26/06/2026

World Leading Petfood manufacturer chooses Samplex CS90 for Chinese Feed Factory.  

The Samplex CS90 is a versatile and efficient device that can sample a variety of products, such as grains, oilseeds, powders and pulses, and pellets. It is used in high throughput facilities worldwide, such as ports, terminals, mills and silos.
  The Samplex CS90 will help them to ensure the quality and safety of their pet food products, as well as to meet the ISO 24333:2009 (E) standards for sampling.
  The Samplex CS90 has a patented spear design that ensures product enters the spear under gravity, providing a truly representative sample, which is vital for quality testing.
  Mars Petcare is the leading pet food company in the world, with annual revenue of USD 37 billion. It owns several well-known brands, such as Pedigree, Whiskas, Royal Canin, and Iams. The company operates in more than 80 countries and employs over 85,000 people.
  China is one of its key markets, and it is committed to providing high-quality and nutritious pet food to Chinese consumers.
  They are investing in innovation and sustainability to meet the changing needs and preferences of pet owners.
  The Samplex CS90 truck probe is exclusively manufactured in the UK by TekPro Ltd., a company that specializes in sampling and insect detection systems for the agricultural industry. The company has been in business since 1989 and has exported its products to in excess of 60 countries around the world


For more information about Samplex CS90 truck probes or other products from TEKPRO, visit their website at www.tekpro.com or contact them by email at info@tekpro.com. Source: Tekpro

03/06/2026

The Invisible Cost of Low-Cost Raw Materials: Their Impact on Profitability

In practice, the unit price rarely reflects the total cost of using an ingredient. Factors such as stability, standardization, technological performance, and supply chain reliability have a direct impact on industrial efficiency and the consistency of final products. Overlooking these variables results in a series of invisible costs that, over time, compromise operational profitability.
The Limits of Price-Based Comparison
Traditionally, many procurement processes are still based on direct price-per-kilogram comparisons. This approach assumes that equivalent ingredients can be evaluated solely based on their purchase cost. However, seemingly similar raw materials may present significant differences in parameters, including particle size, moisture content, purity, active compound concentration, or functional behavior within the formulation.

These differences often go unnoticed during commercial negotiations but become evident during production. When an ingredient shows variability between batches, industrial operations must constantly adapt to maintain process stability. Adjustments in temperature, pressure, moisture, or inclusion rates become necessary to compensate for unexpected variations in the original formulation.
Variability: One of the Main Hidden Costs
Variability is one of the most relevant hidden costs associated with lower-priced raw materials. In extrusion lines, for example, small differences in water absorption capacity or physical behavior can affect kibble expansion, product texture, or final density. These effects require frequent operational corrections and reductions in production predictability.

Another common impact is related to industrial performance. Ingredients with lower levels of standardization may increase the generation of fines, reduce pellet durability, or result in a higher proportion of out-of-spec material. In some cases, this leads to reprocessing or partial product discard, which increases energy consumption and reduces line efficiency.
When the Cheapest Ingredient Requires Higher Inclusion Rates
This is a frequent phenomenon in the industry. Low-digestibility protein sources may require higher inclusion levels to achieve the same nutritional value, reducing the initially perceived savings. Similarly, mineral ingredients with lower concentrations of active compounds may demand higher inclusion rates to deliver equivalent nutritional contributions.

Functional extracts or technological additives lacking proper standardization may also deliver inconsistent performance, requiring frequent formulation adjustments or operational corrections.
In more evident cases, these variations impact the performance of the final product—whether in palatability, appearance, or consistency—leading pet owners to perceive a decline in quality and directly affecting brand trust and satisfaction.
The Technical Cost of Corrective Formulation
Beyond direct production impacts, there is also a frequently underestimated technical cost: the time dedicated to corrective formulation. Regarding raw materials with high variability, R&D and quality teams need time for analysis, internal testing, and specification adjustments. This effort is rarely accounted for as part of the ingredient cost, yet it represents a significant allocation of specialized resources.
Traceability and Supply Chain Reliability
Another relevant factor is raw material traceability. The pet food industry faces growing demands related to supply chain transparency, food safety, and regulatory compliance. Ingredients with unclear origin or limited technical documentation may be challenging during audits, raise regulatory concerns, and generate uncertainty in specification standardization.

In this context, supplier reliability and control over the production chain become strategic factors. Batch-to-batch consistency, availability of analytical data, and clarity regarding the raw material source contribute to reducing operational risks and ensuring more predictable formulation performance.
Redefining the Concept of Value
This reality reinforces the expansion of the concept of value applied to ingredients in the pet food industry. For a long time, purchase price was considered the main selection criterion. Today, the true value of raw material clearly lies in its ability to deliver stability, functionality, and safety throughout the entire production process.

When an ingredient behaves consistently, formulations can be precisely executed, reducing the need for operational adjustments. It results in more stable production lines, better use of industrial capacity, and greater predictability in final product quality.
A New Question for the Industry
In this scenario, evaluating the total cost associated with an ingredient—not just its purchase price—becomes increasingly important. Instead of asking how much an ingredient costs per kilogram, the more relevant question may be: how much does the variability it introduces cost? 

Companies adopting this broader perspective are better positioned to build more stable supply chains, reduce operational risks, and develop more efficient production processes. In the long term, this approach contributes to more predictable margins and stronger brand trust. By Ludmila Barbi Trindade Bomcompagni – All Pet Food
Source: All Pet Food Magazine

By Ludmila Barbi T. Bomcompagni

30/06/2026

Strategic Value in the Pet Food Industry

Today, the real value of raw material is built from multiple factors that go beyond its cost or chemical composition. Traceability of origin, as well as the ability to preserve its properties during storage and production, have become determining variables for pet food manufacturers.
  In this context, the relationship between ingredients and process technology becomes increasingly relevant because the quality of a raw material depends not only on its origin but also on how it is managed within the production plant.
New Ingredients, New Demands for the Industry   The evolution of the pet food market is driving an unprecedented diversification in the types of ingredients used in formulations. In addition to traditional raw materials, new protein sources, functional compounds, and specialized additives are now being incorporated to meet increasingly specific nutritional demands.
  This expansion of the ingredient universe introduces new challenges for production plants. Each raw material has particular physical characteristics that influence its behavior during storage, transport, and dosing.   When the Physical Behavior of the Ingredient Becomes Critical   Beyond their nutritional profile, raw materials used in the pet food industry exhibit very diverse physical behaviors. Variables, such as particle size, moisture, bulk density, or the tendency to compact, can significantly affect how ingredients behave within solid handling systems.
  Ingredients, such as animal and plant-based meals, protein by-products, fish meals, or certain concentrates, often present flowability issues, generating phenomena that include compaction, arching, or dead zones within silos and/or storage cells.
  When this occurs, the consequences may go beyond a simple interruption of the production process. Prolonged retention of stored material can lead to ingredient degradation, cross-contamination between batches, or loss of traceability within the production chain.
  In other words, a high-quality raw material can lose part of its value if it is not properly managed within the plant.
The Impact of Storage on Ingredient Quality   One of the least visible aspects in the pet food value chain is the impact that ingredient storage and retrieval systems have on the final quality of the ingredient.
  In many cases, traditional silos present limitations when handling low-flowability materials. The formation of internal bridges or tunnels can prevent uniform product flow, creating areas where raw material is retained for long periods.
  In the case of flat warehouses organized in cells, there are also relevant challenges from both operational and quality perspectives. The absence of automated extraction systems makes it difficult to efficiently manage material flow, increasing the risk of excessive handling and, consequently, product contamination. Likewise, the inability to ensure proper rotation under the FIFO (First In, First Out) criteria may result in prolonged storage of certain batches. There is also an operational risk associated with storage at height, where pressure exerted by the material itself can cause compaction or crushing, affecting the physical characteristics of the raw material and its subsequent performance in the process.
This phenomenon not only affects operational efficiency but also compromises the proper rotation of stored products. When controlled flow under FIFO principles is not ensured, older raw materials may remain in the system while new batches enter the production process.
  For an industry that demands high standards of quality, traceability, and food safety, these situations represent a significant challenge.
Technology to Preserve Ingredient Value
Faced with these challenges, process engineering and material handling technologies play a key role in preserving the real value of raw materials within the plant.
  Among these solutions are extraction systems developed by Laidig Systems, designed to work with low-flowability materials and products that tend to compact during storage. These systems allow for progressive and uniform recovery of stored raw material, promoting proper rotation.
    This type of technology helps maintain more stable storage conditions, reduce retention, and ensure that ingredients are used within controlled time and quality parameters.
  Additionally, automation of the discharge process eliminates the need for manual intervention inside silos, significantly improving operational safety conditions within the plant.
When Engineering Becomes Part of Quality   Efficient raw material management depends not only on ingredient quality or the design of individual equipment. It requires a comprehensive vision that considers the entire handling chain within the plant: from initial reception to incorporation into mixing or processing stages.
  In this context, industrial engineering solutions make it possible to integrate storage systems, internal transport, dosing, and process control into a coherent and efficient production architecture.
  At Clivio Solutions, we work on the development and implementation of engineering solutions for efficient raw material handling, adapting international technologies to the specific needs of each plant. The goal is to ensure that raw materials maintain their quality, traceability, and functionality throughout the entire production process.
The True Value of Raw Material   The evolution of the pet food sector shows that the concept of value associated with ingredients is changing. Today, raw material is not evaluated solely by its price or nutritional composition but also by its ability to integrate efficiently into increasingly sophisticated production systems.
  In this new scenario, ingredients, technology, and processes are part of the same industrial ecosystem. The way a plant manages its raw materials can directly influence final product quality, process stability, and supply chain reliability.
  For this reason, the real value of raw material is not only found in its origin or formulation but also in the industry's ability to preserve it throughout the entire production process. By Clivio Solutions
Source: All Pet Food Magazine

