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petfood pro 3/2022

PetFood PRO is the international magazine for executives and specialists in the manufacture of food for domestic animals – the pet food industry. The magazine focuses on food and delicacies for dogs, cats and other small animals, ornamental birds and fish, as well as animals kept in terrariums. We publish feature articles, reports and announcements about new ingredients, technology, equipment and processes, packaging machinery and materials as well as marketing trends and developments. Readers are executives, product developers and specialists in the pet food industry, including process and packaging engineers. PetFood PRO will be published in English. Circulation is worldwide, with an emphasis on important growth markets.

PetFood PRO is the international magazine for executives and specialists in the manufacture of food for domestic animals – the pet food industry. The magazine focuses on food and delicacies for dogs, cats and other small animals, ornamental birds and fish, as well as animals kept in terrariums.

We publish feature articles, reports and announcements about new ingredients, technology, equipment and processes, packaging machinery and materials as well as marketing trends and developments. Readers are executives, product developers and specialists in the pet food industry, including process and packaging engineers. PetFood PRO will be published in English. Circulation is worldwide, with an emphasis on important growth markets.

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International Magazine September 2022 ISSN 2628-5851

Technology & Marketing 3/22

Ingredients: Plant-Based Food, Black Soldier Flies, Fibers and Cellulose, Grain Acceptability

Processing: Wet Petfood Processing, Quality Control, Heat Exchangers, Mixing

Packaging: Pouches and Alutrays, No Waste, Weighing Investment


EDITORIAL

What’s a Dog’s Dinner?

As most of us probably know, October

10th is World Dog Day. Or maybe it isn’t,

since many of these ‘Days‘ are nebulous at

best. Canine parents know that every day

is dog day, but at least it gives us a chance

to think about dogs for a few lines.

Dogs have been our partners for as long

as we can think and look back. We have

always cared for them as well as we knew

how to. It was always assumed that dogs

eat meat and vegetables, but also other

things and they are not really all that

fussy. New research is always popping up

to show us something different.

We all agree that a dog's diet has a huge

impact on its health and happiness. The

wrong diet can lead to obesity and lifelong

health issues, just like with their

human parents, so it's important to feed

them the right food to keep them at a

healthy weight and make sure they're

getting all the nutrients they need.

Vets recommend feeding a high-quality,

complete diet suitable for the dog’s life

stage. Here are some suggestions, which

the pet food industry and pet owners

alike will definitely want to know about.

Complete: Always seek out a food that is

‘complete’ because this means it contains

all the nutrients that a dog needs, in the

correct amounts. Commercially available:

It’s really difficult to give your dog

everything they need in a homemade

diet, so we recommend always buying a

commercial dog food rather than making

your own at home. Life stage appropriate:

Make sure a dog is fed the right food for

their current stage of life (puppy, adult or

senior). Wet vs dry: Complete diets can

come in wet or dry forms. Many owners

choose to feed a combination – you’ll just

need to make sure that you’re feeding the

right amount of each by looking at the

packets and working out the amount of

each one you need to feed. Ingredients:

While it’s nice to know what’s in your dog’s

food, the ingredients list can be baffling!

Rest assured that all ingredients need to

legally pass a vet inspection, so it doesn’t

matter which you choose, as long as your

dog is happy eating it.

Feeding a dog the right amount of food is

really important. Just like us, no two dogs

are the same so the type and amount of

food a dog will need varies depending on

their breed, type, age, health and lifestyle.

Ian D. Healey, Editor-in-Chief

A working sheepdog for example, needs

much more energy than a smaller dog

who spends most of the day indoors!

It’s amazing how much of this advice is

relevant to make our pets happier! Finally,

a reminder that a treat or reward should

be used sparingly. This also applies to

dogs.

Sincerely

If you like it subscribe!

Issue 3 2022

3


CONTENTS

International Magazine September 2022 ISSN 2628-5851

Technology & Marketing 3/22

Ingredients: Plant-Based Food, Black Soldier Flies, Fibers and Cellulose, Grain Acceptability

Processing: Wet Petfood Processing, Quality Control, Heat Exchangers, Mixing

Packaging: Pouches and Alutrays, No Waste, Weighing Investment

Issue 3 September 2022

United Petfood Producers is one of the largest private label manufacturers of premium

dog and cat food, biscuits and snacks, with plants across Europe. In an extremely

competitive market, the highest product quality is essential, and the company has

invested heavily to become one of the most technologically advanced and bestequipped

suppliers of dry pet food globally. Read the article on page 38

Cover: © Ishida Europe

Ingredients

Processing

6 The Pendulum Effect

10 The Power of Peptides in the Pet Health Journey

12 Malaysia’s First Sustainable Dog Food with Black Soldier Fly

Larvae (BSFL) as an Alternative Protein source

14 Multifunctional Pet Food Products With Fibers From Nature

17 Plant-Based Proteins for More Sustainable Pet Food

20 Pet Flour Quinoa

22 How Continuous Food Processing Equipment Holds The

Secret To Better Pet Food

24 Quality Control in Pet Food Processing

25 Twin Screw Loss-in-Weight Feeder for Pet Food Ingredients

26 Ultimate Processing of Proteins with New Dicer Generation

27 Highly Efficient Extraction System for Optimized Valorization

of Functional Nutrients

28 Making Even the Impossible Possible : Flexible and Efficient

Due to the popularity of plant-based ingredients, the percentage

of plant proteins in pet food formulations has increased. The

most used products are traditional ingredients such as corn,

gluten meal, vital wheat gluten and soy protein, as well as other

options like rice, pea, potato and sunflower. More recently,

innovative ingredients like single cell protein and Lemna protein,

have started to make an appearance in pet food formulations.

Take a look at our story on page 17.

Thermal processing is a key part of pet food manufacturing, with

processes including heating (pre-conditioning), cooking, drying,

pasteurizing and cooling. However, the thick, viscous nature

of many of the meat-based products presents challenges for

handling, heating and cooling. Scraped surface heat exchangers

are particularly well suited for pet food processing, including

heating ingredients. At the same time they can ensure gentle

handling to preserve produce integrity and texture. See page 32.

4

Technology & Marketing


Departments

3 Editorial

42 Upcoming Events

42 Impressum

Marketing

Come and see for yourse

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International Magazine March 2022 ISSN 2628-5851

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Technology & Marketing

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Perfec

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32 The Role of Heat Exchangers in Pet Food Production

Our publications include:

40 AFB International to Create over 100 New Jobs in

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Columbus GA

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34 wPouch and Alutray Expertise

36 No Waste Through Innovative Highlights in Plastic and

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38 Weighing Investment Reduces Costs For Pet Food

The international specialist magazin

Manufacturer

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The international specialist magazines from Dr. Harnisch You can now explore Publications

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website, and with easily a usable clear applications. focus on Alongside responsive the design Take a look and at general www.harnisch.com information

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Our publications include:

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and easily usable applications. Alongside the

free-to-use digital magazine editions, you will

“From our perspective, it's not about choosing between paper

or plastic packaging, it's about finding the best, most ecoefficient

and best performing packaging for the respective

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Issue 3 2022

5


INGREDIENTS

The Pendulum Effect

Acceptability of Soy, Corn & Wheat for Today’s Pets

The pendulum of public opinion

may be swinging back toward a

positive view of soy, corn, and wheat

for pets. OutsideVoice SM is one

consumer research tool used by the

global ingredient specialist ADM to

quickly gain insights on the attitudes,

preferences, and behaviors of today’s

consumers. Using this proprietary tool,

SOY

the ADM Pet Solutions team sought

CORNto

understand current perceptions about 6%

soy, 15% corn, and wheat in today’s pet

CORN

19%

foods, especially considering growing

interest in plant-based 6% ingredients and

sustainability. 19%

WHEAT

65%

75%

6%

6%

16%

75%

Three independent consumer surveys

conducted by ADM revealed 80% of

today’s US pet owners are intentionally

seeking or open to soy, corn or wheat

in their pet’s food and treats (Figure 1).

While 20% of today’s pet owners are still

avoiding these ingredients, they do not

represent the majority of pet parents.

This is welcomed news for pet food

nutritionists and formulators

WHEAT

who have

long recognized the excellent 6% nutritional

and functional properties 16% of these legacy

WHEAT

ingredients for pet foods and treats.

This changing 6% paradigm also provides

16%

more opportunities for manufacturers to

78%

1. U.S. Pet Parent Perceptions of Soy, Corn & Wheat for Their Pets

arent Perceptions of Soy, Corn & Wheat for Their Pets

hinking about what you feed to your pet (food / treats), please indicate whether you are

eliberately avoiding/reducing OR seeking/adding INGREDIENT in your pet's daily diet.

t you feed to your pet (food / treats), please indicate whether you are

ptions of Soy, Corn & Wheat for Their Pets

g/reducing OR seeking/adding INGREDIENT in your pet's daily diet.

ur pet (food / treats), please indicate whether you are

seeking/adding

20%

INGREDIENT in your pet's daily diet.

develop pet products that mimic human

foods and snacks due to the popularity and

widespread use of these ingredients in the

human food industry.

Based on survey results, today’s pet parents

are seeking or open to soy, corn, and wheat

for their pets because they recognize

and desire the nutritional and health

benefits these ingredients provide to their

pet (Figure 1). Flavor and digestibility

aspects of these ingredients were also

listed as key motivators for choosing pet

products with these ingredients as well as

recommendations from their veterinarian.

Figure 1. U.S. Pet Parent Perceptions of Soy, Corn & Wheat for Their Pets

Figure CORN 1. U.S. Pet Parent Perceptions of Soy, Corn & Wheat for Their Pets

Thinking about what you feed to your pet (food / treats), please indicate whether you are

deliberately avoiding/reducing OR seeking/adding INGREDIENT in your pet's daily diet.

19% Thinking about what you feed to your pet (food / treats), please indicate whether you are

deliberately avoiding/reducing OR seeking/adding 78% INGREDIENT in your pet's daily diet.

n = 4,381

n = 982

SOY

n = 979

CORN

WHEAT

June 2021*

Nov 2021*

Nov 2021*

75% SOY

78% CORN

6% WHEAT

6%

n = 982

20% 15% n = 979

19%

16%

Nov

Avoider

2021*

Seeker

Nov

Open-Minded

2021* 6%

6%

20% 15%

19%

16%

* Source: ADM Outside Voice SM

Avoider n = 982 Seeker Open-Minded

n = 979

Nov 2021*

Nov 2021* 65%

Seeker

65%

Open-Minded

75%

* Source: ADM Outside Voice SM

n = * 4,381 Source: ADM Outside Voice SM

n = 982

June 2021*

Nov 2021*

n = 4,381

n = 982

n = 979

June 2021*

Nov 2021*

Nov 2021*

Figure 1. US pet parent perceptions of soy, corn & wheat for Avoider their pets Seeker Open-Minded

75%

78%

78%

n = 979

Nov 2021*

Avoider Seeker Open-Minded

* Source: ADM Outside Voice

* Source: ADM Outside Voice SM

Table 1. US pet parent perceptions of soy, corn & wheat for their pets

6

Technology & Marketing


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PET FOOD

TASTE GREAT. TM

PALATANT SOLUTIONS AND SERVICES

In an increasingly competitive marketplace, palatability is a critical component of pet nutrition

and a key driver of brand loyalty. Ensuring product performance and repeat purchases for pet

food manufacturers – and their customers – is our business. Whether in a kibble, can, pouch or

cup, our palatants make pet food more appealing to pets and pet parents.

PALATANTS

We develop and produce a

full range of liquid and dry

palatability enhancers proven

to optimize pet enjoyment and

consumption.

