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petfood pro 1/2021

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processing Success Factors for the Efficient Production of Dry Food and Snacks by Thomas Wenk Roughly two thirds of all pets in Germany and the EU are cats and dogs. In terms of numbers and sales volume, these two pet species are also the most important ones on a global scale. Dog and cat owners expect an increasingly wide range of high-quality pet food. New products and presentation are in demand. Cat and dog food can essentially be divided into the categories of wet/moist food, dry food, semi-dry food, snacks and raw or BARF food. In terms of global pet food product launches, dry food, treats and snacks are among the most innovative product categories in the pet food sector. The market is developing rapidly and is subject to significant change. The marketing and associated presentations of these products play a significant role. As a producer, it is important to identify and implement trends quickly and flexibly if you want to remain competitive. The automated production of dry food, treats and snacks for dogs and cats is demonstrated in the following. Product variety and economic efficiency through flexible systems with automation potential The trend towards innovative products continues apace. This also holds true on an international scale: The countries with the most new product launches are the USA, UK, Japan, Germany and China – the major markets for pet food. Especially here in Europe, private labels and private label products are Product trends in the pet food market 8,707 USA 1,624 France playing an increasingly important role, and producers are therefore under mounting pressure from the food retailers to come up with innovations. Cubes, pellets, sticks and bars are the trends of the moment in the dry food and snack segment. To satisfy these trends, producers need to offer innovations such as new products types or shapes. This requires flexible production systems that can easily and automatically produce different product types and shapes. With the exception of mono-production, the entire production line must be used flexibly for a variety of products to ensure its full utilizuation. The decisive factors here are mobility, modular design, simple setup, open interfaces and a straightforward line control 1,391 Mexico 1,319 Brazil The global pet food market: The top 5 markets worldwide by sales in metric tonnes (in thousands) with the USA as the most important market. Source: Mintel Group 1,268 Germany system. When there is a shortage of skilled workers, automated or semi-automated production can minimize the need for skilled personnel. Handtmann offers modular technology with automation options for the production of dry food, snacks and treats. The production process is always based on portioning accurate to the gram by a Handtmann vacuum filler. Diversity is created through the flexible combination with forming systems. Technology can be used either for the multilane, free forming of 3D products, such as balls, cones and nuggets, or the multilane forming and cutting of 2D products, such as slices, pellets, sticks and bars as well as paws, hearts, stars and countless other shapes. Production onto racks and trays is possible to enable subsequent processing. In the case of production onto belt, downstream automation processes can be easily integrated thanks to the interface capability of the Handtmann modules. This can include, for example, feeding products to the packaging solution. Process variety with a consistently high product quality High-quality and robust technology is required to ensure consistent top quality in the high-performance production of dry food products. First and foremost, for 22 Technology & Marketing

processing VF 800 vacuum filler with FS 510 forming system for forming and cutting producers who want to satisfy the trend towards premium pet food, it is essential to preserve the quality of the raw material in a gentle production process. The crucial process step here is the filling and portioning of the product. With Handtmann technology, this takes place in the vacuum filler, which simultaneously pumps the product to the auxiliary device – this is the forming system in the example of dry food and snacks. Handtmann vacuum fillers work according to the principle of the vane cell feed system. This type of feed system is characterized by a very short product path and an operating principle that is designed to reduce the stress on the product through friction and shear during the pumping process to a minimum. The rotor in the feed system turns clockwise. Cells are formed on the left side and are evacuated by a vacuum. The evacuated feed system cells move towards the inlet opening of the hopper. As soon as they pass the opening, the filling product is gently fed into the cells by the vacuum, filling them completely. The filled cells continue to move in direction of the feed system outlet, where the filling product is ejected. This vane cell technology ensures maximum product protection, including at industrial throughputs of several tonnes per hour. Production of training reward treats During the production of snacks and treats using a Handtmann forming system, the vacuum filling machine pumps the product to the flow divider. The flow divider is part of the forming system. The large diameter of 65 or 80 mm allows for a low system pressure and constitutes another important component for gentle product handling during the production process. The product flow is then divided into multiple lanes in the flow divider. Up to 24 lanes are possible at the same time. The flow divider contains 24 small feed systems with adjustable servo drives, which eliminate the need for work at high pressure and ensure the gentle division of the product flow onto the 24 lanes. Above all, this gentle process ensures that the chunky inserts remain in the product. Economical production thanks to the minimization of give-away Finished packaging directives state that, on average, the nominal filling quantity is not to be fallen below and the values specified for the negative deviation from the nominal filling quantity are not to be exceeded (TU1/TU2). The aim is to bring the average filling quantity of a product as close to the declared nominal filling quantity as possible. Everything that FEED AND BIOFUEL FLAWLESS QUALITY FOR THE MOST DEMANDING CUSTOMERS HOW CAN WE HELP FEED YOUR BUSINESS? LET‘S FEED YOUR BUSINESS The growing demands of today’s pet food market require increasingly special ized knowledge, together with advanced processing technologies. As a longtime partner to hundreds of premium pet food producers world wide, ANDRITZ provides comp rehen sive processing solutions and after market services to keep your oper ations ahead of the curve. All to guarantee easy, safe, and efficient operations that can quickly adapt to the next market trend. Find out how our world-class processing solutions and services can feed your business at andritz.com/ft. Issue 1 2021 ANDRITZ FEED & BIOFUEL A/S ⁄ Europe, Asia, and South America: andritz-fb@andritz.com USA and Canada: andritz-fb.us@andritz.com ⁄ andritz.com/ft 23

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