11/05/2026

Greater Efficiency, Less Space: The Rise of Compact Palletising  

Compact palletising has emerged as a response to this reality: automating the stacking of sacks in confined spaces without compromising stability, productivity or pallet quality. In this article, we analyse the technical fundamentals, competitive advantages and operational impact of compact palletising, showing you some examples of solutions proposed by TMI.   What is a compact palletising system?
Compact palletising refers to automated configurations designed to minimise industrial floor space without sacrificing essential functionalities: controlled handling, configurable patterns, compaction, and the ability to integrate wrappers, accumulation tables or empty load modules.
  In other words, the aim is to design automated configurations capable of maintaining positioning accuracy and structural stability, whilst reducing the system's footprint.
  These are typically flexible, pre-assembled, modular and scalable configurations that allow for high OEE without taking up more space than necessary.
  This type of solution is particularly relevant in scenarios such as:
  Plant conversions where it is not possible to expand floor space. Lines with multiple inputs that require decentralised palletising. Medium-speed processes (500–1,500 bags/h) requiring cost-effective yet automated solutions. Architectural constraints, whether due to headroom, structural columns or operator movement.   Design, operation and safety of compact palletising systems   A compact system must meet the same critical requirements as a conventional palletiser:
  Positioning accuracy on the X, Y and Z axes. Mechanical stability of the palletised load (with layer-forming stops). Compatibility with different formats, weights and production levels. Ease of maintenance and technical access.
  In this regard, solutions such as the ILERPAL H, ILERPAL L and ILERPAL P embody different approaches within the compact concept.
  The ILERPAL H model, with a closed structure and vertical bag lifter, allows layer formation and transfer to be integrated into a small space, whilst maintaining high production rates and high-quality finishes.
  The ILERPAL L, designed in a demountable configuration with low-level pallet loading, is particularly suitable for facilities with limited access or logistical constraints, without compromising on stability or performance.
  For its part, the ILERPAL P offers a modular architecture that facilitates extremely compact configurations, adapting to plants where space is the main constraint of the project.
  Furthermore, all TMI's compact models allow integration with strapping via ILERGIR, enabling the end-of-line cycle to be completed without the need to expand the layout, thereby consolidating a fully automated cell within a minimal footprint.   Advantages of compact palletising over traditional systems
The advantage of compact palletising is not limited to space savings, but has other direct implications for day-to-day operations.
  Reduction in the system's total footprint: by reducing floor space by up to 40% compared to traditional configurations with extensive tables and conveyors, space is freed up for circulation, storage or future expansions.
  Energy efficiency: by eliminating lifts, heavy chains or auxiliary conveyors, electricity and compressed air consumption is reduced, which has a direct impact on the operational cost per palletising cycle.
  Reduced implementation times: the modular nature of these solutions typically results in shorter implementation times. The ability to supply pre-assembled cells reduces the need for civil engineering work and speeds up FAT and SAT validation processes, a decisive factor when production schedules are tight.
  High adaptability to format changes: from an operational perspective, recipe management via HMI allows palletising patterns to be changed without manual mechanical adjustments, facilitating adaptation to different SKUs or production batches.
  Minimal impact on the existing layout: compact systems are ideal for integration into existing lines without the need for logistical or flow redesign, thereby reducing friction in retrofit or modernisation projects.   TMI's experience with compact palletising
At TMI, we have deployed compact solutions in plants across more than 40 countries, tailoring each cell to the customer's production, space and flow requirements.
  The rise of compact palletising is particularly evident in sectors where plant density and operational robustness are critical, for example:
  Chemicals and agrochemicals: where mechanical strength and a sealed environment necessitate low-maintenance lines with a closed design. Ingredients and dry food: frequent batch or SKU changes require versatile, compact and easy-to-clean systems. Salts and additives: aggressive or dusty products, where structural simplicity and direct access to the maintenance area are critical.
  The challenge in these cases is not merely to produce more, but to do so with greater space efficiency, lower energy consumption and greater flexibility in the face of market changes. Integrating compact solutions at the end of the line allows for automation in a small space, optimising the layout without compromising performance.
  If you are considering optimising your factory floor space without compromising on productivity and stability, TMI's technical team can help you design a compact palletising solution tailored to your production needs. Find out more about our palletising solutions on our website.
Àngel Pedrós Castany, Product Owner en TMI Bagging & Palletizing. Source: TMI Bagging & Palletizing

10/07/2025

Challenges in Batching in Animal Nutrition Plants

Batching is a critical process in the manufacturing of animal nutrition, impacting product consistency, efficiency, cost management, and overall quality. A proper batching 'system' (or process) ensures that raw materials are combined in the correct proportions to produce consistent, high-quality products that meet industry standards and consumer expectations. This relates to collecting and weighing all bulk, major, micro and nano ingredients and mixing them until the mix is ready for the next steps in the process.   In this whitepaper, you will learn: The Critical Role of Batching: Why batching is fundamental to consistent product quality, cost control, and operational efficiency in animal nutrition plants. Key Industry Challenges: Insights into ingredient variability, labor shortages, and manual errors that impact production in feed, pet food, and premix manufacturing.  Automation and Smart Systems: How advanced batching systems, including feeders, weighers, and control software, improve accuracy, flexibility, and traceability. Best Practices for Optimization: Actionable strategies for reducing downtime, improving mixing efficiency, and maintaining compliance with regulatory standards. Cost of Poor Batching: A breakdown of the hidden costs - from waste and recalls to brand damage - and how proper systems mitigate these risks.   Click here to download it   Source: KSE Group

