09/12/2025

AI is Transforming the Pet Food Industry

The Current Challenge in Pet Food
Producers today face constant variations in raw materials, rapid formula changes, precise moisture control, and multi-ingredient dosing—along with growing demands for energy efficiency and sustainability. Addressing these challenges requires advanced automation that combines the physical robustness of machinery with the predictive power of AI.
The 'Eyes and Ears' of Industry 4.0
The use of sensors in plant engineering to measure variables, evaluate signals, and communicate with higher-level systems has long been a standard procedure. ANDRITZ takes it a step further by employing micro and wireless sensors, which expand data collection capabilities in critical plant areas. This enables much more detailed monitoring to optimize operations.
How AI Turns Operations into Tangible Benefits
The benefits that Metris brings to pet food plants are clear and measurable: production performance has increased by 7% to 16% thanks to automation and end-to-end process optimization, while energy consumption has been reduced by 3% to 17%, contributing to more sustainable operations. Additionally, the use of simulation and digital twins resolves up to 90% of issues before physical start-up, significantly reducing commissioning times. At the same time, proactive cybersecurity ensures asset protection through comprehensive monitoring under international standards such as IEC 62443, in collaboration with OTORIO.  
How Metris Boosts Pet Food Production
At ANDRITZ, automation in pet food production already enables precise dosing, moisture control, traceability, and flexibility in formula changes. Integration with Metris enhances these operations, making them even smarter. The platform allows for automatic adjustment of moisture and dosing based on the actual condition of each batch, predictive machine monitoring through sensors like Metris Vibe—which detect vibrations or temperature changes before they impact production—and direct interaction with the system via Copilot, which helps anticipate problems, suggests adjustments, and responds to operational queries in natural language.
Conclusion
With platforms like ANDRITZ Metris, the move toward more efficient, resilient, sustainable, and autonomous pet food plants is already a reality. At Clivio Solutions, we are ready to support the pet food industry in embracing the digital era by connecting technology, expertise, and results.
  By Clivio Solutions
Source: All Pet Food Magazine

03/12/2025

Control System Upgrade Streamlines Pet Food Production

The facility was operating with outdated electrical equipment that had become increasingly difficult to maintain. The existing automation was minimal, with operators manually adjusting critical parameters like water and steam rates based on moisture content readings. What automation did exist was fragmented across multiple PLCs scattered throughout the plant, creating 'islands of automation' that required operators to physically walk the production line to monitor and adjust different systems.
  The original Motor Control Centers (MCCs) were particularly problematic. During NorthWind's initial design assessment, the team discovered that the MCC layout was confusing and poorly documented, with unclear connections between buckets and the systems they controlled. This disorganization made troubleshooting time-consuming and complicated routine maintenance tasks.
Our Approach
NorthWind developed a comprehensive control system modernization strategy that addressed both the electrical infrastructure and control system architecture. Rather than working with the existing MCCs as initially planned, NorthWind proposed designing and building new Motor Control Panels (MCPs) that would house all motor control equipment for each system in one organized location.
  A key advantage in NorthWind's approach was the coupling of automation and electrical installation services. Instead of the manufacturer having to coordinate between separate vendors, NorthWind's integrated teams worked directly together to identify and resolve equipment changes, determine I/O panel locations and quantities, and design the network architecture. This collaborative approach minimized the burden on the manufacturer's team and allowed for rapid problem-solving without overwhelming the end user.
Phased Implementation
The implementation was carefully phased to minimize production disruption.
  Phase 1, completed in August, involved removing the existing MCC and Dryer I/O panel and installing new MCPs and I/O panels to control the existing dryer and newly installed coater. Despite an ambitious two-week timeline for equipment removal, installation, electrical work, I/O checkout, and commissioning, NorthWind's automation and installation teams coordinated efforts enabled I/O checkout to begin two days ahead of schedule and equipment commissioning to start three days early.
  Phase 2, which began 2 months after Phase 1 implementation, focused on the complete replacement of the second extrusion line. The NorthWind team maintained the project schedule and even performed some initial I/O checkout ahead of schedule. Their on-site presence throughout the installation process allowed them to identify and address system changes proactively, preventing potential delays during commissioning.
  On the automation front, NorthWind transformed the manual processes into an integrated control system. The new system automatically adjusts water and steam rates based on recipe setpoints, eliminating the need for manual valve adjustments. Instead of scattered PLCs and HMIs for each subsystem, the facility now has one unified control system per line with HMIs that monitor all systems, allowing operators to control and monitor the entire process from centralized locations.   The Impact   The modernization project delivered significant benefits to the pet food facility:
  Streamlined Operations: The unified control system eliminated the need for operators to physically walk the line to monitor different systems, improving efficiency and reducing labor requirements.
  Enhanced Maintenance Support: Updated electrical and controls hardware, along with accurate documentation, significantly reduced troubleshooting time and simplified maintenance procedures.
  Improved Process Control: Automated adjustment of critical parameters based on recipe setpoints ensures consistent product quality and reduces operator intervention.
  Operational Consistency: Similar controls for both production lines facilitate operator training and flexibility, allowing staff to seamlessly transition between lines.
  Reduced Downtime: The organized electrical system design minimizes the time required to locate and replace components, improving overall equipment effectiveness.
  Future-Ready Infrastructure: The control system upgrade provides a foundation for further automation and data collection initiatives.
  The customer has expressed extreme satisfaction with both NorthWind teams, particularly noting the quality of the electrical installation work and the process knowledge demonstrated by the programmers and controls technicians.
  Learn more about NorthWind's Solutions the Pet Food Industry or reach out to schedule a walk through of a system.
  By Bryan Reinecke, Senior Project Manager
Source: NorthWind