SM

SERVICES

In addition to palatant expertise,

AFB supports our customers with

additional services. Technical

palatability trials, behavior trials

and an in-house pilot plant are

just some of the benefits we offer

our customers.

TECHNICAL PALATABILITY

Palatability trials to

measure a pet’s food

acceptance or preference

BEHAVIOR

Performance Beyond

Consumption SM

PILOT PLANT

Process research lab

producing palatants

and protypes

AFB International

Global Headquarters

St. Charles, Missouri USA

afbinternational.com

GLOBAL CUSTOMER SERVICE

1-800-218-5607

©2022 AFB International


INGREDIENTS

To understand the appeal of different

ingredients for pet foods and treats, the

survey participants were presented with

lists of various soy, corn, and wheat based

ingredients and asked the question:

Thinking about ingredients in your pet’s

food... When you’re buying your pet’s food

and look at the ingredients label, how

appealing would it be to see the following

(soy/corn/wheat) ingredients listed on

the label? 1 = not at all appealing; 5 = very

appealing. The ranking of the individual

ingredients from the most appealing to

the least appealing is shown in Table 2.

Table 2. Appeal of Corn, Wheat and Soy Ingredients to U.S. Pet Parents

Table 2. Appeal of Corn, Wheat and Soy Ingredients to U.S. Pet Parents

Table 2: Appeal of

soy, corn, and wheat

Thinking about ingredients in your pet’s food... When you’re buying your pet’s food and looking

ingredients to US pet at the ingredient label, how appealing would it be to see the following ingredients listed on the

Thinking about ingredients in your pet’s food... When you’re buying your pet’s food and looking

parents

label using a scale from 1 (not at all appealing) to 5 (very appealing)?

at the ingredient label, how appealing would it be to see the following ingredients listed on the

label using a scale from 1 (not at all appealing) to 5 (very appealing)?

More

Appealing

Neutral

Less

Appealing

Corn Ingredients 1

Wheat Ingredients 2 Soy Ingredients 3

Corn Ingredients Corn Wheat Ingredients Wheat

Soy Protein Conc.

More

Soy Ingredients 3

Ground Corn

Ground Wheat

Appealing Corn

Wheat

Soy Protein Conc. Soy Flour

Ground Corn Corn Meal

Ground Wheat Wheat Flour Soy Flour Textured Soy Protein

Corn Meal Corn Protein Conc.

Wheat FlourWheat Bran Textured Soy Soybean Protein Meal

Neutral Corn Protein Corn Conc. Grits

Wheat Bran Wheat Germ Meal Soybean Meal Soy Protein Isolate

Corn Grits

Corn Bran

Corn Bran

Corn Oil

Wheat Germ Vital Meal Wheat Gluten Soy Protein Isolate Soybean Grits

Vital Wheat Gluten Wheat Germ Oil Soybean Grits Soybean Hulls

Less Corn Oil Corn Germ Meal

Wheat Germ Wheat Oil Shorts Soybean Hulls

Appealing

Corn Germ Meal Corn Gluten Meal

Wheat Shorts Wheat Middlings

Corn Gluten Corn MealSyrup

Wheat Middlings

Corn Syrup

1,2 ADM Outside Voice SM Consumer Study, Nov. 2021

3 ADM Outside Voice SM Consumer Study June 2021

1,2 ADM Outside Voice SM Consumer Study, Nov. 2021

3 ADM Outside Voice SM Consumer Study June 2021

Corn, ground corn, and corn meal are

the most appealing of the corn-based

ingredients, while corn oil, corn germ

meal, corn gluten meal, and corn syrup

are the least appealing. Corn protein

concentrate, corn grits, and corn bran

are intermediate in their appeal to the

survey participants. Wheat, ground

wheat, wheat flour, buckwheat flour, and

wheat bran are the most appealing wheat

ingredients. In contrast, wheat shorts and

wheat middlings are the least appealing.

Wheat germ meal, vital wheat gluten, and

wheat germ oil are intermediate in their

appeal, but generally trend towards the

least appealing of the wheat ingredients.

For the soy-based ingredients, soy protein

concentrate, soy flour, and textured

soy protein are most appealing, while

soybean grits and soybean hulls are least

appealing. Soybean meal and soy protein

isolate are intermediate in their appeal to

today’s pet parents.

The survey results clearly show 4 out of

5 pet parents are willing to purchase pet

foods and treats containing soy, corn

or wheat with certain products being

more appealing than

others. Today’s pet

owners recognize

the nutritional and

health benefits these

ingredients provide to

their dogs and cats.

The pet food industry is

continuously evolving

and staying at the

forefront of trends is

paramount for success.

ADM’s consumer

insights suggest that

including soy, corn

or wheat ingredients

in pet foods and treats may not be as

negatively perceived by pet parents as

once thought. Ultimately, increasing

the ingredient options for use in pet

foods allows for the creation of a greater

variety of products to meet the individual

nutritional needs of pets while satisfying

the desires of today’s pet parents.

At ADM, you will find the industry’s most

comprehensive portfolio of pet food and

treat ingredients which includes a variety

of soy, corn, and wheat products. These

ingredients provide the nutritional and

functional needs for your products. They

also ensure your products are meeting

the desires and expectations of today’s

pet parents. When you partner with ADM

as your nutrition solution provider, you

also gain access to their team of scientists,

engineers, and nutrition experts that

can help you solve today’s problem and

develop tomorrow’s innovation.

Technology & Marketing

For more information

www.admpetnutrition.com

8

Technology & Marketing


INGREDIENTS

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Issue 3 2022

9


INGREDIENTS

The Power of Peptides

in the Pet Health Journey

Photo: Biomega

The history of humans and domestic pets

are inextricably linked. In fact, the term

‘animal connection’ may have played

a significant role in human evolution –

especially when you consider how some

animals transitioned from being seen

purely as food to that of a friend, and the

significance of this relationship.

This animal connection, or the process

by which pets or livestock become

companions and members of a human

family, started about 2.6 million years

ago, when we started studying animals,

Biomega®is a producer of premium

Norwegian salmon-based innovative

ingredients, both for premium petfood

and human nutrition. Biomega’s

business model is fully sustainable and

uses proprietary biotech to transform

high quality raw material into premium

food and petfood ingredients. In its

modern food grade biorefinery in

Norway, Biomega produces salmon oil

and peptides using enzymatic hydrolysis.

Biomega continuously invests in R&D

to ensure best-in-class technology and

respond to customers’ needs, including

traceability and sustainability.

and this close contact eventually led to

regular social interaction.

A new term, coined by highly regarded

anthropologist John Bradshaw, refers

to ‘anthrozoology.’ It describes the

interaction between animals and

humans and how in this two-way street

of interaction, pets and humans provide

each other with company, assist with

physical and mental health - crossing the

pet/human divide.1

Building on this close relationship, it is our

duty as the human caregivers of domestic

pets to ensure that they have access to the

right nutrition that will contribute to their

optimum physical and mental health.

As pets become a more natural part of a

household, they often suffer from health

problems normally associated with

humans, including obesity, depression,

and a decline in joint health.

Modern day pet health

Statistics released by the Pet Food

Manufacturers’ Association (PFMA)

confirms that 3.2 million households in

the UK acquired a pet since the start of

the pandemic with two thirds (59%) of

new owners aged 16 to 34. It is the belief

of Nicole Paley, PFMA deputy CEO that

while many people are benefiting from

pet ownership, they need to consider the

welfare of these new pets by ensuring

that they get enough exercise, attention,

and the right food.2

With a return to post-pandemic routines,

with normal office hours and kids at

school, pets are left on their own more

often, without the requisite exercise and

companionship. While sedentary lifestyle

could have an impact on joint health,

there are other factors as to why pets

might need extra joint support.

These include old age, being overweight,

trauma and injury. During the colder

months, joint stiffness can appear more

pronounced in pets, and it is especially

important to support joints in senior pets,

as they may feel the cold more. If your pet

has had any broken bones, this may also

mean they are more sensitive to the cold.3

Another factor that could impact on

joint health in pets is the cost-of-living

crisis across the UK and Europe. This

has resulted in a situation where pets

are potentially not getting the best

food available to them, purely due to

economic constraints.

The ability to offer optimum nutrition

in petfood at affordable prices means

10

Technology & Marketing


that there is significant research on how

functional ingredients such as peptides

can assist in bone and joint health,

cognitive wellness and maintaining a

healthy body weight.

A snapshot of the pet market

On the continent, an estimated 80 million

households own at least one pet, and

globally, the pet care market was worth

$164.68bn in 2019. It is projected to reach

$241.67 by 2025, with a CAGR rate of 6.6%

between 2020 and 2025. For businesses

in the pet food, dietary and supplement

markets, the projected growth presents a

lucrative opportunity.⁴

Current trends in pet nutrition includes

pet ‘humanization’ and ‘premiumization’

and these are seen as primary drivers in

the development of nutraceutical pet

food, while increasing consciousness

about pet health has catalyzed European

pet owners to turn towards nutraceutical

food. The increasing number of single

families, rising animal healthcare costs,

aging pet population, and poor outcomes

of the use of drugs have led to consumers

looking for alternatives in the form of

natural and organic products. ⁵

The addition of active ingredients based

on intended functionality could be a

highly beneficial category to petfood

scientists, brand owners and ingredient

suppliers.

A sustainable solution

Since 2000, Norwegian-based biomega®

has focused on advancing innovative

biotechnology to release the full

nutritional and functional value of

previously underutilised side streams

during salmon processing. Using various

enzymatic hydrolysis processes, biomega

can offer a comprehensive range of

protein peptides to the petfood industry.

This source of traceable and sustainable

functional ingredients means that

biomega biorefineries can turn foodgrade

fresh raw material into premium

feed and nutritional compounds – backed

by several world-leading accreditations,

including Good Manufacturing Practice

and Friend of the Sea certification.

says Silke Middendorf, chief commercial

officer at biomega.

The ability to reduce the impact of

human food waste by using these

underutilized side streams as alternative

healthy proteins that are not usually fit

for human consumption, offers a full

circle, zero waste solution and biomega is

continually looking at additional research

in the development of sustainable

ingredient streams.

The benefit of peptides

Salmigo® is the company’s brand name

for its salmon proteins and peptides used

in premium petfood applications. These

salmon peptides are processed from

fresh Norwegian salmon tissue by natural

enzymatic hydrolysis. The ingredient

contains about 90% proteins in the form

of peptides and free amino acids and

is a highly digestible nutritional source

of protein that has a high biological

value. It also contains long-chain EPA

(eicosapentaenoic acid) and DHA

(docosahexaenoic acid) omega-3 fatty

acids, natural vitamins and astaxanthin,

a natural antioxidant coupled to a wellbalanced

amino acid composition. These

products also offer an enticing smell and

are available in both spray dried and liquid

formats for trouble-free application.

References:

1. blogs.scientificamerican.com/

anthropology-in-practice/the-animal

connection-why-do-we-keep-pets/

2. NEW PFMA Pet Population Data

highlights Pet Peak but the number

of owners giving up their pet is huge

concern | PFMA News

3. Top tips to manage your pet’s joint

health | nutravet

4. Statistics - FEDIAF

Technology & Marketing

5. Europe Pet Food Nutraceuticals Market

| 2022 - 27 | Industry Share, Size,

Growth - Mordor Intelligence

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environmental impact on our planet,”

For more information

www.biomegagroup.com

Issue 3 2022

11

Leiber GmbH | Hafenstraße 24 | 49565 Bramsche

Germany | info@leibergmbh.de


INGREDIENTS

Malaysia’s First Sustainable

Dog Food with Black Soldier Fly

Larvae (BSFL) as an Alternative

Protein source

Photos: Nutrition Technologies

• Pet World Nutritions, SPCA Selangor and Nutrition Technologies signed an MOU to produce sustainable Black Soldier

Fly Larvae based dog food in Malaysia.