10/09/2024

Innovating together: A new development for the premix pet food industry

The customer's choice of the CS-WP solution   An American-based customer of KSE, operating in the premix industry, selected the CS-WP solution due to an urgent need to optimize space utilization in their production facility. This innovative solution enabled them to save significant vertical space, with reductions of 4 to 5 meters compared to a conventional weighing system. Additionally, the CS-WP system offers direct separation of contaminants for all raw materials, ensuring the entire facility remains free from contamination.   Another customer in Spain, a leading manufacturer in the food additive industry, has also expressed interest in the CS-WP solution because of their stringent contamination control requirements. The CS-WP system allows macro ingredients to be safely transported in dedicated containers, ensuring clean and flexible distribution to three separate mixing lines.   Exploration of market-based alternatives   The customer explored two alternative solutions. Initially, a traditional pneumatic conveying system was considered but dismissed due to hygiene issues and excessive energy consumption. The second option involved a container concept relying on AGVs (Automated Guided Vehicle). Ultimately, KSE's CS-WP concept emerged as the most fitting and seamlessly integrable solution, enabling the maintenance of the desired compact building height.   Future expansion and developments   The client positions the CS-WP project as the ''Next Generation Plant'', hinting at the possibility of establishing future plants based on the same concept. This marks the inaugural joint project for the Spanish customer and KSE, with aspirations to extend this concept to other facilities, thereby assuming a pioneering role in the Spanish food additive industry.   A breakthrough solution   The CS-WP emerged as a groundbreaking weighing solution within the ACT (Automatic Container Transfer) framework, renowned for its internal transport capabilities. Manufacturers are seeking space-saving solutions in their plants while aiming to achieve minimal contamination by dispensing products directly into containers. Tailored to accommodate a wide dosing range, this solution stands out for its versatility.   Intensive development process   The concept promptly resonated with our customers' needs and industry demands, particularly in sectors like premix and pet food. The development process of the CS-WP entailed tackling several design challenges, such as achieving optimal balance in the setup. With dimensions of approximately 1.5 meters x 1.5 meters and a height of 5 to 6 meters, this resulted in a column four times as tall as it is wide. This configuration posed potential tipping hazards, especially when the system was in motion while carrying weight at the top. To prevent this, rollover safeguards were implemented, and extensive testing was performed.   Another crucial aspect involved a meticulous examination of the system's extraction process. Customers typically invest in an ACT system to maintain a pristine working environment with minimal contamination. However, if dust escapes through open joints during each movement, this objective is compromised. Moreover, the extraction process must not interfere with the weighing signal during the dosing process, ensuring that accuracy is not compromised.   Following extensive consultation and collaboration with suppliers, multiple concepts were devised and executed by the mechanical, electrical, and software teams. Presently, two variants are available: one where dust from the filters returns with the product, minimizing contamination but ensuring all product accompanies it through processing, and another where dust extraction directs waste to a remote unloading point, eliminating contamination but resulting in waste. The selection between these variants depends on the customer's specific needs and requirements.   The operational phase   During the implementation phase of industrial solutions, addressing technical challenges is only part of the equation; understanding real-world usage is equally vital. Hence, KSE engages its service department from the beginning of a project to ensure that aspects, such as cleaning positions, accessibility, and installation safety are meticulously accounted for. This approach establishes a robust groundwork for a successful project, enhancing both efficiency and safety.   By: KSE Process Technology   Source: All Pet Food Magazine

25/11/2025

Increasing Efficiency in Pet Food Production - Why You Should Think About Grinding

The main challenges pet food producers face in grinding today are:
  New high fat and protein rich recipes for optimal nutrition. Demand for fine uniform texture and well looking appearance requires fine grinding.  Increased energy cost decrease margines and grinding is one of the most energy consuming process steps.   Evolving Ingredients, Evolving Demands   Modern pet food recipes incorporate a growing variety of ingredients or higher meat and bone meal content causing unique milling challenges due to higher protein, fat, and moisture content. Premium pet food recipes often contain bone meal and meat content of more than 30% and a fat level higher than 8%.
  Older hammermills struggle with these recipes, tend to clog when processing such components, leading to increased energy consumption and heat buildup. These issues not only drain more power but also degrade sensitive nutrients, compromise product quality, and necessitate more frequent maintenance.   FD 32 Pro hammer mill installed in pet food production   Fine Grinding and Extrusion Performance   Beyond the nutritional benefits, particle size has a significant impact on extrusion performance. Finer and more uniform grinding improves water absorption and starch gelatinization during the extrusion process. These factors influence the consistency, fineness, and bulk density of pet food. In addition, finer and more uniform grinding reduces wear on extrusion equipment, thereby reducing maintenance costs and downtime.
  While fine grinding offers clear advantages in terms of nutritional value and processing, it also poses a significant challenge for hammer mills. Smaller screen sizes are required to achieve finer grinding, which often results in lower throughput and higher energy consumption. In addition, the risk of screen clogging increases and more heat is generated due to longer grinding times.
  Excessive heat can break down sensitive nutrients and cause starch to gelatinize prematurely. This heat can also overheat mechanical parts and, in extreme cases, increase the risk of fire.
  Many hammer mill systems were not designed for fine grinding. Older systems were designed for coarser grinding degrees, where a medium fineness was completely sufficient. Fine grinding requires higher rotor speeds, larger screen areas, optimized air flow, and intelligent process integration. Without these prerequisites, manufacturers are faced with rising operating costs, production losses, and unnecessary losses that have a direct impact on profitability.   The FD 32 Pro: Modern Hammer Mill Made for Pet Food Producers   Tietjen new FD 32 Pro hammer mill was designed to face these challenges and is engineered to address precisely these energy and process challenges. Key innovations include:
  Expanded 4.8 m² screen area: Allows high capacity grinding to feed the new generation of extruders with only one mill. This saves investment and operational costs 
  Reduced beater-to-screen gap: Minimizes screen clogging even with high-fat ingredients
  Variable speed drives: Permit optimized rotor speed, so the mill only uses as much energy as needed for each recipe
  Impact plates & modular screens: Shorter retention time of the product in the mill and screens that fit ideally for the product allow for faster grinding with less energy 
  Quick-change beater frame system and User-Friendly Design: Large sliding doors, easy beater change, and robust construction allow for long service life, further lowering downtime.
  In sum, the FD 32 Pro is the next step in hammer mill design—a focus on energy efficiency, high-capacity fine grinding, and operational simplicity—helping pet food manufacturers turn modern processing into opportunities for sustainable, profitable growth.    0.8 mm (20 -25 mesh) screens after grinding fat and protein rich pet food recipes   Due to its large size, the FD 32 Pro mill enables pet food producers to achieve both high throughput and fine particle size simultaneously when grinding pet food formulations. The throughput of the hammer mill complies with the requirements of the newest generation of high-capacity extruders.   The FD 32 Pro can process even protein- and fat-rich recipes through a 0.8 mm screen (roughly mesh size: 20 to 25) without clogging—something most mills cannot achieve without repeated stoppages or multiple machines.   Save More Energy with an Optimally Designed Grinding System   To achieve even greater improvements and maximize both energy and production efficiency, it is essential to rely not only on the high-capacity FD 32 Pro hammer mill, but on the entire grinding system. Looking at the grinding process as a whole opens up several opportunities for significant energy savings and operational improvements. 
  Pre-crushing of coarse ingredients
By integrating a pre-crusher such as the CR900 from Tietjen, coarse ingredients (legumes or large pellets) can be pre-crushed before entering the hammer mill. The result is a more homogeneous product that requires less time in the hammer mill, reducing both residence time and heat generation.
  Optimized aspiration and product transport save energy
Correctly designed aspirations contribute significantly to increasing process efficiency in hammer mills.
  Improved product discharge
The extraction system supports the targeted removal of particles that have reached the desired fineness. Coarse components remain in the grinding chamber until they are sufficiently crushed. Insufficient extraction would also leave fine particles in the grinding chamber, resulting in reduced throughput, higher energy consumption, and unnecessary strain on the machine.
  Thermal stabilization of the ground material
During the grinding process, frictional heat is generated, which can significantly heat up the ground material. Aspiration reduces this effect, as the air flow continuously cools the material. This prevents temperature-related damage to sensitive ingredients, helps to ensure consistent product quality and minimizes the risk of dust explosions.
  The professional design and integration of aspiration is therefore a key factor for operational safety, energy efficiency and product quality in the hammer mill process.   Uniform product distribution
The feed device of a hammer mill performs several key tasks: it distributes the feed material evenly across the entire width of the mill in order to make optimum use of the impact and sieving surface, keep the wear uniform and use the drive power efficiently. For product mixtures with components of different weights and that are difficult to grind, the system automatically adjusts the feed rate—controlled by the motor load of the mill (load-dependent dosing)—so that the operating point always remains optimal. In addition, the feed system ensures the separation of foreign objects such as metal or stones to prevent damage to the mill and explosion hazards.
  It also supplies the intake air for grinding. Tietjen has developed a new DA 376 drum feeder for the FD 32 Pro, which is specially designed for the mill and the properties of pet food and aquafeed. 
  A magnet separates magnetic foreign matter, and the aspiration air is used for heavy material separation. The throughput is regulated by the speed of the drum.   Conclusion   Fine and homogeneous grinding is the key to producing high-quality premium pet food. 
  With the specially developed FD 32 Pro hammer mill, Tietjen offers a powerful solution that combines maximum grinding fineness with high throughput thanks to innovative technology and is ideal for processing demanding, fat- and protein-rich recipes.
  However, the overall system remains crucial for maximum efficiency and product quality: The optimal coordination of hammer mill, pre-crushing, aspiration, and regular maintenance results in energy-efficient operation, reduces downtime, and ensures a consistently high-quality end product. Those who rely on modern grinding technology from Tietjen and a well-designed system are ideally equipped for the pet food production in the future. By Tietjen
Source: All Pet Food Magazine