04/11/2025

ANDRITZ Chile Integrates AI for Pet Food Manufacturing

This shift is a fact at ANDRITZ Feed & Biofuel—we use technologies such as ACE (Advanced Control Expert), which integrates AI to optimize processes, reduce variability, and lower energy consumption.
  'The premise is clear: advance to more efficient, sustainable, and reliable processes. Thanks to AI, our equipment learns from data record, adjusts critical variables in real time, and makes decisions with no human intervention, ensuring more consistent stability in kibbles while contributing to our global commitment to decarbonization through the motto Growth that Matters,' says Ignacio Oliva, Sales Engineer from the Feed & Biofuel sector at ANDRITZ Chile.
  To illustrate, the executive affirms that their wide and robust portfolio has many developments, e.g., the 'intelligent copilot'—integrated in the HMI (Human Machine Interface)— that assists the operator with accurate insights depending on the recipes and conditions.
  'Technology works as a real-time conversational tool able to answer why pressure increases or which parameter needs adjustment, accessing the technical manual from the operation screen,' he adds.
  According to Oliva, ANDRITZ Chile plans to implement full autonomous process control by 2027-2028. In this way, AI will not only strengthen operational efficiency but also transform the experience of humans in plants, releasing time to do more valuable tasks.

  By ANDRITZ 
Source: All Pet Food Magazine

10/09/2025

Technological Revolution in the Pet Food Sector: Automation and IA are Changing the Industry

By María Candelaria Carbajo

Automation: Efficiency, Precision… and Scalability?
One of the most significant changes lies in the implementation of automated systems throughout the manufacturing process. From precise ingredient dosing to intelligent packaging, automated systems reduce mistakes, optimize time, and improve food safety. 

Production plants equipped with robotic arms and integrated production lines enhanced efficiency and minimized manual handling, allowing the technical staff to focus on higher-value tasks. The main advantage of robotics is production optimization. Robotics not only improve efficiency and product quality but also enhance scalability. Machines can operate 24/7 without downtime, ensuring continuous output when properly maintained. In addition, this automation facilitates regulatory compliance due to its traceability and real-time monitoring, while reducing variability in the final product because of human-related fatigue. 
Data-Driven Decisions Powered by AI
AI is playing a vital role in quality control, predictive analysis, and formula personalization. Using Machine Learning algorithms, companies can detect faults in the extrusion process, anticipate mechanical failures, or adjust production parameters to meet specific market needs.

Tools, such as generative AI, are being tested to enhance information and analysis through chatbots, allowing human operators to enhance their performance. By combining AI with Machine Learning, manufacturers can improve forecasting, simulate production scenarios, and make better-informed decisions. The goal: to empower decision-makers with accurate and well-informed insights.

While AI is increasingly integrated in manufacturing, data security and scalability emerge as critical concerns. Cloud Computing —cloud technology that allows manufacturers to test AI-driven pilot programs at single facilities before scaling them across multiple locations— is being implemented in different companies.

Another application is artificial vision, which enables millimeter-precise control over kibble size, shapes, and color —ensuring consistent standards without human intervention.

Companies joining digital transformation hand in hand with these tools will benefit themselves in many ways. However, they will face certain challenges, including investment costs, staff training, and the integration with existing systems.
Beyond Operational Performance
The advantages of adopting automation and artificial intelligence go far beyond speed and error reduction. Its impact changes the whole operation, generating more sustainable processes —by improving the use of raw materials and energy, they reduce waste and optimize available resources, crucial in a context with increasing precision for efficiency and sustainability.

They also provide agility in responding to changes in market demands, e.g., new nutritional trends or regulatory updates. In an environment where launches are more frequent and personalized, data-driven, flexible production systems offer a major competitive edge. These technologies also facilitate regulatory compliance and documentation required by the global market, which strengthens the commercial position. Digital transformation in pet food manufacturing not only improves operational performance but also redefines industry standards in quality, innovation, and adaptability.
Conclusion
Digital transformation in the sector does not happen in isolation, it addresses a sustained, growing context and a more competitive market. According to the American Per Products Association, in 2023, the pet food and snack industry reached $64.4 billion in sales, representing a 10.8% increase over 2022.  Projections are even more ambitious: the market is expected to exceed US$112 billion by 2030. Considering this, investing in automation and artificial intelligence not only is an operational improvement but also a key strategy to ensure long-term competitiveness, efficient scaling, and respond to a growing global demand.