• SPCA Selangor will be the first NGO in line to support this sustainable dog food ahead of its commercial launch.

Pet World Nutritions Sdn Bhd is proud

to announce a strategic partnership

with SPCA Selangor and Nutrition

Technologies Sdn Bhd to launch

Malaysia’s first sustainable dog food

using Black Soldier Fly Larvae (BSFL) as

an alternative protein source.

The MOU was jointly signed by Mr PY

Choy, CEO of Pet World Nutritions Sdn

Bhd, Ms Christine Chin, Chairman of

SPCA Selangor and Mr Nick Piggott, CEO

of Nutrition Technologies. They agreed

to enhance collaboration, including to

promote the use of Black Soldier Fly

Larvae (BSFL) in commercial pet food, to

facilitate educating the communities on

the benefits of BSFL, and to support the

ecosystem for sustainable future living,

with a reduced carbon footprint, as well

as giving back to society with this ‘Cause

for the stray’ campaign.

Pet World Nutritions is a pet loving

company that provides uncompromising

pet nutrition so that pet and pet owners

will have more meaningful years

together. “We are honored to have the

full support from SPCA Selangor and

Nutrition Technologies in embarking on

this meaningful sustainable pet food

project, for a better future together”, said

PY Choy. We stay abreast and beyond

the pet food trends, always being

the innovator in the market. With the

introduction of this first ever commercial

sustainable dog food in Malaysia, we are

marking a new milestone in Pet World’s

sustainable mission of “Bridging Better

Future”, a step closer to our sustainable

goals, for our future generations to come.

SPCA Selangor, a Non-Profit Organisation

founded in 1958 to promote kindness

and compassion towards all animals

great and small, aiming to alleviate

cruelty and reduce suffering. Christine

Chin, the chairman of SPCA Selangor

shared that SPCA has also set up the

Plant-Based Campaign Unit to work on

the initiatives that empower Malaysians

to reduce meat consumption while

in turn reducing animal suffering.

She added, “We want to give the best

nutrition to our pet companion, to

keep them healthy and this inclusion

of sustainable Black Soldier Fly Larvae

12

Technology & Marketing


INGREDIENTS

(BSFL) pet food is indeed in line with

our mission of reducing suffering while

saving the environment”.

Nutrition Technologies is a biotechnology

company that focuses on the cultivation

of Black Soldier Flies Larvae (BSFL) to

recover nutrients from organic byproducts

and provide a sustainable

supply of high-grade proteins and

oils into the global food supply chain.

“We have a big vision and mission to

revolutionise the pet food sector with

the integration of insect-based protein

for better functional performance as well

as saving the future of our planet and

providing food security for generations

to come” said Nick Piggott, Co-CEO.

“Black soldier fly larvae have a unique

combination of nutrients, rich in protein

and lipids. This protein source also has

a lower environmental impact in the

farming and harvesting process. By

incorporating black soldier fly larvae

meal into pet food, we will be able to

materialise the production of sustainable

yet highly palatable dog food for dog

lovers as an option. This is part of

the CSR initiatives of the company to

support the welfare of animals through

this sustainable project of helping the

shelters with great nutritious pet food”.

Bridging Better Future Together

With the increasing population in

Malaysia, it also generating tremendous

solid waste estimated to be 38k

metric tonnes per day in 2021. Food

wastage stands as the top contributor

of greenhouse gas globally, with more

than 11% of the total GhG emission

coming from the food system. Malaysia’s

Government has committed to become

a carbon-neutral nation by 2050. To

this end, black soldier fly larvae could

reduce the carbon emissions from food

waste going into landfill because the

larvae eat pre-consumer waste. And

hence, bridging a better future for our

generations to come.

Technology & Marketing

For more information

www.nutrition-technologies.com

PY Choy (CEO of Pet World Nurition Sdn Bhd),

Christine Chin (Chairman of SPCA Selangor),

Nick Piggott (Co-Founder Nutrition Technologies)

Issue 3 2022

13


INGREDIENTS

Multifunctional Pet Food Products

With Fibers From Nature

by Sabine Straka

"Adding value in Pet Foods" is the

promise of the J. RETTENMAIER &

SÖHNE Group, JRS, based in Rosenberg

in Gemany. For more than 60 years, JRS

has been successful in the development,

production and use of high-quality

plant fibers for humans and animals.

These include functional products made

from renewable raw materials such as

cellulose, grain, fruit or wood fibers.

They are odorless, tasteless and versatile

in various applications. The fibers enable

new functions and their properties

help to avoid waste, conserve valuable

raw material and energy resources

and thus ensure greater efficiency and

sustainability. JRS focuses on research,

development and processing of organic

fibers from renewable, plant-based raw

materials. The family-run business group

researches and produces plant fiber

products for many areas of daily life:

for food, pharmaceuticals, cosmetics,

hygiene, plastics as well as for products

for modern, natural and healthy animal

nutrition. The multi-functional raw fiber

concentrates give the pet food products

various positive properties, such as

a stable consistency. They also offer

good nutrient digestibility combined

with high energy density and enable

economic production, as many fibers

serve as auxiliary materials to run

processes efficiently and save water

and energy. JRS, however, is not only a

manufacturer and raw material supplier

of innovative and sustainable additives.

Today, Rettenmaier is a global expert

and market leader in the technological

use of plant raw materials and their

functional properties. With its many

years of production experience, its

extensive know-how and its JRS plant

fiber technology, Rettenmaier makes

many functions of these valuable natural

materials available to modern industry

and is also an innovation partner for

customized and sustainable solutions

for a wide range of applications in almost

all areas - including the production of

pet food.

Figure 1: The key to product development is to be close to the customer and to the product

Suitable fibers for every

function

In the JRS Pet Food department plant

fibers for modern animal nutrition

are researched, tested and produced.

Rettenmaier uses fibers from cereals,

apples, peas, potatoes or cellulose as

well as fibers from psyllium husks with a

water binding capacity of 2400%, which

are used for example for dry or senior

feed. The fibers are processed into fine

fibers, granulates, blends and other

dosage forms as required. JRS follows

the principle of short distances: all raw

materials come from within a radius

of 300 kilometers from the processing

plant. Apple fibers come from Germany,

Austria and Switzerland for example.

Cellulose-based fibers, which are

processed into powder or pellets, are

used particularly frequently. The specially

developed grinding technology unlocks

the maximum water-binding capacity of

the raw fiber concentrate. In elaborate

processes the functionality of the fibers

is tested and optimized. After all, the

fibers determine the consistency of the

end product. Most important for later

use is the composition and length of the

fibers. The plant fibers come in 10 to 12

different lengths, from 6 micrometers

to 2 millimeters. Long fibers up to 2

millimeters form a network and hold

a product stable together. In pet food,

these can act as a toothbrush in a chew

stick. They also have a positive effect on

faeces consistency. The faeces remain

soft yet formed. The shortest fiber length

is 6 micrometers, it dissolves very well in

liquid and is suitable for the production

of imitation meat.

Finest fiber ingredients for high

quality pet food

In the area of animal nutrition

Rettenmaier offers innovative raw fibers

for the health and well-being of almost all

animal species. For this purpose, mainly

cellulose fibers are used. The plant fibers

fulfil several functions: for the animal,

for the process of production and for

the product itself. In livestock farming,

VITACEL® raw fiber concentrates made

from cellulosic fibers are used, which are

particularly compatible for the sensitive

gastrointestinal tract of young animals,

e.g. calves. While livestock farming is

mainly about the functions of the fiber

14

Technology & Marketing


INGREDIENTS

as well as economic rearing, the petfood

market is much more demanding. Here,

the products are often compared to food.

They have to please the pet owner and

taste good to the animal and thus fulfil

various requirements. Fibers made from

lignocellulose, a brown cellulose fiber,

are used for the feed of adult pets. It is

extracted from a tree and processed into

powder or pellets. The highly functional

raw fiber concentrate ARBOCEL® offers

various advantages in pet food and

can positively influence the health of

a pet in many ways. Feed with a high

crude fiber content and a lower energy

density with the same nutrient content

is particularly suitable for older and

overweight animals. Due to its good

swelling, the stretch receptors of the

stomach are activated and thus satiety

occurs. It improves nutrient digestibility

and reduces the amount of faeces. The

fiber network of ARBOCEL® has a slightly

abrasive effect that gently cleans the

teeth and thus improves dental health.

It can also positively influence the

animal's behavior when cleaning its coat,

because it encloses the hair in its network

structure and expels the swallowed hairs

Figure 2: Focusing on details - small changes achieve a big impact

via the intestines. This prevents cats from

regurgitating the hair during grooming.

Finally, ARBOCEL® improves nutrient

digestion and thus reduces the number

of undigested nutrients in the colon. The

insoluble fiber network with its capillary

effect ensures better thickening in the

large intestine and thus dry and consistent

faeces. Finally, ARBOCEL® can improve

the quality, consistency and texture of

various feeds. In wet feed, ARBOCEL®

provides a high water and fat binding

capacity, it improves the structure, the

insoluble fibers can imitate meat fibrils.

Always a better solution

Plant-based

proteins

Antioxidants

Colors

Barentz Animal Nutrition is a global distributor of technical and nutritional ingredients

for the pet food industry. We have several solutions for clean label, hypoallergenic,

sustainable, vegetarian and organic concepts. We are your one-stop-shop.

www.barentz.com/animal-nutrition

Hydrocolloids

Issue 3 2022

15


INGREDIENTS

Figure 3: High-end equipment meets modern fiber technology

ARBOCEL® is stable even at extreme pH

values and high temperatures. Due to

its enrichment in dry feed, ARBOCEL®

is also suitable as a natural caloriefree

filler, e.g. for diet products, and

can help to reduce an animal's weight.

ARBOCEL® prevents oiling out and also

leads to faster and more uniform drying

during feed production. In semi-moist

feeds, ARBOCEL® improves water and fat

binding as well as microbiological stability

and enhances the nutritional value of

the end product. ARBOCEL® also fulfils

a variety of positive functions in snacks

as a calorie-free raw fiber concentrate. It

provides a stable texture and prevents a

baked product, such as a dog snack, from

breaking too easily. It can also improve an

animal's dental health.

Natural products for the future

Rettenmaier sets trends in modern

animal nutrition with its functional plant

fibers. The special fibers help in the

development of vegan meat alternatives,

they give the substitute products the right

consistency and the desired structure.

Also in raw feeding, the food becomes

firmer and more comfortable to handle

due to the fibers, and it can also prevent

diarrhoea in dogs. Finally, the use of plant

fibers can also make the production

processes more sustainable; for example,

the drying time in the production of

dried food can be reduced by 50%. And

sometimes Rettenmaier's fiber products

are even ahead of their time. For example,

the pure cellulose fiber ARBOCEL® FIF 400

was already developed in 2020. It has a

white color, is odorless and tasteless and

can also be used in the premium sector,

for example for preparing light sauces.

For a long time, this was produced with

the white pigment titanium oxide until

this substance was finally banned as an

additive in food in February 2022. That's

when ARBOCEL® FIF 400 finally came into

use as a much healthier colorant.

Tailored solutions to the

customer's needs

Rettenmaier operates its own pilot

technical center for the development

of recipes with functional plant fiber

concentrates. Here, Torsten Trampe,

Head of Technical Application, and Cora

Weippert, Application Manager Pet

Food, work on developing the specific

properties of various raw materials and

on optimizing recipes and processes.