This is Tietjen
We have been developing, designing, and producing hammer mills and size reduction technology in Germany since 1959. Complex customer requirements are our specialty: from first contact to design and delivery of the optimal plant, to after sales service, we are your competent partner for all types of impact grinding. We develop your grinding solution and take care of the implementation—worldwide.  

20/11/2025

FD 24 Pro, the New Hammer Mills for the FD Pro Series

The proven characteristics of Tietjen hammer mills, such as robustness, ease of operation and smooth rotor running, have been retained and supplemented with innovative details. For example, the rotor diameter has been increased by 100 mm to achieve a higher circumferential speed of the beaters. In addition, the distance between the hammer tips and the screen has been reduced, effectively reducing clogging of the screen openings in high-fat and high-protein recipes.
In the FD 24, the grinding chamber is 1200 mm long and divided by a centre wall, making the 600 mm wide screens easy to handle. The screen area is 3.6 m² (5,580 sq in), with four screens used per chamber segment. A special screen fastening seals the screens so that no oversize particles can get into the product.

The particle size distribution can be specifically influenced towards finer structures with a narrower grain size range if impact plates are used instead of the upper screen. Additional impact zones between the screen segments create further opportunities for optimisation. This allows larger screen apertures to be used without compromising product quality–resulting in noticeable energy savings.

In operation, the FD 24 Pro impresses with its ease of maintenance and efficiency. Sliding doors on both sides of the machine facilitate access when changing screens and beaters. The beaters are changed using the proven beater frame system. The result: faster service, short downtimes and a more energy-efficient operation overall.
  Source: Tietjen Verfahrenstechnik GmbH

Contact
Tietjen Verfahrenstechnik GmbH
Marketing
Sandra Mohr
Vor der Horst 6
25485 Hemdingen
Email: pr@tietjen-original
Website: www.tietjen-original.com

02/07/2026

Bühler ushers in a new era of extrusion systems with Nutrex 7 Series  

Uzwil, Switzerland, May 6, 2026 – Bühler Group, a global leader in processing equipment for food, feed, and advanced materials, is launching its new generation of extrusion systems. With Nutrex 7 Series, the Swiss family-owned company is responding to increased market requirements for food safety, efficiency, and user-friendliness. The first extruders have already proven themselves in operation at customer sites and are delivering trusted reliability with improved functionality.
Food and feed manufacturers worldwide are operating in a rapidly changing market environment. Requirements for greater food safety are constantly increasing, while every minute of machine downtime for cleaning or maintenance means the loss of valuable production time. With this in mind, Bühler's engineers set to work with the goal of improving process hygiene, increasing productivity, and integrating the latest digital technologies. Building on 40 years of reliable extrusion manufacturing for cereals, snacks, pet food, meat alternatives, food ingredients, and much more, one central element remained unchanged: the proven twin-screw extrusion technology that has been serving reliably in hundreds of machines around the world for decades.
  'We focused on a holistic approach based on four main categories: hygienic design, process stability, integrated intelligence, and service excellence, all with the aim of increasing Overall Equipment Efficiency (OEE) for our customers,' says Stefanie Hardtmann, Product Manager Value Nutrition at Bühler.
  Designed for modularity and efficiency   With Nutrex 7 Series, Bühler addresses the diverse requirements of various applications using a modular concept. Since extrusion technology is used to manufacture a wide range of products across different industries, the system must be designed for different process requirements. What all applications have in common is that the systems must be operated safely. In the food industry and pet food sector, high hygiene requirements and maximum uptime in 24/7 operation as well as high performance ranges are the priority. Covering this broad spectrum required a holistic approach.
  'Here, we drew on four decades of experience based on hundreds of installed systems around the world. A decisive factor was viewing the extrusion system as a whole in the context of the food processing chain,' explains David Meile, Project Manager R&D at Bühler. The Nutrex 7 Series was developed in close collaboration with customers.
  Hygienic design in the spotlight   An important aspect is access to the machine during cleaning. The easier the access, the more efficiently cleaning can be carried out and the faster the system can be put back into operation. Nutrex 7 Series is designed in every respect for short and efficient cleaning processes. 'Externally, we focused on a slimmer design for the extruder. The elevated base frame creates more ground clearance, and the hydraulic box has been integrated from the base frame to the side of the extruder. This allows direct access with cleaning equipment, simplifying cleaning and shortening cleaning time,' says David Meile.
  This hygiene concept is complemented by new cleaning solutions such as the patented Cleaning Lance, which enables effective internal cleaning, raises the hygiene level, and at the same time improves safety for operating personnel. The system is made of stainless steel and designed for wet cleaning from both the outside and the inside. The concept is supported by new automation and digital service solutions. Options such as CCP (Critical Control Point) Monitoring and the OEE (Overall Equipment Efficiency) app help continuously monitor processes, document deviations traceably, and support targeted corrective measures. This can reduce the effort required for audits and validation. In addition, together with RedLog, Bühler offers the Extrusion Kill-Step Validation Service, which provides customers with a robust basis for evaluating extrusion as a critical process step.
  Measurable benefits thanks to digital solutions   Another central component is integrated intelligence. The fully revised control system is the flagship of Bühler's automation strategy, which aims to standardize all machine and plant control systems on a single platform by 2030. 'An extruder is not simply a machine, but an integrated process step in the food industry. Our new visualization concept does justice to this complexity and maps the various processes – such as preconditioning, weighing, extruding, and cutting – schematically across various levels. In addition, the control system is completely browser-based, meaning the processes can be monitored and controlled from anywhere,' explains Adrian Staerkle, Team Manager R&D Automation Software at Bühler. With these new features, operators can detect any messages and alarms more quickly and reduce downtime. Thanks to location-independent monitoring, they can devote time during production to other tasks such as quality control. The system is complemented by new control hardware with a hygienic stainless-steel 24-inch screen, designed for expandability and incorporating the latest components.
  The new StepFlow is also a technical milestone. When starting up an extrusion process, the operator's experience is crucial to reach full production as quickly as possible and keep product waste to a minimum. The StepFlow function now gives customers the option of leaving the ideal settings for start-up and shutdown directly to the machine, based on Bühler's expertise gathered over decades in hundreds of systems. 'The StepFlow function allows the fastest start-up procedure to be achieved automatically, based on pre-defined production values,' explains Adrian Staerkle. Thanks to the StepFlow, customers can avoid up to 30% waste per run and further increase process efficiency.
  Services as a differentiating factor   With its service network, Bühler offers modular solutions for different service requirements and bundles them into a dedicated service package. Specific service components such as Vibration Monitor, Oil Condition Monitor, Spare and Wear Parts Packages, and Expert Services make it possible to monitor the condition of the system in a targeted manner, make maintenance predictable, and further improve availability. In this way, Bühler supports its customers in strengthening productivity and innovation in a targeted way, while ensuring reliable operation, plannable maintenance, and additional operational safety.
  Proven in the field   Bühler's close partnerships with its customers enabled the team to develop Nutrex 7 Series with producers from various areas such as pet food, extruded flours, and cereals, and to test them in industrial operation. One of the first test customers for Nutrex 7 Series is Kärntner Mühle in Austria. Decades ago, the company expanded its portfolio and added the production of specialty mixes for the baking industry to its traditional flour production. Martin Kropfitsch, owner and Managing Director of Kärntner Mühle, says: 'As the first customer of Nutrex 7 Series, we were closely involved in the development process. The collaboration with Bühler was partnership-based and practical. We were particularly impressed by the simple integration into our existing line and the significantly simplified handling. The intuitive control system makes day-to-day operation noticeably easier.'
  Additional Nutrex 7 Series units are in operation at test customer sites. The system is available for order and delivery immediately. Stefanie Hardtmann sees the launch as another milestone in Bühler's long history. 'For 166 years, Bühler has been launching new processing technologies with the goal of making its customers more successful. With Nutrex 7 Series, we are seamlessly continuing this tradition and offering food and feed producers worldwide a system that equips them for the challenges in their markets. It can be used flexibly, meets the highest hygiene requirements, and is equipped with the latest control technology for smooth and efficient operation.'
  Explore related news and resources on the Nutrex 7 Series page. Source: Buhler

