstead comments. The technology in general might not be new, he says, but it’s new to pet food manufacturers.

Freymoyer has noticed interest in co-extrusion equipment that can create filled treats for pets. “We’re seeing a lot of high meat content. But besides that, if you’ve walked through the pet treats aisle, you’ve probably seen Oreo-type cookies: filled pretzels without the salt,” she states. “They’re not just human-grade; they actually look like human treats.”

To identify technologies that can be applied to pet food production, manufacturers are not only looking to the baking sector for inspiration – as Reading Bakery Systems has experienced – but also to the ready-to-eat sector. According to Olmstead, a growing number of customers are looking at buying equipment like spiral ovens and dicers.

Concern about environmental impact

It’s not just human-grade pet food that is affecting manufacturers’ equipment choices though. With consumers increasingly concerned about the environmental impact of the pet foods they buy, more manufacturers are asking about energy-efficient equipment and other sustainable options, including the use of alternative fuels.

This has prompted Reading Bakery Systems to offer more energy-efficient ovens, says Freymoyer, and also to begin looking at the next generation of baking equipment. The company has recently added electric ovens with gas penthouses to its line of offerings. This should make it easier for pet food manufacturers to reduce their carbon emissions by switching from gas to all-electric operations. In response to customer inquiries, Reading Bakery Systems has also experimented with other alternatives to gas – including hydrogen – and has various tests in the pipeline.

KSE is similarly working with manufacturers to help them proactively reduce greenhouse gas emissions. According to Van Eijk, upgrading equipment can reduce energy consumption. For example, movable mixers eliminate the need for energy-intensive machinery such as conveyors, chains and pneumatic systems.

The wave of the future

While the human-grade and sustainable pet food trends are already here, the biggest trend on the horizon for manufacturers is automation, believes Olmstead. Automation can help manufacturers cope with many of the challenges they face in today’s market, such as high costs for materials and labor.

“Manufacturers are embracing sustainable practices and addressing labor shortages through automation,” agrees Martijn van Eijk. Automation can also reduce human error, leading to enhanced product quality and reliability, while also increasing efficiency and reducing waste.

Moreover, automated equipment is increasingly intelligent, offering potentially innovative solutions such as fully automatic container transfer and flexible container weighers. This kind of smart equipment can allow manufacturers to take advantage of automation without losing the flexibility that is needed to shift between products and adapt to rapid changes in market expectations.

Versatile and intelligent

According to Van Eijk, equipment must be versatile, intelligent and capable of handling various products and recipes. Reporting tools associated with smart technology can also help manufacturers gain greater insight into their production processes to further lower costs, reduce errors, manage maintenance and energy use, and support compliance with supply chain traceability requirements.

“Responsible pet owners are conscious of what they feed their furry companions and demand transparency in the ingredients used,” comments Van Eijk. “A traceable supply chain, which guarantees contamination-free equipment and comprehensive track and tracing throughout the manufacturing process, has become essential.