The results are scientifically sound. With

empirical research and applicationoriented

development in its own

laboratories, Rettenmaier offers its

partners a special service: technical

know-how, market knowledge and

suggestions to turn good ideas into

produceable products and bring them

faster to market. "The right product

is individually put together for each

customer," explains Torsten Trampe. "Our

customers come with a raw material, a

food mix, an idea or with a problem, e.g.

that a dog snack breaks too easily". For

example, if the customer comes in with a

fiber, the first step is to observe what this

fiber can do in the first place and then

determine its functionality. Rettenmaier

then makes a recommendation and -

together with the customer - tailor-made

solutions are developed to improve

recipes and processes. During joint

product development, specific recipes

are developed and the product is put

together according to the requirements.

No two fiber products are alike, because

each product is individually tailored to

the customer's needs. For this purpose,

special tests are carried out on site on

behalf of the customer. These tests are

usually free of charge. In the technical

competence center, a small-scale test

run can be carried out quickly and easily.

Up to three such trials are possible per

month.

With their extensive expertise from the

various fields and the specific JRS plant

fiber technology, Rettenmaier helps to

solve the customer's problems with the

use of natural fibers and also supports

smaller companies and start-ups in

tackling complex tasks. "Rettenmaier

helps to design trend products when

something reaches its technological

limits and brings in their expertise from

all areas," says Torsten Trampe. "That is

really unique in the world." Since raw

materials for pet food are also hard to

come by globally, existing recipes are

no longer as easy to implement with

the available ingredients. This creates a

higher awareness of fiber quality. "In order

to offer pet food products to consumers

in the usual quality and availability

in the future, pet food suppliers and

manufacturers will have to cooperate

more intensively in the area of research

and development," Trampe adds.

Technology & Marketing

For more information

www.jrspetfood.com

16

Technology & Marketing


INGREDIENTS

Plant-Based Proteins for More

Sustainable Pet Food

With the tremendous growth of the pet food industry and its impact on the environment, there is an increasing

need for an alternative to meat ingredients. Plant-based proteins which is becoming more and more popular in

pet food, might just be the perfect solution.

According to the latest data, the number

of dogs and cats in the world is around

471 and 370 million respectively,

however, this population is constantly

increasing, especially due to Covid-19

when many people decided to adopt a

pet for company. This has resulted in a

huge increase of pet food production,

with annual worldwide sales currently

at 102.6 bn USD. This in turn, also has

consequential impacts on the planet.

Environmental impact

What is the global environmental impact

of the pet food industry? To produce dry

food for our dogs and cats, around 41-

48 million hectares of land (an area twice

the size of the UK) is used annually. This

is linked to 56–151 million tons of CO₂

emissions annually, which represents 1,1%

− 2,9% of global agricultural emissions.

The main cause of this problem is due to

the high amount of meat included in pet

food. To produce meat, land is needed for

both livestock breeding and for the crops

to produce their feed.

Moreover, a consistent component of

commercial pet food are animal byproducts

(ABPs). To be in line with the latest

human trends, the usage of ABPs will most

likely be reduced in the coming years. The

decrease of ABPs in pet food would be

also important for sustainability reasons.

In fact, contrary to the common belief that

ABPs are zero-impact ingredients, their

use provides a financial return to livestock

industry that incentives increased animal

production, with negative consequences

on the environment.

Furthermore, the competitive market

of ABPs is expected to grow (i.e. use in

fertilizer and biofuel sectors) which will

impact their price and availability. In

this contest, plant based proteins can

represent a good alternative solution

for pet food producers, creating a new

balance in the market.

Switching to plant-based

products

Data shows the need to minimize the

use of animal proteins and the need

to replace these products with more

efficient plant-based products which are

sustainably grown and harvested. This is

not only better for the planet, but also

for our pets. According to the review

research of Mueller et al. (2016), the most

common food allergens causing negative

cutaneous reactions in dogs (see figure

1) are beef (34%), dairy products (17%),

chicken (15%), lamb (14,5%) and wheat

(13%). A similar situation (also figure 1)

can be found in cats, where the main

food allergens were reported to be beef

(18%), fish (17%), chicken (5%), wheat

and dairy products (4%) and lamb (3%).

To conclude, partly replacing meat

and fish products with plant-based

ingredients will most likely also help to

reduce food-derived allergic reactions in

pets.

Figure 1: Prevalence (%) of food allergens in dogs and cats’ diets (Mueller et al., 2016)

Issue 3 2022

17


INGREDIENTS

Figure 2: Expected growth of global pet food market value (USD billion) from 2020 to 2028

Organic and vegan

Taking this all into account, it is not a surprise that

we are seeing a huge increase of pet food trends

such as; natural, organic, sustainable, vegetarian

and vegan. In fact, recent market research (see

figure 2) shows that the global organic petfood

market value is expected to grow from 4,9 billion

USD in 2020 to 9,1 billion USD in 2028. The global

vegan pet food market value is expected to grow

from 9,6 billion USD in 2020 to 15,6 billion USD

by 2028.

In the future we also expect more human food

trends to influence the pet food market. For

example, one currently emerging human trend

that could potentially become popular for pets

is the flexitarian (or flexible vegetarian) diet.

This means reducing, without eliminating, the

consumption of meat and animal protein in favor

of plant-based proteins.

Figure 3: Several examples of plant-based proteins

All these trends are starting to increase the

demand for alternative, non-animal protein

ingredients in pet food.

Innovative plant-based proteins

Due to the popularity of plant-based ingredients,

the percentage of plant-based proteins in pet

food formulations has increased. The most used

products are traditional ingredients such as; corn

gluten meal, vital wheat gluten and soy protein,

as well as other options like rice, pea, potato and

sunflower. More recently, innovative ingredients

like single cell protein and Lemna protein, have

started to make an appearance in pet food

formulations.

18

Technology & Marketing


INGREDIENTS

Various solutions

Since there are several plant-based

ingredients currently available on the

market, it is important to choose the right

product for each application. Below are

listed some possible plant-based solutions

with their recommended usage in pet food

formulations.

Rice protein

Rice protein is a great ingredient for both

wet and dry pet food which is particularly

beneficial for hypoallergenic diets and in

formulations for puppies and kittens. It is

highly digestible, has a balanced amino

acids profile and is a source of energy.

Pea and potato protein

When it comes to grain free, gluten

free and hypoallergenic diets, a perfect

solution is pea protein. Thanks to its high

digestibility and palatability, pea can be

used in all kinds of formulations. It also acts

a stabilizer, improving the consistency of

pet food.

Another great solution for hypoallergenic

and grain/gluten free diets, is potato

protein, characterized by a highly

digestible and balanced amino acid profile.

Sunflower protein

Last but not least, another sustainable and

natural protein source is sunflower protein.

This protein source can be used in both dry

and wet pet food, also acting as a coloring

agent. It can be a great solution for grain/

gluten free and hypoallergenic diets, it is

highly digestible and has a neutral taste

that does not create palatability issues.

Single cell proteins and Lemna

protein

In addition to sustainable ingredients,

more innovative products have started to

appear in the pet food ingredient market,

such as single cell proteins or Lemna

protein.

Single cell proteins are the dried microbial

cell or total protein extracted from pure

microbial cell culture (algae, bacteria,

filamentous fungi, yeast). Due to their

origin, they can be successfully used in all

kinds of pet food diets, i.e. hypoallergenic,

grain free, natural, etc.

Water lentils or Lemna protein is very

digestible and palatable, with a high level

of antioxidants and minerals, like calcium

and phosphorous. Thanks to its omega 3

content, it is also a good solution to improve

immunity and skin/coat conditions.

Yeast-based protein

Yeast products can also be used as

sustainable alternative protein sources

for animal products. Beside the more

traditional brewer’s yeast, pet food diets

can also be supplemented with other

yeast-based products like yeast extract,

hydrolyzed yeast or autolyzed yeast. The

benefits of these products are mainly

related to the high palatability and

digestibility, plus their good content of

MOS, β-glucans and nucleotides for a

better immunity.

As a leading global life science ingredients

distributor, Barentz Animal Nutrition

can supply all the above-mentioned

plant-based proteins and help pet food

manufacturers find the right products for

their formulations.

Technology & Marketing

For more information

www.barentz.com/animalnutrition/pet-food/

Plant-based Performance

Trigovit ® Tex brings unique flexibility and

nutritive protein to plant-based chew sticks

Flexibility Binder Plant-based Protein

Technology & Marketing

Refining

pet food.

crespeldeitersgroup.com

Issue 3 2022

19


INGREDIENTS

Pet Flour Quinoa

Quinoa is a highly nutritious edible seed native to South

America, where it has been a prominent food source for 6000

years. Coined as a superfood, quinoa provides a wide array of

essential nutrients to both humans and animals. When heated

the super food is safe for dogs to eat and considered as a very

healthy addition to their diets.

Limagrain Ingredients launches a

heat treated quinoa flour product

specially for dog food. Our new

PetFlour Quinoa is a great innovative

launch playing a role in rising market

demands and the quest for higher nutritional benefits for dog

food.

The quinoa undergoes a special process in which it is heat

treated. After this process the flour is very usable in many

different pet food applications due to good flowability, nice

hydration, dough processability and better availability of the

nutritional benefits.

Quinoa provides a complete source of protein. That means it has

all 9 essential amino acids. It’s also a fantastic source of fiber, B

vitamins, and iron. It is considered a healthy alternative to wheat

flour since it has so many essential nutrients and is grain-free.

Besides all that it is considered as a sustainable option as the

quinoa is sourced locally in the Netherlands and Belgium.

Technology & Marketing

For more information

www.limagrain.com

arketing

20

Technology & Marketing


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PROCESSING

How Continuous Food

Processing Equipment Holds

The Secret To Better Pet Food

Continuous naturalness in wet pet food

People love to treat their pets to the best,

so the demand for high quality pet food at

a reasonable price continues to rise. A big

challenge is to maintain consistency with

large production volume while achieving

shortest possible processing times – and

to create a nutritious product at the same

time. Valuable nutrients and proteins from

meat, fish, vegetables and cereals ideally

remain unchanged during processing

so that the product can meet the high

demands of animals and their owners.

Common Challenges In Pet Food

Production

Many factors can jeopardize consistency

and quality – both within a single batch

and between batches. Slow ineffective,

or over, heating causing inefficient use

of ingredients, degradation of proteins

and deviations in the product quality.

In contrast to typical batch and retort

cooking, the RotaTherm® heats the product

rapidly, but gently, in a continuous process

within seconds only to the required

temperature using priority direct steam

injection technology and thus offers

many advantages, like original colour of

product, unchanged shape of particulates,

low denaturation of proteins, minimized

waste, production breaks, utilities and

cleaning chemicals. You benefit from

more efficient, more productive and costeffective

manufacturing, your customer

from a more nutritious and consistent

product.

Consistency

As with most processed food, maintaining

consistency across large production

volumes can be challenging. This becomes

an even bigger problem if batch cooking

process is in use. With batch cooking,

you waste a substantial amount of time

to process each batch, often having to

wait to fill from a large buffer tank. This

stag ing, with varying dwell times before

filling can magnify inconsistencies,

leading to temperature loss and changes

in pressure, moisture, color and texture,

further overcooking without necessarily

hydrating.

Each of the issues above poses a threat

to consistency, within a single batch and

in between batches, leading to a lowerquality,

less consistent product. With end

customers willing to pay a premium for

quality pet food, this is the last thing you

want to happen! Inconsistencies alone

may not be the biggest concern, but they

are the source of inefficient ingredient

usage and end product variation.

Most pet food recipes combine several

different ingredients including meat,

vegetables, grains, stabilizers, by-products,

etc. Each of these have different levels of

viscosity and chunkiness, and different

requirements, therefore demanding

specific optimal cooking conditions to

guarantee a consistent texture – every

minute, hour and week of production.