What once felt like science fiction is now the reality of many pet food plants around the world. The convergence of automation, artificial intelligence, and analytics is setting a new industry standard —one that is smarter, more efficient, and more interconnected. Companies embracing this transformation will not only optimize current operations but also prepare themselves for the future.


By All Pet Food
Source: All Pet Food Magazine  

23/06/2025

Digital Transformation Journey: Guiding a Pet Food Manufacturer to Industry 4.0

Our Approach   To start the audit, NorthWind's Team met with plant production leads and process experts from each area of the plant, including forecasting, planning, production, maintenance, information and technology, research and development, purchasing, distribution, and accounting, with the primary goal of gathering information about current operations and flow of data throughout the organization. These meetings helped the NorthWind team understand the existing infrastructure and identify focus points.   Information Gathering Focus Points Evaluation of current technological infrastructure Diagnosis of the level of automation and current digital methodologies Identification in areas of opportunities for improvement Manufacture's capabilities to integrate industry 4.0 technologies Review of current metrics on operational efficiencies and quality Evaluation of current metrics on safety and sustainability Review of current key performance indicators (KPIs)   After gathering the information NorthWind developed, in collaboration with plant personnel, an on-site agenda planned around production schedule and personnel availability. While on-site NorthWind identified and analyzed the existing gaps, deficits, and areas of opportunities with respect to the adoption of Industry 4.0 standards.   At the conclusion of the site visit, NorthWind developed a comprehensive report outlining the plant's digital transformation journey. The report included the current status of the manufacturing practices, diagnosis of areas of opportunity, and proposed an actionable plan with progressive milestones to fully achieve Industry 4.0 manufacturing standards.   Digital transformation recommendations   Below is a sample of the recommendations the NorthWind Team provided or discussed with the manufacturer based in the findings in the audit. Discussed the importance of a Raw Material Silo Inventory System. Reviewed Manual Documents that would benefit from a digital format. Recommended a replacement and modernization of the existing control system. Reviewed alternatives to implement seamless upstream and downstream equipment. Reviewed data collection and material tracking benefits for ingredients throughout the plant. Reviewed automation alternatives for Setpoint management for dosing raw material. Established Rework Integration Protocol on Production Line. Reviewed the benefits of automation for the Extrusion Process. Reviewed the benefits of automation for unloading finished product silos and provide material tracking. Proposed a data collection system in the packaging area by communicating with robotic arms, bagging machines, and using a barcode tracking system. Reviewed implementation of a Warehouse Management System (WMS). Increase cybersecurity of the plant control system.   The recommendations can be completed in phases, and the desired Industry 4.0 goals can be achieved with modernization of the process control system, MES Dashboards (Manufacturing Execution System), Digital Solutions (network architecture and topology), Integration with their ERP System, Cloud connectivity, and redundancy.   The impact   Based on the report's findings, the customer can expect the following Customer Benefits after implementing Industry 4.0 practices: Increased Efficiency: Automation and connectivity lead to streamlined processes, reducing downtime and enhancing productivity. Improved Quality: Advanced technologies such as machine learning and AI can monitor production quality in real-time, allowing for quicker adjustments and reducing defects. Greater Flexibility: Smart manufacturing systems can quickly adapt to changing market demands, enabling mass customization and shorter lead times. Enhanced Data Analytics: Industry 4.0 collects vast amounts of data, allowing manufacturers to gain insights into operations, customer preferences, and market trends for better decision-making. Cost Reduction: Optimized processes and predictive maintenance can lower operational costs through efficient resource utilization and reduced waste. Supply Chain Optimization: Real-time data sharing enhances collaboration across the supply chain, improving inventory management and reducing bottlenecks. Sustainability: More efficient energy use and reduced waste contribute to more sustainable manufacturing practices, aligning with environmental goals. Workforce Empowerment: Digital tools can enhance worker capabilities and safety by providing real-time information and training resources, fostering a more skilled workforce. Remote Monitoring and Management: IoT technologies facilitate remote oversight of manufacturing processes, enabling quicker responses to issues and greater operational control. Innovation benefits: The integration of advanced technologies encourages continuous innovation, allowing manufacturers to develop new products and services quickly.   The pet food manufacturer gained a clear, actionable roadmap for their digital transformation journey toward Industry 4.0. The comprehensive site audit provided valuable insights into their existing infrastructure, allowing them to identify key areas for improvement. With NorthWind's guidance, they now have a strategic plan to enhance efficiency, performance, and future scalability. As they implement these recommendations, they are well-positioned to optimize operations and stay ahead in an increasingly digital and automated industry.   Learn more about NorthWind's Solutions the Pet Food Industry or reach out to schedule a walk through of a system.   By Aldo Martínez Source: NorthWind Technical Services