26/11/2025

How to Choose a Pet Food Extruder for Your Pet Food Line

 Here is how manufacturers can choose the right pet food extrusions to produce a superior and consistent quality of pet food.   Key Factors to Consider When Choosing a Pet Food Extruder   While selecting the pet food extruder, consider the following factors:
  Production Capacity and Size
The right pet food extruder should match your production goals and expected output. Small and medium businesses may benefit from compact extruders that maintain efficiency without excessive power demand.
  However, large-scale manufacturers require high-capacity models that can handle continuous operation with consistent performance.
  Having said that, it is also a wise approach to plan ahead and choose the pet food processing equipment that not only meets current needs but also allows for future expansion as your production grows.
  Product Type and Recipe Flexibility
A flexible extruder allows you to produce a wide range of pet food types, from dry kibble to semi-moist products and specialty treats. This adaptability helps you cater to evolving consumer preferences, such as high-protein, grain-free, or functional formulations.
  A system that supports recipe customization gives your production line greater versatility and competitive strength in a dynamic market.
  Single-Screw vs. Twin-Screw Extruders
The choice between single-screw and twin-screw extruders depends on your production scale and product complexity.
  Single-screw extruders are ideal for straightforward formulations and lower production volumes. They are simpler to maintain and cost-effective for basic operations.
  On the other hand, twin-screw extruders deliver better mixing, cooking uniformity, and ingredient flexibility. They are preferred for complex recipes and high-performance production lines where precision and consistency are essential.
    Fresh Meat Injection Technology
Adding fresh meat during the extrusion process enhances both the nutritional value and flavor of pet food. This technology helps retain natural proteins, improving digestibility and taste appeal of the pet food.
  Automation and Control Features
Advanced automation and control systems in pet food extruders enable precise regulation of the extrusion process.
  Go for the pet food machines that bring features like temperature control, pressure regulation, and moisture management to ensure that the final product meets strict quality standards.
  Safety, Hygiene, and Compliance
In pet food production, maintaining hygiene is non-negotiable. The extruder must comply with EHEDG (European Hygienic Engineering & Design Group) and 3-A Sanitary Standards, which guarantee food-safe design and easy cleaning.
  A well-constructed machine prevents contamination and supports strict regulatory compliance. Smooth surfaces, tool-free disassembly, and easy washdown access are features that ensure consistent food safety during every production cycle.   Benefits of Investing in the Right Pet Food Extruder   When you invest in the right pet food extruder, it comes with the following features:
  Improved Product Quality
The right pet food extruder directly enhances product quality. It ensures every batch has a consistent texture, digestibility, and flavor that pets enjoy.
  Advanced temperature and pressure control preserve nutrients while improving the physical structure of the pellets. This consistency not only improves pet health but also helps brands maintain consumer trust.
  Cost Efficiency
Investing in the right extruder reduces waste, energy use, and operational costs. Efficient machines optimize feed conversion ratios and minimize ingredient loss during production.
  Energy-efficient systems also lower electricity consumption and extend equipment lifespan. Over time, this combination of precision and efficiency leads to a noticeable reduction in production expenses. The result is a more profitable and sustainable manufacturing operation.
  Flexibility and Innovation
A modern pet food extruder gives producers flexibility to meet shifting market demands. It allows easy adjustments to recipes, shapes, and textures without major equipment changes. This adaptability encourages innovation as manufacturers can develop new product lines or specialty diets faster.
  Competitive Advantage
High-quality extrusion technology provides you a clear competitive edge. Products made with precision-controlled extruders consistently outperform those made with outdated systems.
  This reliability helps manufacturers differentiate their brand through better nutrition, texture, and overall value.     Wrapping-Up
Choosing the right pet food extruder defines the consistency, quality, and efficiency of your production. A reliable system reduces waste, improves product texture, and ensures better nutrient absorption.
  The FAMSUN PX190 Pet Food Extruder is a strong choice for manufacturers aiming for consistent results. Its three-shaft conditioner with water-steam co-injection achieves up to 95% starch gelatinization, improving digestibility and pellet uniformity.
  It also meets strict hygiene standards and offers automated controls for stable, high-quality output. Backed by FAMSUN's global service network, this pet food extruder combines advanced performance with long-term reliability, making it a trusted solution for professional pet food production.
  Contact us today to upgrade your pet food production line!
  Source: FAMSUN