Consistency is directly related to your

market growth because it keeps your

customers coming back.

Production Volumes

As part of the fast-moving consumer goods

industry, pet food is generally sold at low

profit margins, so high production and

sales volume are key to long-term survival

and a successful pet food business. With

batch processing, gaps in production are

often a part of daily operations. The batch

process is more time consuming, with time

allocated for preparing each batch, mixing

the ingredients, heating the formulation,

adjusting settings, waiting to fill before

starting the next batch and rinsing.

Each of these steps negatively impact

your efficiency and productivity as they

are done in series not parallel. Much of

your time is consumed performing nonvalue-adding

tasks, instead of producing

pet food, limiting the production volumes

your business strives to achieve.

Quality

Many recipes use a variety of different

ingredients – yours might combine

vegetables, meat and fish, as well as

powders, by-products and grains. As

we mentioned above, temperature,

moisture and pressure fluctuate between

batches, affecting the final composition

and causing unpredictable ingredient

usage. Denaturation of the proteins is the

result of long heating processes and the

naturalness of the products is no longer

guaranteed.

After cooking, a defined holding time

ensures the relevant bacteria killing to

be able to offer the final product with a

perfect shelf life. A hot fill process into

cans, casings or trays will help to keep

the product safe and protects against

recontamination. ‘Post filling’ cooling can

be done in a flexible way with a spiral cooler,

waterbath or cooling tunnel. Continuous

22

Technology & Marketing


PROCESSING

food processing systems provide nonstop,

consistent cooking, unlike traditional

batch cooking. Many of the potential

problems with pet food production are

tied to the batch production process.

Therefore, the RotaTherm® consistent

continuous cooking process offers a

solution.

How Continuous Food

Production Systems

Improve Consistency

By applying the same process (heat

treatment temperature, pressure,

cooling, etc.) to all product at each

stage, continuous cooking substantially

minimizes the risk of variations in the final

composition. The look and taste of the

product is controlled, leading to a much

more consistent end-product. Compared

to labor intensive batch processes and

even other continuous cookers, the

RotaTherm® offers automated efficient

non-stop pet food production.

In addition to the fundamental advantages

of continuous cooking, RotaTherm® uses

multiple direct steam injectors and many

other design elements that ensure your

pet food is cooked optimally and evenly

without the risk of undercooked or burnt

parts.

Continuous Cooking =

Continuous Production

As the name suggests, continuous

cooking means no stopping in production.

This process minimizes waste, time and

cleaning chemicals, and leads to a much

more stable, efficient and productive

food manufacturing process. The vertical,

column design of the RotaTherm® occupies

very little space, and thus requires only

a small footprint for the heating process

in the production line. The design and

accurate control of the processing

conditions in the column allows products

with particulates to be heated without

being destroyed.

The RotaTherm® can operate non-stop

without cleaning for up to 156 hours, 6.5

days

In an industry that relies on production

volume like pet food, every second

of additional production can make a

difference. The fact that the RotaTherm®

heats the product in a very short time, that

100% of the steam introduced is absorbed

by the product, i.e. no energy is lost, and

that 100 kg/h to 20,000 kg/h of pet food

varieties can be produced in a space of

only one square meter means that this is

definitely a "state of the art technology".

RotaTherm® Holds the Secret to

Better Quality Pet Food

Every customer has the right to be selective.

They want healthy looking nutritious

products for their pets, instead of poorlypresented,

low-quality food. By combining

continuous cooking with sophisticated

automated systems, RotaTherm®

consistently produces a natural-looking,

nutritious product.

The RotaTherm® heats to the target

temperature in as little as 10 seconds,

using multiple steam injectors to ensure

even cooking. The automated process

control and recipe systems guarantee

temperature, steam and moisture,

consistency etc are as required, minimizing

unacceptable product. This ensures your

pet food recipes are being prepared to

the same ideal specifications every single

time.

Technology & Marketing

For more information

www.natec-network.com or

contact.natec@natec-network.com

Issue 3 2022

23


PROCESSING

Quality Control in Pet Food

Processing

Digital solution with signalling function in the VF 800 vacuum filler

ensures quality standards in processing

The VF 800 vacuum filler generation from Handtmann offers a wide

range of solutions for quality control and ensuring quality standards

in pet food processing. With the “Handtmann Monitoring Function”,

the VF 800 monitors the situation in the feed system on the basis of

pressure, temperature, vacuum and drive load and reports potential

causes of impaired quality in good time via the control system of the VF

800 and the optionally available warning lights.

The “Handtmann Monitoring Function

(HMF)” is a very practical solution whose

basic function is the automatic parameter

monitoring in the production process.

Rejects are often only discovered after

completion of a product. The delay

between filling process and quality

control may also result in a large and

correspondingly expensive quantity

of rejects. The Handtmann Monitoring

Function effectively helps to avoid

such rejects as it signals already during

production if quality-relevant production

parameters are undercut or exceeded.

The warning is clearly and precisely

indicated on the screen of the monitor

control. If, for example, the filling product

temperature were 3.5°C although a filling

product temperature of 2.5°C was set,

the machine would issue a warning. Now

the operator is given the flexibility to

decide that production should continue

by actively confirming the “excessively

low temperature” or to stop the process

and take corrective action. If no action is

taken, the machine will stop automatically

after 30 seconds. In addition to issuing

the message via the monitor control, an

optional signal light can be used on the

VF 800 vacuum filler. In case of deviations

from the defined upper and lower limits

of the production parameters, the signal

light lights up orange and thus warns

the operator of the current status. If no

action is taken in time, the machine stops

automatically and the signal light indicates

the machine stop in red. This solution

effectively supports meat processing

operations in terms of quality control and

reproducibility of quality standards in

processing.

Technology & Marketing

About Albert Handtmann Maschinenfabrik

GmbH & Co. KG:

The owner-managed company based in Biberach/Riss in

southern Germany is part of the Handtmann Group of

Companies and employs over 1,200 people worldwide.

The Maschinenfabrik is a leading manufacturer of process

technology for food processing and offers modular process

solutions for grinding, mixing, portioning, dosing, forming,

co-extruding and product handling. The Handtmann

customer base includes both small businesses and startups

as well as medium-sized companies and large industrial

enterprises from all over the world. In the state-of-the-art

Customer Forum at the company headquarters, Handtmann

offers its customers the opportunity to test process solutions.

Quality controlled processing of pet food

For more information

www.handtmann.com/food

24

Photos: Handtmann

Technology & Marketing


PROCESSING

Twin Screw Loss-in-Weight

Feeder for Pet Food Ingredients

applications with free flowing to very

poorly flowing powders (e.g., lumpy,

moist or bridge building materials) as

well as fibers, flakes, and other bulk

materials. The twin and single screw

feed modules can be interchanged to

provide for quick cleaning, minimized

product changeover, and increased

production flexibility.

Technology & Marketing

For more information

www.coperion.com

K-ML-KT20-50L

Coperion K-Tron's modular Lossin-Weight

feeders are ideal for the

high accuracy addition of ingredients

to batch or continuous mixers and

extruders. Loss-in-Weight gravimetric

feeders are the best choice for long

term accuracy, repeatability, and

quality.

The twin screw feeder with

interchangeable feeding tools is

mounted on a D5 weigh bridge. The

weigh bridge is stainless steel, and the

scale housing is completely enclosed.

All parts in contact with the material

being fed are stainless steel. The

horizontal agitator gently moves the

bulk material to the large throat and

then into the screws. Feeder screws

are easily interchangeable. This

equipment conforms to CE standards

regarding EMC and safety.

Highest precision through state-ofthe-art

processing technology

With over 100 years of industry experience

in the food industry, Biosteril has revolutionised

the purification of raw materials.

Our state-of-the-art sterilisation equipment

offers industry-leading benefits to ensure

maximum safety for you and your customers

at all times.

Find out more at: www.kuendig.com

Quick Change loss-in-weight feeders

are specially designed for pet food

Issue 3 2022

25


PROCESSING

Ultimate Processing of Proteins

with New Dicer Generation

New from Urschel, meet the M

VersaProTM (MVP) next generation

protein powerhouse. The 2-D dicer

excels in processing of meat, poultry,

and alternative proteins. The machine

provides the best in sanitary design and

the ultimate in versatile cutting of all

types of protein.

“After years of R&D, Urschel is proud to

release the MVP. Thank you to all of the

leading processors who shared with us

their must-have wish lists and to those

who allowed in-plant testing,” stated

Alan Major, CSO.

The MVP offers 33% increased feeding

capacity versus the standard M6 due

to wider belts, optimized cutting, and

increased horsepower. The belt fed MVP

delivers 2-dimensional dices, strips, or

shreds from product of a predetermined

thickness.

Wider 12” (304.8 mm) infeed and

takeaway belts work together to provide

even transitioning of product and

prevention of product buildup. Takeaway

belt facilitates discharging into totes.

Stainless steel construction throughout

with solid, round bar frame, motors, and

hinged panels. Hinged panels provide

easy and complete access to promote

sanitation and ease of maintenance

without having to rest any panels on the

production floor.

New patented, fluted crosscut option

provides gentler cutting action. Deeper

circular knife to feed drum penetration

produces an improved cutting method.

The crosscut is driven by 5 HP (3.7

kW) motor equipped with a variable

frequency drive to allow adjustment

of the cut size without the additional

expense of changing parts. Other active

cutting components are driven by a 5 or

7.5 HP (3.7 or 5,6 kW) motor.

Available intiutive touchscreen HMI

option ealily gathers data, monitors

machine components including sensors

and amperage; adjusts operating speeds

and saves recipes. Touchscreen swivels

for full visibility.

Designed for continuous operation

for uninterrupted production. IP69K

certified electrical enclosure features a

double-sealed door for extra protection

during washdowns. Mechanical zone

is isolated from the product zone to

promote sanitation.

Simple to operate at the push of a

button. Backed by Urschel solid support.

More information on how the M VersaPro

Dicer can improve your line is available

on request.

Technology & Marketing

For more information

www.urschel.com

MANAGING

ENERGY

EFFICIENTLY

HRS provide a range of tubular and scraped surface heat exchangers, components, modules and complete processing

systems that help you to optimise production, make the most of raw materials, while reducing energy consumption, waste

and emissions:

Pasteurisation/UHT Evaporation

Sterilisation

Aseptic Filling

Direct Steam Injection

CIP Systems

Hot Water Sets

Complete Lines

26

info@uk.hrs-he.com

+44 1923 232 335

www.hrs-heatexchangers.com

Technology & Marketing


PROCESSING

Highly Efficient Extraction System

for Optimized Valorization of

Functional Nutrients

International technology group ANDRITZ has developed Turbex, a highly efficient extraction system to

produce functional nutrients.

ANDRITZ Turbex helps to produce high-quality extracts from botanicals and natural products and turn waste

such as orange peel or brewer’s spent grain (BSG) into revenue-generating nutrients.

Turbex can be installed as a retrofit to improve existing process

line performance thus making a useful addition to process line

solutions such as those in the ready-to-drink-tea market.

Technology & Marketing

For more information

www.andritz.com

This patented extraction technology works by generating high

turbulence, shear, and cavitation, hundreds of times more

than conventional extractors. It uses a series of rotors and

stators to cause thousands of cavitation events per second,

resulting in higher yields in shorter processing times. Assisted

by a counter-current process, ANDRITZ Turbex delivers

yields up to 50% higher than conventional systems. The low

extraction temperature combined with the short processing

time improves the product quality as oxidization of valuable

polyphenols and antioxidants is avoided.

