This issue starts off with an interesting article from Bestmix, Carmen Sook describes the process of making dry kibble. Yes, the process is quite involved and takes numerous steps to achieve the in the bag desired formula. Knowing your starting moisture, what to add, remove and what the losses are in down-stream equipment coupled with the added ingredients, normally liquids, not passing through the extruder need to add to one hundred percent to achieve the designed in formula. It has been fun understanding the goal, studying the equipment and designing accordingly to achieve the goal and it is also exciting to see software to assist in these endeavors. Considering the number of formulas made in petfood plants, this assistance shows value to the producers.
Marine hydrolysates are the next topic and one of great interest as I have always thought these products could be used to a higher degree. Instead of making a fishmeal by drying they are enzymatically processed into a hydrolysate which in liquid form makes it quite easy to program via a variable speed pump and flow meter into the production system. I firmly believe these kinds of ingredients have a better flavor profile due to avoidance of the added drying step to make them into a meal.
Dr Shiguang Yu, Global Director Pet Nutrition, dsm-firmenich, explains the advantages of using premixes now produced in Haag, Austria; Tonganoxie, Kansas (USA) and Itatiba, Brazil, strategically located in major petfood markets.
Bruna Agy Loureiro, Senior Pet Nutrition Expert, Protix, reports on black soldier fly testing for preference in a blind dog owner test procedure. Results show that the total protein source diet with black soldier fly was equally, slightly better, then the chicken- based diet. The Interview with Marco Prati of PLP Systems points out the interactions with clients for improving processes. Must admit having specified his system on multiple projects and how they worked to perfection. Keep up the good work and beyond.
This issue has centered on ingredient advancements thus a side note on what is being seen in the machinery production side of petfood processing. As a note following Andritz, Famsun, Wenger, Extru-Tech and Bühler closely it is apparent that the development of improved- equipment is ongoing and continuing. All of these have worked hard at some level of increased meat inclusion in their process. The level of inclusion might vary but the trend is clear. Without a doubt the improvements are in preconditioning, barrel set ups and die related advancements. The question is how high do you wish to go in meat or fat inclusion?
Wenger, owned by JBT Marel, has taken the inclusion level to new heights with possibilities near or exceeding 90 percent fresh meat inclusion. The synergy with JBT Marel has offered new and exciting options within the equipment ranges offered to achieve these levels. Samples viewed are amazing and not expected in extrusion cooking. The same equipment can also be utilised for more standard applications or designed for solely high meat inclusion. Specialised drying formats enhance the ability of the extruders to achieve the final product specifications. The EXPRO AI system as mentioned below is available as well as the PetFLEX and AquaFLEX design extruders. These systems allow processors to easily switch back and forth between traditional or high fresh meat formulas or control density with ease.
Extru-Tech also owned by JBT Marel is advancing the meat level and petfood production process with novel precondition advancements as well as in-barrel designs to achieve elevated levels. They now also offer the EXPRO AI, a system to optimise process setpoints using predictive modeling and real time data to automatically determiner the setpoints.
Andritz has come out with a new end of barrel flow restriction device which increases the level of hard-to-produce ingredients with improved ease. Years ago, they acquired Aeroglide and thus have always been a powerhouse in drying technology as well the full line of gear offered. Moves in the digital arena with their Advanced Process Control for real time monitoring and reduced energy consumption. High efficiency conditioners in the EX and SPEX series improve production by 15 to 20 percent.
Bühler has always had a multitude of possibilities with their wide range of equipment offered and continue to advance their processes. Their new Nutrex 7 Series centers on food safety, efficiency and user friendliness.
Famsum is also uniquely advancing with reviews of higher meat inclusion in their FX190 extruder. This includes advanced preconditioning also promoting the new water and steam injection and increased gelatinisation, up to about 95 percent. In addition, they have also advanced some end of barrel flow control devices as well as technology to control the process with starch gelatinisation optimisation. Start-up waste reduction as well as advanced drying techniques now exist.
Without a doubt there are many others, but the point is the industry is advancing not only in the ingredient arena but also in the equipment side of the business. Mixing and mixing programs, micro ingredient measurements, extrusion, drying, conveyors, packaging, automatic controls, sanitation methods and equipment, inventory controls, plant designs and many others are changing the industry with advancements constantly moving forward.