02/12/2025

Ensuring Food Safety: Kill Step and Validation in Pet Food Baking

Growth of the Pet Food Market and Rising Safety Concerns   Growing pet ownership and greater nutritional awareness have fueled strong demand for commercial pet food in recent years. More consumers now prefer 'complete and balanced' foods, prompting a wave of manufacturers entering this dynamic market. While product variety is at an all-time high, the race for novelty sometimes overshadows food safety considerations.
  For example, raw diets, once regarded as the most 'natural' choice, have faced heavy scrutiny following avian influenza outbreaks linked to pet deaths (Goodman, 2025). But contamination risks extend well beyond raw products. A review of recalls from 2003-2022 found that up to 35% of pet food recalls were caused by biological contamination, most often Salmonella (DeBeer, J. et al., 2024). This presents a particular risk to young children and older adults exposed during handling (PetfoodIndustry, 2024).
  Even baked products, which undergo high temperatures during the baking process, are not immune if processes are inconsistent. A single safety lapse can erase years of brand trust, underscoring the importance of robust food safety controls. This paper explores the design and validation practices required to ensure an effective kill step in baked pet foods.   Challenges in Achieving the Kill Step in Pet Food Baking   Baked kibble is valued as a healthier, 'humanized' alternative to extruded products, yet ensuring every piece reaches a validated kill step is not guaranteed. Common risks include:
  Cold or dead spots in ovens: Inconsistent airflow or temperature distribution can leave small kibble (5-6 mm) under-processed. Extending bake times to compensate often results in over-browning or burnt products.   Figure 1: Customer expectation of consistently baked kibble.   Excessive product piling: Loading too much product onto the belt impedes heat penetration into the inner layers as the kibbles pile up, especially in single-pass systems where the oven is the bottleneck in line throughput.
  Post-baking contamination: Poor line layout or hard-to-sanitize conveyors can re-introduce pathogens after baking.
  These risks highlight why oven design and process validation are critical for consistently achieving a verifiable kill step.   The RBS Approach to Safe and Efficient Baking   RBS addresses these challenges with a two-stage baking and drying process designed for both safety and throughput.
  Step 1: Baking
RBS convection ovens feature a centralized penthouse system with independently controlled top and bottom airflow delivered through perforated plenums (Figure 2). Operation is simple—operators only need to set the penthouse air temperature, balance the airflow, adjust the exhaust fan speed, and control bake time. This is all done on the control screen, and recipes can be stored for easy and repeatable production.   Figure 2: RBS Convection Oven with centralized penthouse. Perforated plenums for consistent airflow.   This oven design delivers uniform airflow and precise temperature control, ensuring consistently baked products every time.  The oven functionality can be validated with the Scorpion® 2 Profiling System.  The Oven Air Velocity Graph (Figure 3) generated using data collected by Scorpion 2 shows different color lines to represent the sensors' position from left side to right side of oven belt. Overlapping lines indicate that air velocity from left to right side of oven belt is highly uniform. As the sensor travels along the tunnel oven from zone 1 to zone 5, velocities are largely uniform within each zone, where each peak represents the airflow surge from perforations on the plenum surface.   Figure 3: Scorpion 2 Air Velocity Graph.
  Products are loaded in mono- or bi-layers, maximizing heat penetration and ensuring each piece receives sufficient heat. Over-stacking is avoided to prevent uneven baking between outer and inner layers. This high-temperature, short-time bake achieves the kill step while maintaining color uniformity and maximizing throughput (Figure 4).
  Figure 4: Baked kibble entering the oven in one layer to ensure efficient baking.   Step 2: Drying
Once the kill step is secured, products move into a low-temperature, long-time drying phase to gently reduce residual moisture. Dryers use the same oven airflow design principles to maintain uniformity. Depending on space and capacity needs, customers may choose:
  Single-pass oven with separate 3-pass dryer, or 2-pass oven/kiln system that integrates baking (top pass) and drying (bottom pass) into one zone. This set-up allows for a smaller footprint.
  This separation allows shorter bake times with mono/bi-layer product loading for effective kill steps, followed by multi-layer drying (typically 4-5 product layers) for efficiency (Figure 5).   Figure 5: Multi-Pass Dryer for slower drying to gently reduce residual moisture.   Validating the Kill Step   Kill Step Validation requires direct measurement of the product's internal temperature during baking. The Reading Thermal Scorpion 2 Data Logger uses temperature probes for measurement of product internal temperature during the baking process (Figure 6).  By combining this data with specific thermal tolerance coefficients (Tref, Dref, z), lethality can be calculated using the Kill Step Calculator developed by AIB International, in cooperation with Kansas State University, the American Bakers Association (ABA), and the University of Georgia, to determine if kill step is complete (Kill Step Calculator | Bakery Process | BAKERpedia, 2016). Our SV8 software can then be used to generate the kill step report. Bake time and baking temperature can be further optimized by analyzing the lethality curve generated by SV8 software.     Figure 6: Scorpion 2 R&D Kit with product probes. Product probes for measuring internal product temperature.   Figure 7: Internal temperature vs time and cumulative lethality vs time graphs as part of kill step report generated by SV8 software.   Beyond kill step validation, the Scorpion 2 can be equipped with air velocity, temperature, humidity, and heat flux sensors to better understand oven performance. The air velocity sensor and air temperature sensor arrays can be used to validate the convection oven design to ensure that air flow and temperature distribution is uniform both across and along the oven belt (Figure 8).   Figure 8: Temperature and air velocity sensor arrays for oven profiling, temperature and airflow distribution data within tunnel oven can be collected and displayed as 2D or 3D graph in SV8 software to identify cold/ hot spots in oven chamber.   Conclusion   RBS mitigates these risks with proven baking and drying solutions, paired with the Scorpion® 2 profiling system, giving manufacturers confidence that every batch meets FDA FSMA kill step requirements. With RBS, you can achieve both safety and efficiency—ensuring your products earn consumer trust and stand out in a crowded market. By Readin Bakery Systems
Source: All Pet Food Magazine
  References
DeBeer, J., Finke, M., Maxfield, A., Osgood, A.-M., Mona Baumgartel, D. and Blickem, E.R. (2024). A Review of Pet Food Recalls from 2003 Through 2022. Journal of Food Protection, [online] 87(1), p.100199. doi:https://doi.org/10.1016/j.jfp.2023.100199. Goodman, B. (2025). With bird flu cases rising, certain kinds of pet food may be risky for animals – and people. [online] CNN. Available at: https://edition.cnn.com/2025/01/18/health/bird-flu-pet-food-cat-deaths/index.html [Accessed 12 Feb. 2025]. Kill Step Calculator | Bakery Process | BAKERpedia (2016) BAKERpedia. Available at: https://bakerpedia.com/processes/kill-step-calculator/ (Accessed: 25 February 2025). PetfoodIndustry. (2024). US pet food recalls: More than 40% due to Salmonella. [online] Available at: https://www.petfoodindustry.com/blogs-columns/adventures-in-pet-food/blog/15678178/us-pet-food-recalls-more-than-40-due-to-salmonella [Accessed 13 Feb. 2025].

21/08/2024

Carousel dryer/cooler from CPM's IDAH offers sustainability in petfood industry

The carousel working principle   In the carousel dryer, the product enters through a rotary valve onto the revolving trays. The Carousel system ensures a first in, first out (FIFO) principle, after nearly one revolution, the product is gently discharged and mixed into the next lower tray. This process is repeated until the product drops from the last tray into the outlet where a rotary valve prevents air leakage. The revolution means that the product undergoes the same treatment all along the decks, ensuring that the product comes out in uniform moisture. Furthermore, the multiple tumbling action gives an efficient heat exchange with the air, resulting in a low dryer exhaust air temperature.   Integrating dryer and cooler as one solution   The Carousel technology is a unique solution for both energy efficiency and precise moisture control. Optimal moisture control is made easy by using carousel technology in both the dryer and cooler. Additionally, the exhaust air from the cooler can be directed as make-up air for the drying process. Therefore, an integration of the dryer and cooler into one compact machine with a FIFO discharge principle like the carousel dryer will give an outstanding moisture control performance. Ambient air cools the product and after filtered and heated it is used as drying air for the upper section. This carousel model offers many benefits and features when compared to traditional equipment.   Improving product moisture control   Managing the temperature and moisture content of the finished product is the main task for the drying and cooling process. However, when the feed is overdried, it causes material loss, as well as extra energy consumption. When the feed is too wet, the product will have a higher risk of quality degradation and mold growth.   Due to its unique working principle, all the products in this carousel dryer will get the same heat treatment and retention time. This is combined with a unique and easy control system, along with real-time monitoring and modification of the drying parameters. The carousel dryer will give a uniform and constant moisture level that makes it easier to achieve the target average moisture, which will save energy and raw materials.   Improving energy efficiency   The drying and cooling process accounts for a significant part of the overall energy consumption. Rising energy costs and sustainability awareness regarding energy consumption have driven feed manufacturers to request further support to improve their drying and cooling functions. To maximize energy efficiency, we have to look into: Maximizing the use of warm product energy. Minimizing the amount of water evaporation. Minimizing energy loss with the exhaust air.   By using the cooling air as makeup air into the dryer, the heat energy can be reused. Also, efficient heat exchange lowers the amount of exhaust air. Low exhaust air volumes will reduce the cost needed for odor treatment.   Reducing the space required   While upgrading the production capacity of a feed mill or improving the production process, the introduction of new equipment into the facility is required and space limitations may arise. The carousel dryer is already more compact than a typical dryer.   Potential savings   A direct result of using cooling air as makeup air for the dryer is savings. If you assume that the temperature differential between the ambient and cooler exhaust air is 25°C, you save up to 30 kg/t steam. At the same time, you will reduce the amount of exhaust air by 50%, reducing odor treatment costs significantly. Getting better moisture control, for example 0.5%, is saving not only about 10 kg/t steam consumption in the dryer but, even more importantly, saving 0.5% raw materials cost and having a 0.5% higher output capacity.   For more information, contact Idah@cpm.net.   Source: CPM IDAH