THE RIGHT

MACHINE

FOR ALL

APPLICATIONS

CUTTERS · GRINDERS

MIXER GRINDERS · MIXERS

Requiring up to 30% less energy than conventional extraction

methods, ANDRITZ Turbex has a faster return on investment

and less environmental impact. The fact that it does not

necessarily require ethanol as an extraction solvent but can

operate using only water also reduces both costs and carbon

footprint. Thanks to lower investment costs and operating

expenses, Turbex also makes by-product valorization an

attractive option for a broad variety of applications.

The Turbex extractor is an efficient method of extracting

vegetable proteins, polyphenols, essential oils, extra virgin

olive oil, antioxidants and (dietary) fiber from waste products

such as spent brewer’s grain or coffee grounds, botanicals, tea

leaves, citrus peel, or cannabis leaves. With the right extraction

sequence and process parameters, the valorization process

can be optimized in terms of purity and product composition

to obtain products with maximum commercial value. ANDRITZ

kgwetter.de/en/hygienic-plus

Issue 3 2022

www.kgwetter.de

27


PROCESSING

Making Even the Impossible

Possible: Flexible and Efficient

by Sabine Straka

For more than 70 years, KARL SCHNELL

has been an established name worldwide

for the development of high-quality

application-oriented machines and

plants in the food industry. The mediumsized

company was founded in 1948 by

Karl Schnell and his wife Margarete in

Winterbach near Stuttgart and started

out with emulsifiers, the so-called musers.

Soon, this vertical universal grinder with

a knife and a hole plate was used as a

standard machine in the agricultural

sector.

The muser was used to chop vegetables,

crops and fodder, but it could also be used

to chop products which were difficult to

process like pork rinds and tendons. This

key machine was the cornerstone of the

KS success story. Around this machine, the

entire process technology with further

equipment such as mixers, grinders and

breakers subsequently was developed.

In the post-war period, Karl Schnell

invented further machines that had great

impact on industrial food processing,

such as the "Mince Master", a further

development of the muser in a horizontal

design with several cutting stages, which

still shapes an entire industry sector today.

In the 1960s, a second factory was built

in Creglingen. The production of the

first automatic processing machines for

boiled sausage and pâté and vacuum

fillers began. Further developments

followed such as the first combi grinder

(a combination of primary breaker and

mincer) or the first process automats –

all-in-one machines that combine the

functions "mincing-mixing-emulsifying"

in one device.

Today, the Swabian company is still a

third-generation family business with

350 employees worldwide and offers the

complete product range from individual

machines to complete processing lines.

The process steps are covered from raw

material intake to portioning, including

planning and realization, installation and

commissioning at the customer's site.

In the pet food sector, KARL SCHNELL

provides customized and flexible

solutions for many applications.

In order to offer an optimal user

experience to the customers, a

new virtual pet food arena tailored

specifically to the pet food sector will go

online in autumn 2022 - as a supplement

to the existing virtual showroom. There,

Figure 1: Petfood Arena – the virtual showroom, user-friendliness rethought

the extensive KS portfolio of solutions

for this sector will be presented in a

three-dimensional virtual environment.

(Figure 1)

The tool for success: robust

machines for complex

requirements

Today, KS focuses on machinery and plant

engineering for the industrial processing

of meat products, delicacies and processed

cheese products as well as pet food. The

diversity of products results in synergy

effects from one area to another.

With a share of around 40 % of sales, the

pet food sector is a cornerstone for the

company. For this, KS supplies robust,

wear-resistant and reliable machines

that meet the high demands of pet food

production, such as the grinding of highly

viscous, difficult-to-process products, for

example bones or frozen meat blocks,

which are processed at temperatures

of -20 °C. In order to meet these special

requirements, KARL SCHNELL developed

its own motors with a special cooling

concept from the very beginning.

Like other areas of meat processing, the

production of pet food is characterized

by a high degree of automation. With KS

machines, approximately 16 tonnes of

meat can be processed per hour without

interruption in a continuous process. The

machines operate continuously for several

weeks, and product carry-over must be

avoided. This are very complex challenges

for the design.

Photos: Karl Schnell

The hygiene requirements for the

production of pet food are coming closer

and closer to those for human food. As a

result, CIP (Cleaning in Place) systems are

increasingly being used in this area. The

process plants are cleaned automatically

to save energy, water and time.

KARL SCHNELL works with a very high

vertical range of manufacture. This begins

with the cutting of the sheets with water

28

Technology & Marketing


PROCESSING

jet cutting machines, the welding of the

individual components, mechanical and

electrical assembly, the programming of

the systems up to the packaging and final

inspection of the finished product.

Manufacture for processspecific

special solutions

This extraordinary vertical range of

manufacture is the precondition for

customized solutions. KARL SCHNELL

offers automated plants for many product

applications and for any production

quantities in the appropriate size.

The machines consist of standardized

modules that are individually configured

and combined with each other

depending on the requirements. Thus

they are available to the customer as

flexible solutions.

"For our customers, we also make

the impossible possible in order to

implement even unusual processes,"

explains Eugen Jöchner, Specialist

in the Engineering Department at

KARL SCHNELL. "We work hand in hand

with our customers and support them in

the development of individual solutions.

This applies both from a technical point

of view in the selection of the suitable

machine, as well as technologically in the

development of new processes." Private

labels usually have the most creative

ideas and the most unusual requirements

for new processes. "Our company does

not focus on series production. We are

a manufacturer that also creates exotic

products," Eugen Jöchner adds.

Figure 2: KS emulsifier - hygiene concept for more product safety

Emulsifiers are the core of the range.

Due to the modular design of the

cutting systems, many different

products can be developed from

them. A total of four systems can

be installed and combined with

each other, resulting in a variety of

different process possibilities.

In addition, new machines are

constantly being developed.

For example, the first mincer

in hygienic design with HDW

(HygienicDesignWeihenstephan)

certification and water-cooled

servo motor sets new standards in

terms of reliability and compactness

as well as energy efficiency and wear.

The motor is encapsulated (IP69) and

can be cleaned with a high-pressure

cleaner. Furthermore, the emulsifier

can be integrated into an inline process

and act here as a "CIP pump" to clean

the pipe system and integrated plant

components. (Figure 2)

Flexible high-performance

machines for efficient pet food

production

KS has decades of experience in

processing animal feed and has become

one of the world's leading suppliers of

turnkey solutions for wet feed systems.

The product range covers all steps of meat

processing from raw material reception

to machines for emulsification, which

can also be used to grind very abrasive

products in the production of pet food,

such as bones.

Left: Philipp Schnell – Plant Manager

at Creglingen and Member of the

Management Board

Right: Eugen Jöchner, Pet Food Project

Manager and contact person for all pet

food issues

With a new, fully automatic grinding

system – called the Mincing System –

emulsions for the wet feed and dry feed

process can be produced with minimal

machine and space requirements. The

conventional pre-grinding process is

completely eliminated.

The basis of this plant is the FL248

emulsifier, a high-performance machine

with a flexible feeding and cutting

system. This can be fed with frozen and

pre-broken meat blocks, with fresh meat,

carcasses with bones or also with byproducts

such as offal. In this process,

the previously frozen product (similar to

soft ice cream) becomes pumpable and

can be transported over long distances

by pipeline to the next processing step.

The processes can further be influenced

by adding direct steam, inert gases or

other additives. The robust components

of this shredding system enable a high

continuous throughput, ensure process

reliability and thus offer added value for

the entire production.

Conventional meat grinders are also

used for the production of pet food.

Automatic grinders from KS process

various raw materials at temperatures as

low as -25 °C. Even whole frozen meat

blocks can be minced in a single step.

KARL SCHNELL supplies the complete

system. The range extends from large

Issue 3 2022

29


PROCESSING

industrial grinders for use in continuous

processes to smaller machines for

special applications or for handicraft.

Combined with connected KS mixers,

equipped with the appropriate mixing

tool and drive for intensive and productfriendly

mixing, the most diverse pet

food processes can be produced, for

example "Natural Chunks" for AllMeat

or BARF. KS mixers in the modular

system with the various components

and special equipment offer sufficient

flexibility for this.

KARL SCHNELL's manufacturing programme

also includes crushers for

coarse crushing, conveyors, equipment

for buffering and dosing and much

more.

With the "All-in-One" of the FD series

already mentioned at the beginning,

high-viscosity emulsions can be

produced for the OFM steam tunnel

process - these are also the perfect

machines for all start-ups.

Thinner masses for the liquid snack sector

are produced on the FC series process.

The simpler design of the B series has

made a great name for itself in the field of

gravy/jelly dispersion. (Figure 3)

Multiple demands for the

future

The industrial processing of pet food

is subject to increasingly stringent

requirements. The high-quality machines

and systems from KARL SCHNELL meet

these requirements in several respects.

With its flexible and innovative machines

and complete production lines, KS offers

a high degree of standardization and thus

consistent product quality with reliable

and economical operation. By using

efficient technologies, processes are

becoming more and more automated.

For example, -25°C cold meat blocks

can be emulsified in a fully automated

process.

In addition, the production processes

must be documentable. The process

recording is done with a report manager,

which specifies which raw materials,

recipes, settings and temperatures etc. are

used. This creates reproducible processes

with automatic recipe accuracy, so that

individual recipes can be reproduced

easily even on large systems.

Product changes are taking place more

frequently, with production quantities

becoming smaller and recipes changing

faster and faster. The individual batches

should be traceable.

Integrated weighing systems in the system

parts dosing tank, buffer screws and

mixers enable exact batch measurement

and thus offer reliable production

and traceability. In all these complex

processes, KS supports customers not

only with technical solutions, but also with

technological assistance and know-how.

(Figure 4)

Current trends in pet nutrition

KS also has the suitable answer for

current trends in pet food. For example,

snacks and treats are increasingly being

produced in unusual shapes, e.g. in

bone form or as animal imitations. In

Figure 3: Wet Pet Food - one of the core competences at KARL SCHNELL

addition, not only smaller quantities,

but also increasingly exotic ingredients

are processed, such as buffalo, ostrich

or kangaroo, each of this ingredient has

only be included in the raw product to

the extent of 3%.

Since more and more pets suffer from

allergies or intolerances, there is an

increased demand for mono-proteins,

which are derived from only one protein

source coming from a single type of meat.

It may contain different components

such as offal (liver, heart, lungs, stomach),

muscle meat, bones or cartilage, but only

from one animal.

Feeding with monoproteins is particularly

easy with raw feeding, so-called BARF,

since only the pure meat is used here

anyway. In the production of raw feed,

the meat should be processed as gently

as possible, using all parts of the animal,

so that only small residual quantities

remain. KS also offers solutions for this:

the combi grinder, for example, whose

cutting system is equipped with separate

drives for the worm and knife. Coupled

with conventional grinders, this unique

system allows the length of the material

to be cut to be influenced via variable

speeds. Furthermore, with this principle,

the pressure on the product can be

influenced when a load limit is set. The

system also automatically recognizes

fresh and frozen meat. This smart control

concept is also used in the mincing

systems.

Investing in the future

The family business KARL SCHNELL has an

established structure and is continuously

expanding. In order to continue to meet

the increasing demand for machinery

and equipment for the food and pet

food industry, KS has steadily expanded

its plants and production capacities over

the years, making major investments in

the process. A new modern company

was founded for the production of spare

parts and investments were made in the

latest state-of-the-art turning and milling

centres at the site in Winterbach.

In order to position itself even better for

the future, another hall with an area of

2800 sqm is currently being built at the

Creglingen site for welding work with a

solar system, extraction technology and

heat recovery.

30

Technology & Marketing


PROCESSING

Photos: Karl Schnell

Figure 4: Pet Food Line - flexible high-end solution for large capacities

Sabine Straka is Assistant Editor with

PetFood PRO at Dr. Harnisch Publicatiions

"In the future, we will continue to improve

the technology, simplify the system

and invest in technology for production

methods, e.g. robotics in plants," explains

Phillip Schnell, Plant Manager at the

Creglingen site and future Company

CEO. Because the use of welding robots

means that skilled workers are no

longer necessarily needed, and they are

becoming increasingly difficult to find.

Since 2020, there is also a location in

Romania, where 10 employees support

the electrical and mechanical design, and

there are also subsidiaries in the USA and

France.

Due to the rapid growth in pet food

demand, not only in Germany but

worldwide, KARL SCHNELL in cooperation

with the companies of the Pet Food

Competence Network is already well

prepared for the future.

Technology & Marketing

For more information

www.karlschnell.com

A SMART

MOVE.

Innovative raw material handling

for efficient pet food production.

Plant engineering

from a single source.

Zeppelin Systems has decades

of experience in raw material

handling and food processing.

We offer innovative solutions for

almost all processing stages to

efficiently produce dry and wet

pet food.

In addition, our 24/7 service and

decades of spare parts supply

ensure permanently smooth

production.

Pretty smart, isn’t it?

zeppelin-systems.com

Issue 3 2022

31


PROCESSING

The Role of Heat Exchangers in

Pet Food Production

By Matt Hale, International Sales & Marketing Director, HRS Heat Exchangers

Europe boasts some of the highest feed safety and animal welfare standards in the world, and consumers are

increasingly knowledgeable about products and quality. However, producing high quality pet food which

appeals to pets and their owners and which meets the necessary standards presents manufacturers with

some specific challenges.

Matt Hale, International

Sales & Marketing Director,

HRS Heat Exchangers

Thermal processing is a key part of pet

food manufacturing, with processes

including heating (pre-conditioning),

cooking, drying, pasteurizing and cooling.

However, the thick, viscous nature

of many of the meat-based products

presents challenges for handling, heating

and cooling.

Heat exchangers, often based on designs

for food and drink manufacture, provide

a safe and energy-efficient method of

performing these thermal processes to

meet the stringent regulations on safety

and quality which are often comparable

to other foodstuffs.

Scraped surface heat exchangers (SSHEs)

are particularly well suited for pet food

processing, including heating ingredients

such as meat slurry, jelly and gravy before

further processing, as well as heating or

cooling soft meat or fish ingredients.

However, while many food ingredients

such as meat products and slurries are

comprised of very thick and viscous

materials, they often need gentle

handling to preserve produce integrity

and texture. Therefore, the exact choice

of SSHE design will depend on the

material being processed and the level

of mixing required.

The HRS R Series uses a rotary scraper

bar which can reach speeds up to 300

rpm, providing high levels of shear and

mixing at the heat transfer surface:

increasing heat transfer. In contrast,

the patented HRS Unicus Series uses a

reciprocating design to provide high

efficiency heat transfer in a range of

Where ingredient integrity is not required by the end product, the

HRS R Series of rotating scraped surface heat exchangers is ideal

The patented HRS Unicus Series uses a reciprocating design to

maintain product integrity

32

Technology & Marketing


PROCESSING

difficult meat products which have high

fouling potential, but which also need

delicate handling to preserve fragile

product integrity.

Located in the UK, HRS Heat Exchangers

is part of the EIL Group (Exchanger

Industries Limited) which operates at

the forefront of thermal technology. HRS

offers innovative heat transfer solutions

worldwide across a diverse range of

industries. With 40 years’ experience in

the pet food and feed sectors, specialising

in the design and manufacture of an

extensive range of turnkey systems

and components, incorporating our

corrugated tubular and scraped surface

heat exchanger technology, HRS

products are compliant with global

design and industry standards. HRS has

a network of offices throughout the

world: Australia, Canada, New Zealand,

UK, Spain, USA, Malaysia and India; with

manufacturing plants in the UK, India,

Spain and Canada.

Technology & Marketing

For more information

www.hrs-heatexchangers.com

Matt Hale and Ian Healey

discuss the pet food sector

> extruders > feeders > components > pneumatic conveying > complete systems

COPERION’S ZSK Mv PLUS.

LEADING-EDGE TECHNOLOGY

FOR PET FOOD EXTRUSION.

+ Very gentle product handling for maximum quality

+ Hygienic design: open base frame, stainless steel

+ Less downtimes due to fast, efficient cleaning

+ Optimal accessibility

+ Screw speed up to 1800 rpm

Coperion‘s ZSK pet food extruder is a top-quality product at the highest technical level. It is known for very gentle

product handling at maximum throughput rates. For further information about Coperion‘s ZSK Mv PLUS please

visit Issue our website 3 2022at www.coperion.com/petfood-extruders

33


PACKAGING

Pouch and Alutray Expertise

Photos: Normandise Pet Food

NORMANDISE Pet Food is an expert in

manufacturing high added value on dry

and wet pet food for dogs and cats. It is

located in the city of Vire in a Normand

region called “le Calvado”. This Business

is in full growth by relying on an ultramodern

factory. NORMANDISE Pet Food

opens its doors every Thursday to visitors.

NORMANDISE Pet Food was founded

in Vire in 1991 by a veterinarian and

his wife. At that time it was the first

manufactury site of wet petfood in

France. This society is now a major actor

in petfood : “We manufacture 600 million

pouches and 300 million alutrays. Our

turnover is of 134 million euros” remarks

Julien Moureaux, NORMANDISE Pet

Food’s Communication Project Manager.

“We are the first manufacturer of single

pouches in France,” he also mentions.

There are more than 70 diversified occupations.

The company manufactures wet (mostly)

and dry, high value-added food for

cats and dogs. These complete feeds

are suitable for the physiological and

therapeutic needs of animals at different

growth stages.

NORMANDISE Pet Food’s portfolio

includes ten ranges and nearly 500

“varied and balanced” recipes, based

on fresh and frozen meats. “Our food

contains no processed animal protein

and nearly 80% of the meat comes from

France and the rest of the sourcing

normally takes place in Europe.”

“The formulations are based on the

knowledge of François and Jean Charles

Duquesne, the children of the founders,

who joined the family company in

2000 and are now in charge. François

Duquesne is an agro-food engineer

while Jean Charles is a veterinarian

which gives our products a guarantee of

quality,” underlines Mr Moureaux.

“We also rely on a high-performance

R&D department” and on a few

manufacturing secrets, including

large-scale sterilization techniques

which allows a two-year shelf life.“ To

accompany these “premium products,

elaborated with care,” the company has

just equipped itself with "a real logo, chic

and clean.”

NORMANDISE Pet Food develops its own

brands and also works for distributors

nationally and internationally. The

company thus accounts for 64% of its

export activity, relying in particular on

its strategic location near the port of Le

Havre.

“Our products are sold in many countries

of Europe, Australia, China, Mexico, Africa...

We are developing in South America and

in many countries in Asia,” says Julien

Moureaux. In France, the ranges are

sold in supermarkets, pet stores, on the

Internet or even at veterinarians’ cabinets.

“All cats and dogs from France have at

least tasted one of our products,” admits

Julien Moureaux

Label Industry of the Future

Showcase

Today the production site stretches over

40 000 m2, ”everything is done here and

the size of the factory grows regularly to

follow the growth of the production.” This

site is associated with a logistic platform

of nearby 25 000m2.

“Lately, a fourth extension has been

settled, which enables to increase the

storage space of 25%” points out the

communication project manager and

adds: “Our strength is to have a very

modern and automated factory” he also

34

Technology & Marketing


PACKAGING

quotes “the automated laser guided

forklifts which transport the pallets from

one line to another”.

Three years have passed since the

factory was certified as “Industry of the

Future Showcase". This certification

label is attributed to companies that

fully developed an innovative project

for the production organization through

digitalization and at the same time

letting the human force at the center

of this engaged transformation. “The

employees have key position”, stresses

Montreaux. ”There are more than 70

diversified jobs inside the company such

as line conductors, forklift operators,

administrators, dieticians, R&D engineers

and technicians, developers, etc. Due to

the fact that this activity is flourishing,

we are recruiting: experienced or

beginner line operators and drivers and

maintenance technicians.”

“We are proud of our site and products

we produced”, emphasizes Montreaux.

NORMANDISE Pet Food decided to open

its doors to the general public, ”As close as

possible to the production line”. Packing,

labeling, exchange with the operators…

These visits started on November 2021,

as part of the “Week of the Industry”

“These tours create a real interest in the

eyes of the employees that are eager to

share their working environment, and

people of the area, training centers and

industrial tourism passionate.” After this

“great success”, the board of directors,

“enthusiastic to show this beautiful

industrial tool”, continue this open house

every Thursday. NORMANDISE Pet Food

even plans to create a gateway over the

black spots for a complete visit. “As far as

I know, we are the only one to show all of

this. Our objective is to de-demonize the

pet food”.

Technology & Marketing

For more information

www.lanormandise.fr/en/

NORMANDISE Pet Food opens its doors to the

general public every Thursday

When it comes to food, our pets count on the reliability of their masters and

mistresses. And they in turn have to count on the reliability of their products –

so put your trust in VEMAG!

From wet food in bowls and cans to chew sticks and strips, jerkies and snacks:

with VEMAG‘s flexible and reliable machine solutions, pets get only the best.

VEMAG: The sign of success for your pet food production!

www.vemag.de · e-mail@vemag.de

Issue 3 2022

35


PACKAGING

No Waste Through Innovative

Highlights in Plastic and Paper-

Based Packaging

temperatures (0% at 150°C) which

makes them an alternative packaging

for a wide range of food, pet food and

non-food products. Additionally, they

support the circular economy through

better recyclability.

The Coveris Group will be introducing

a new range of sustainable innovations

supporting its industry-leading No

Waste vision at FachPack 2022.

Targeting shelf-life extension and

packaging waste reduction, Coveris will

showcase a comprehensive range of

both plastic and paper-based solutions

that meet these criteria.

Coveris is a leading European

packaging company that manufactures

flexible packaging solutions for some

of the world's most respected brands.

The company develops packaging

that protects all types of products -

from food to pet food, from medical

devices to industrial and agricultural

products. Organised in Business Units

that are focussing on Films, Flexibles

and Paper, Coveris is providing the

perfect platform to develop sustainable

packaging solutions for a greener

future. Coveris is headquartered in

Vienna, Austria and operates in 29

sites in the EMEA region with 4,100

employees.

“From Coveris’ perspective, it's not

about choosing between paper or

plastic packaging, it's about finding

the best, most eco-efficient and bestperforming

packaging for the respective

product - without any limitations in

material”, explained Jakob A. Mosser,

CEO of Coveris Group. “We are proud

to again display an industry-leading

range of sustainably designed films,

laminates and premade packaging

innovations at this year’s FachPack”.

Innovating for the future

To close the loop, Coveris’ innovation

power focuses on the development of

advanced, high performance packaging

designs with recycled content and

easy recyclability. One of the key

innovations at FachPack will be the

extended CPP Cleancast Films product

range for duplex and triplex laminate

alternatives on a polypropylene base.

The key benefit behind the excellent

performance of these cast unoriented

polypropylene films is the ability

to withstand re-shrinking at high

Increasing recycling and recovery in

a circular economy, Coveris will be

presenting two new solutions. New

wash-off labels, now available with

DPG approved security inks (1), are

designed for use with PET and rPET

bottles and containers. Compatible with

deposit return schemes (DRS), washoff

labels enable maximum clean PET

recovery for use in rPET and together

with DPG inks where required, support

a fully traceable, circular process. The

second solution is fully recyclable

transportation films with 30% recycled

content. Stretch films, including tubes,

are made using recycled plastic and

energy from renewable sources,

offering an efficient and sustainable

solution to stabilize up to 900 kg of

freight using just 800 grams of film.