09/10/2025

Technology Behind Spraying: Enhancing Nutrition in Pet Food and Animal Feed

In a wide range of industrial sectors, from animal feed to pet food processing, the efficient combination of liquids and solids is essential. Whether injecting liquid formulations into batch mixers or coating products with additives or flavour enhancers, the key lies in effectively dispersing the liquid over a broad surface area.
  This process plays a particularly important role in pet food and animal feed production, where liquids such as palatants, vitamins or nutritional additives are applied to enhance product quality and appeal.
  There are three primary methods used to achieve this liquid-solid integration: spraying, atomizing, and nebulizing. Each technique is based on distinct technologies designed to accommodate different types of liquids and application needs.
  Among these, advanced solutions such as PLP Systems' SMOG atomization technology stands out, offering highly efficient dispersion that improves palatability and consistency in the final product. OPTIMIZING LIQUID DISPERSION: SPRAYING, ATOMIZATION AND NEBULIZATION TECHNOLOGIES
SPRAYING
Is the most common method and widely used across various applications. It is suitable for liquids of different viscosities, producing relatively larger droplets, typically in the range of hundreds of micrometers in diameter. These droplets are generally more visible and can cover surfaces more thoroughly, delivering a larger amount of liquid.
  Spraying is often employed when a medium or large amount of liquid needs to be added to a batch mixer. The larger droplets tend to fall quickly due to gravity, making spraying ideal for applications where homogenous absorption of the liquid by the solid is desired.
  Spraying is mechanically generated by reducing the exit section, or 'nozzle,' and increasing the pressure in the pipeline.
  The shape of the nozzle allows for different spray patterns, including:
  Flat Fan, with angles ranging from 25° to 110° Full Cone, with angles ranging from 40° to 120° Hollow Cone, with angles ranging from 50° to 180°
  ATOMIZING
Involves breaking the liquid into very fine droplets. While it is possible to use viscous liquids, not all atomizing technologies can handle higher viscosities. The droplet size typically ranges from 10 to 300 micrometers in diameter.
  This method is used when a medium or small amount of liquid is added to a batch mixer, enhancing the homogeneity and dispersion of the product within the solid. Atomizing is also common in coating processes where even coverage of a solid surface is critical, such as in painting, food flavouring and pet food greasing.
  Different technologies are used for atomization, depending on the application and liquid properties:
  High-Pressure atomization: High pressure forces the liquid through a small nozzle, creating fine droplets.
  Ultrasonic atomization: Ultrasonic waves break the liquid into very fine droplets, producing a mist-like aerosol. This method is suitable for small amounts of liquid with limited viscosity.
  Air-Assisted atomization: Air jets break the liquid into droplets as it exits the nozzle.
  Rotary atomization: Commonly used in spray drying, coating and various industrial processes, where a spinning disc disperses the liquid, with droplet size dependent on the speed of rotation and liquid properties.
  Motorized SMOG atomization: This method, used by PLP Systems, combines rotary and air-Assisted atomization. The liquid passes through a spinning closed chamber; when the small droplets exit the nozzle, air jets further reduce the particle size. This technique is particularly useful for viscous liquids such as oils, fats, creams, hydrolysed pastes, molasses, syrups, chocolate, honey and more.
  NEBULIZING
Nebulizing produces much finer droplets, often only a few micrometers in diameter. These droplets are so small that they can remain suspended in the air as a mist or aerosol. Due to this characteristic, nebulizing is not typically used for adding liquids in mixers or coating applications. Instead, it is commonly employed for dispersing aerosols into the air for disinfection purposes.   ATOMIZING TECHNOLOGY FOR APPETIZING KIBBLES
In pet food production, palatants are typically applied post-oil coating to enhance the external flavor profile of kibbles. Achieving optimal palatability hinges on the even distribution of these viscous substances across all kibble surfaces. Traditional spraying methods often struggle with high-viscosity liquids, resulting in inconsistent coverage and potential nozzle clogging.
  To overcome these challenges, PLP Systems developed the SMOG technology. This advanced atomization system excels in spraying high-viscosity liquids onto kibble surfaces or within batch mixers, ensuring precise and uniform application.
  The SMOG XL series of sprayers is specifically engineered to handle molasses, a highly viscous liquid, across a broad range of viscosities. Achieving optimal spray quality with molasses necessitates careful control of the flow rate. As viscosity increases, the flow rate must be reduced to maintain a consistent and fine spray pattern.
    The higher is the viscosity of the molasses the less should be the flow rate in order to obtain a good quality of spray.
  Below an example of the curve trend of molasses spraying at different flow rates. This however depends on the viscosity, the temperature of molasse, the quantity of air of the blower, the type of pump used and the application.
  PLP Systems specializes in both liquids and powders, with a special focus on the pet food and feed industries. An important area for PLP is the accurate and precise handling of liquids and powder for pet food and feed production, with a specific focus on post-pellet coating and kibble palatability enhancing.
  This process involves adding micro-liquids such as enzymes, vitamins, flavors, probiotics amd yeast to the pellets, aiming to enhance their quality and oils, digest and palatants to kibbles.
  Whether you're looking to improve your current production line or explore innovative methods to increase product appeal, our technologies offer the reliability and excellence you need.
  Need more information or want to dive deeper into our systems? We're here to provide tailored solutions and answer all your questions. Call us today at +39 0523 891 629 or email us at info@plp-systems.com for a free consultation.
We're here to help you find the perfect solution for your needs!