Coveris’ extended range of recyclable PE

and PP MonoFlex films and laminates,

including grated cheese packaging, is

available in various formats and sizes

up to 12 kg and will also be on display.

Providing a direct replacement for

non-recyclable or difficult-to-recycle

plastics, MonoFlex packaging has been

developed to maintain product shelflife,

performance, functionality and

packaging efficiency.

Visitors at FachPack 2022 can also

experience first-hand Coveris’ focus

on paper-based solutions. Since its

introduction in 2021, the PaperBarrier

Seal barrier properties have been

further developed and extended,

offering functionality and product

safety while minimising both packaging

and product waste. Applicable for a

36

Technology & Marketing


PACKAGING

wide range of dry foods and snacks, this

development stands out by its special

paper coating which enables sealability

while remaining fully recyclable in

existing paper streams.

Full product range under one

roof

Brands looking for attractive dairy and

fresh produce recyclable packaging

alternatives will also find exciting

opportunities enhancing shelf-appeal,

product freshness and sustainability.

Among the wide range of industryawarded

lidding films, films and

laminates, every product combines

the best features of standard Coveris

products, including enhanced

convenience for opening and reclosing,

material weight reduction with an

attractive, premium look at point-ofsale.

A good example for the booming onthe-go

market is Coveris’ RecyclaPEel

MAP sandwich skillet developed for

longer shelf-life demands, excellent

product visibility and on-shelf appeal.

Featuring a sustainably sourced carton

board and a peelable polyethylene

(PE) film liner, the components are

separable and fully recyclable.

“We thoroughly believe in our No

Waste vison, reducing packaging

waste, product waste and operational

waste. We are continuously launching

truly sustainable innovations that

avoid waste in all its forms with no

compromise in quality and safety”,

summarized Jakob A. Mosser.

Technology & Marketing

For more information

www.coveris.com

Christian Kolarik, Coveris Group’s Chief Operating Officer (photo above , center), said “We are thrilled that

our sustainability strategy was recognized with a Green Star Packaging Award. We are convinced that

we are making an important contribution to protecting our climate with our No Waste vision, which is

characterized by an approach in two dimensions: On one hand avoidance of product waste, packaging

waste and operational waste and on the other hand the involvement of the entire Coveris organisation

from the shop floor via the group-wide Green Teams, to the management level and executive board. The

award we received and the fact that two other Coveris products were among the finalists makes us very

proud. This is an award for our employees as after all, they are working every day to make our vision of a

more sustainable future a reality.”

WHATEVER YOU

WANT TO PACKAGE:

JUST CLIP IT.

Experience our sustainable solutions

at FACHPACK on 27–29 September 2022.

Hall 3C, Stand 505

As usual, you can experience our machines live at the trade show booth. For the first time, we will

also be showing them virtually in action - a digital experience that will give you an even more vivid

demonstration of our high-quality clip solutions.

Issue 3 2022

polyclip.com | Excellence in Clipping

37


PACKAGING

Weighing Investment Reduces

Costs For Pet Food Manufacturer

The accuracy of Ishida weighing

technology has enabled leading Polish

pet food manufacturer United Petfood

Polska to maximise efficiencies and

reduce operating costs in the packing of

a range of granulated pet foods, leading

to a payback on the investment within 18

months.

The two Ishida CCW-SE3-214W-1S-20-

SS multihead weighers, 14-head models

with 2 litre hoppers, together with a

DACS-W and DACS-GN checkweigher, are

handling a range of products between

6mm and 25mm in size for pack weights

from 750g to 3kg. Speeds are 25 per

minute for packs up to 2kg and 16 per

minute for the heavier sizes.

United Petfood Producers is one of the

largest private label manufacturers of

premium dog and cat food, biscuits and

snacks, with plants across Europe including

two in Poland in Radom, Mazovia, and

Biskupice Ołoboczne in Greater Poland.

In an extremely competitive market, the

highest product quality is essential, and

the company has invested heavily to

become one of the most technologically

advanced and best-equipped suppliers of

dry pet food globally.

“The accuracy of the Ishida weighers

helps us to meet stringent quality

standards,” confirms Michał Gierz, Head of

Maintenance at United Petfood Polska.

The proven accuracy of the Ishida

multihead weighers delivers for United

Petfood consistent pack weights and

minimises product giveaway.In addition,

the multihead weighers have the

flexibility to handle a variety of differently

shaped products, meaning United

Petfood Polska is able to respond easily to

specific customer requests.

The installation of the Ishida weighers

formed part of the opening of the

new factory in Biskupice Ołoboczne in

2018.

The decision to invest in Ishida equipment

was born out of Michał Gierz’s previous

experience of the company while working

in the meat and dairy industries.

“Ishida equipment is very accurate and

reliable,” he explains. “The machines

work flawlessly. For me, they are the ideal

solution.”

He adds that the weighers are also easy to

set up and operate. “The software is very

intuitive,” he comments.

Top of CCW SE-214 close up Product on RFT

38

Technology & Marketing


PACKAGING

Mr Gierz says that the weighers work well

in all conditions. Cleaning takes place

every four hours for the dustier products,

and every eight hours for other varieties,

and the process is very quick and simple,

with moving parts easy to remove and

replace.

The initial installation of the equipment

went very smoothly, and full training was

provided for operators to help maintain

the efficient running of the lines.

“The cooperation between our plant and

Ishida is exemplary,” concludes Mr Gierz.

"We are very satisfied."

Technology & Marketing

Pack on DACS with

exactly 2kg

Finished packs after DACS

For more information

www.ishidaeurope.com

Issue 3 2022

39


MARKETING

AFB International to Create over

100 New Jobs in Columbus GA

Governor Brian P. Kemp has just

announced that AFB International,

a global manufacturer of pet food

ingredients, will invest more than $79

million in a new facility in Columbus,

Georgia, creating more than 100 new

jobs in the next five years.

"Since taking office, I have been laserfocused

on bringing opportunities to

every corner of our state, and I am

excited that a great company like AFB

is answering that call and investing

in the Columbus community," said

Governor Kemp. "Near Fort Benning,

AFB will find a highly capable

workforce ready to meet their needs.

I look forward to seeing this project's

impact, including its impact on the

many military and veteran residents

who could fill these quality positions."

AFB develops, manufactures, and

sells palatant ingredients to pet food

companies worldwide. Palatants are

ingredients that make pet foods,

treats, and supplements taste great,

About Applied Food Biotechnology

For over 30 years, AFB International

has been providing pet food solutions

that enrich the lives of pets and their

people. The company's palatants

are specially designed to make pet

foods, treats and supplements taste

better, ensuring pets receive the vital

nutrients they need. Headquartered

in St. Charles, Missouri, USA, AFB

has offices and production facilities

strategically positioned around the

globe in the United States, Argentina,

Brazil, Mexico, the Netherlands,

China, and Australia. AFB is a wholly

owned subsidiary of Ensign-Bickford

Industries, Inc., a privately-held,

family-owned, professionally managed

technical business that traces its roots

back more than 175 years.

ensuring pets enjoy their feeding

occasions and get the vital nutrients

they need.

"AFB is excited to become part of

the Columbus community," said

AFB International President Jared

Lozo. "We are proud of the work

we've done since 1986 to make pet

food taste great, and pleased to

continue our growth with the talented

workforce in the Columbus region.

For AFB, this plant is key to fulfilling

our commitment to be the most

responsive and reliable supplier of pet

food palatant solutions in the world."

AFB's new facility will be located at the

Muscogee Technology Park, a Georgia

Ready for Accelerated Development

(GRAD) Certified site in Muscogee

County. Operations are expected to

begin in 2024. The company will be

hiring for management, engineering,

operations, and administrative support

positions.

"As a global science and technology

leader, AFB will be a great partner

for our community," said Heath

Schondelmayer, Chairman of the

Development Authority of Columbus.

"We are extremely excited about this

announcement today because growing

Columbus and creating jobs for this

community is our top priority. Our

local economic development team and

our State of Georgia partners came

together to turn this opportunity into

a win, and we're confident that our

top-notch quality of life and talented

workforce will ultimately set up AFB

to achieve business success for many

years to come."

Project Manager John Soper

represented the Georgia Department

of Economic Development's (GDEcD)

Global Commerce team on this

competitive project in partnership

with the Greater Columbus Chamber

of Commerce, Georgia Power, and

Georgia Quick Start. For more than 50

years, Quick Start, provided through

the Technical College System of

Georgia, has helped assess workers,

train new employees on unique

processes on projects, and develop

customized job specific training using

the most current techniques and

media.

"AFB perfectly aligns with Georgia's

spirit of collaboration and innovation,

and we are excited for the jobs and

opportunities their new facility will

create for local communities," said

GDEcD Commissioner Pat Wilson.

"Urgency of customer demand has

been a key challenge for many

companies in the last year. We are

grateful for our partners in Columbus

for investing in speed-to-market

solutions like the GRAD program,

and we look forward to AFB's future

success in Georgia!"

In order to earn a GRAD program

certification, a property must undergo

due diligence and complete specific

certification requirements before a

prospective business visit. Completing

the GRAD certification program with

GDEcD is a proactive way for both

community planners and landowners

to help catalyze economic growth and

industrial development for the regions

they serve. Through this program,

Georgia has more than 60 industrial

certified sites ready for fast track

industrial projects.

Technology & Marketing

For more information

www.afbinternational.com

40

Technology & Marketing


MARKETING

Issue 3 2022

41


LAST PAGE

Upcoming Events

October 4 - 5, 2022

Nordic Pet Food Conference & Exhibition

Barcelona, Spain

www.norpetfood.com

December 3-4, 2022

12th India International Pet Trade Fair 2022

Bombay, India

www.iiptf.in

December 6-8, 2022

FI Food ingredients Europe 2022

Paris, France

www.foodingredientsfirst.com

May, 2023

Zoomark International 2023

Bologna, Italy

www.zoomark.it

October 3-5, 2023

VICTAM LatAm 2023

Sao Paulo, Brasil

www.victamlatam.com

March, 2024

Anuga FoodTec 2024

Cologne, Germany

www.anugafoodtec.com

March 18-19, 2023

Expozoo 2023

Paris, France

www.parisanimalshow.fr

May, 2024

Interzoo 2024

Nuremberg, Germany

www.interzoo.com

International Magazine November 2022 ISSN 2628-5851

Technology & Marketing 4/22

Preview November 2022

Food Ingredients Europe,

Vitamins, Hydrocolloids, Omega-3 Fatty Acids

Drying, Mixing, Extrution

Trays, Labelling, Pouches

… and lots more!

Ingredients: Insect Proteins, More Sustainable BARF, Pet Nutrition, Plant-Based Food

Processing: Healthy Kibbles, Hygienic Cooking, Modular and Flexible Solutions

Packaging: Recyclable Packaging and Bags, Inline Tray Sealer

Marketing: Vet's Corner, Pet Food Competence Network, Anuga FoodTec, IFFA, Interzoo

Impressum

ISSN 2628-5851

Technology & Marketing

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International Magazine September 2022 ISSN 2628-5851

LAST PAGE

Technology & Marketing 3/22

Fax-Inquiry

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or E-mail: food@harnisch.com

Ingredients: Plant-Based Food, Black Soldier Flies, Fibers and Cellulose, Grain Acceptability

Processing: Wet Petfood Processing, Quality Control, Heat Exchangers, Mixing

Packaging: Pouches and Alutrays, No Waste, Weighing Investment

Issue 3/22

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