Source: PLP Systems

03/09/2025

Palatability & Manufacturing: Impact on Pet Preferences

Differences Between Cats and Dogs   To begin the discussion on palatability, we must first understand our main customers: cats and dogs. The variability between these companions —their behavior, eating habits, and nutritional needs— must be considered to satisfy them and encourage pet owners to repurchase their food. Understanding what makes cats and dogs want to eat will help optimize feed manufacturing and achieve greater palatability.
  A key difference between cats and dogs is their feeding behavior. Cats are carnivores, while dogs are omnivores, which leads to different nutritional needs and formulas. For example, cats require higher levels and better quality of proteins compared to dogs. FEDIAF recommends between 18% and 25% protein for dogs and between 25% and 33% for cats, which affects the starch content in their recipes and the nutritional values of the food. These differences require adjustments in production parameters to improve palatability.
  The sense of taste in cats and dogs, although both are based on a carnivorous pattern, varies significantly. Dogs enjoy sweet and sour flavors, such as carboxylic and phosphoric acids, while cats prefer bitter flavors and are not sensitive to sweetness. Dogs generally consume large meals quickly, possibly due to their pack heritage, and tend to take the food with their teeth and crush it, preferring softer foods. On the other hand, cats eat several small meals a day, mimicking their hunting habits, and use their tongues and molars to break the food, preferring harder and drier foods.
  Finally, the sense of smell is a critical factor in palatability for both cats and dogs, with their sense of smell being much more sensitive than that of humans. Cats have twice as many sensory olfactory cells as humans, and dogs may have up to 300 million olfactory receptors compared to about 5 million in humans.   Importance of Ingredients   Improved palatability begins with the proper selection of raw materials. Factors, such as protein quality, freshness, lipid oxidation, and ingredient proportions directly influence the texture and flavor of the food.
  In one trial, chicken meal and chicken liver were replaced with hydrolyzed chicken liver in a standard recipe. "Versus" tests showed a clear preference for diets that included the hydrolyzed liver, even with 5% and 10% inclusion rates. Choosing the right protein is, therefore, the first step toward higher food acceptance.   Processing: From Grinding to Drying   The initial processing stages, such as grinding and mixing, affect particle size and product homogeneity. Improper grinding can cause irregularities that negatively impact texture.
  In extrusion, starch gelatinization is critical. This process, which begins with the preconditioner, improves food cohesion. Insufficient starch content can cause kibble to disintegrate, while excess increases density. For cats in particular, kibble hardness influences acceptance: they prefer more compact products.
  A common challenge is balancing protein and fat levels in cat foods without compromising product expansion. The key is adjusting ingredients to achieve both the appropriate nutritional profile and an attractive texture.   Coating Optimization   Coating is one of the most decisive steps to achieve superior palatability. It is done by applying fat and liquid and/or powdered palatants. Fat, used at levels from 1% to 15%, serves nutritional functions and acts as an adhesive base for palatants. However, fat alone is not enough to ensure high acceptance.
  Liquid palatants (1% to 4%) enhance aroma and are more used in dog foods, where higher moisture and softness are sought. On the other hand, powdered palatants (0.5% to 3%) add flavor and moisture control, being common in cat foods, which require low moisture content and high protein levels.
  To maximize coating effectiveness, it is recommended to apply fat first, then the liquid palatant, and finally the powder. This ensures better adhesion and homogeneity.   Technical Factors of Coating   Nozzles: The diameter and pressure of the nozzles affect coating quality. Very low pressure generates large droplets that do not disperse well, while excessive pressure produces a mist that can be lost in the air. Proper positioning and spacing ensure uniform coverage.
  Mixing: In batch systems, the mixing direction influences homogeneity. Mixing from the outside inward improves palatant distribution, while the opposite creates clumps. Optimizing this process enhances the sensory experience of the food.
  Types of applicators: Batch applicators allow greater control, better homogeneity, and adjustments per batch, ideal for super-premium products. Although slower and more expensive, their efficacy in palatability terms makes them preferable in high-end segments. In contrast, continuous applicators are faster and more economical but may have lower precision.   Conclusion   Understanding the unique needs and behaviors of cats and dogs is fundamental to optimizing the palatability of pet foods. Given their distinct feeding habits, nutritional requirements, and sensory preferences, it is clear that a one-size-fits-all approach is ineffective. 
  The manufacturing process, from grinding to drying, plays a crucial role in determining the texture and palatability of the final product. Proper starch gelatinization, precise mixing, and controlled extrusion and drying processes are essential to achieve the desired consistency and flavor of the food. Each stage must be carefully adjusted to maintain the integrity and appeal of the product, responding to the specific preferences of cats and dogs. Coating, one of the most critical stages to improve palatability, requires careful ingredient selection and application techniques. By optimizing fat and palatant use and ensuring both efficient application and homogeneous mixing, it is possible to develop a much more attractive product.
  In conclusion, improving the palatability of pet foods involves a multifaceted approach that encompasses ingredient selection, precise manufacturing processes, and effective coating techniques. By addressing these factors, we can ensure that both cats and dogs receive foods that satisfy their flavor preferences.


By Maïlys Le Thiec - Kemin Nutrisurance
Source: All Pet Food Magazine

04/12/2023

Countdown to Pet Food Conveyor Launch: Starting Up On Time and With Confidence

To move delicate pet food products or powders, most processors do extensive homework before purchasing a tubular drag cable conveyor to ensure that it meets their needs in terms of function and price. After the purchase, the conveyor must be expertly assembled and tested to ensure smooth production startup and continued performance. The challenge is that the typical third-party contractors installing various plant systems might need to become more familiar with specialized pet food conveyors and, thus, are more prone to make costly errors. A more prudent choice is using the OEM's team of experienced technicians. The OEM's experts have the advantage of designing the specialized conveyor and understanding its installation, operational requirements, and potential problem areas. 'If a tubular drag cable conveyor is installed incorrectly by a third party, it often needs to be completely pulled apart and rebuilt, which is costly and time-consuming. If the conveyor is run incorrectly, damage will occur, and components must be replaced. All this only delays startup,' says Terry Derby, Director of Parts and Field Service for Automated Handling Solutions (AHS). AHS is the service-focused subsidiary of Cablevey Conveyors, an Oskaloosa, Iowa-based conveyor manufacturer that has been designing, engineering, and servicing enclosed cable and disc tube conveyors for 50 years and is in more than 65 countries. As a solution, pet food processors seeking superior conveyor performance from the start rely on expert-supervised installation and commissioning to ensure they will be ready to run products on time, at the necessary volumes. Today, a tubular drag cable conveyor requires considerable expertise to install. These systems gently move material through a sealed tube using a coated, flexible, stainless-steel drag cable pulled through on a loop. Solid circular discs (flights) attach to the cable, pushing the product through the tube without air.  'This type of conveyor is uniquely engineered to transport delicate materials gently. The tubes form a continuous loop that must be carefully assembled for a tight fit to ensure no misalignment or gaps between sections. While the modular components lend great flexibility to system design, each component must act in concert with the rest for proper conveyor functionality,' explains Derby. After selecting and purchasing a conveyor, the pet food processor's next step is installing it, which often requires professional assistance. Reliability Starts with Supervised Installation Whether relying on internal staff members for installation or contracting the job to an outside team of millwrights or skilled pipefitters, supervised conveyor installation can ensure proper system installation. Getting expert assistance is still essential during installation, even with the manual that has detailed instructions and QR-code links to videos for each conveyor component. 'Supervised installation is important to ensure that your system is installed properly so you don't run into maintenance problems due to an improper install,' says Derby. Derby insists that 'supervised installs are probably the most important support service we offer.' This step is often neglected when a less experienced third party performs the installation, which can escalate costs. At this point, AHS is frequently asked to complete final preparations and correct any problems before production startup, a process known as commissioning.  'When a processor brings us to their facility after declining a supervised installation, we often have to work backward for a day or two to correct issues. Having us there for supervised installation eliminates the need for correction and any idle contractors waiting on us for the repair, so it pays for itself,' says Derby. In the case of AHS, the company's technicians have logged hundreds, if not thousands, of hours on-site in various manufacturing facilities worldwide. This singular focus gives them the knowledge and expertise to streamline the installation process and prevent issues that can lead to system inefficiencies, product loss, or complete system failure. As part of the supervised installation, skilled technicians ensure the correct positioning of the conveyor's hangers and the proper torque for couplings. The system is properly cleaned to remove any metal fragments or foreign contaminants introduced during installation. In addition, the technician confirms that all conveyor inlets are in place and that all discharges are functioning. Even seemingly minor gaps or misaligned areas in the conveyor tubing can become a severe issue. 'If gaps are in the conveyor's tubes, the discs will 'catch' when crossing the joint, causing excessive wear on the cable and motor. If not corrected, this could lead to premature failure, production downtime, and added repair and replacement costs,' says Derby. According to Derby, another common wear item in tubular drag cable conveyors is sweeps, areas where the tube changes direction. He explains that sweeps are where the cable is under the most significant tension and where the discs rub inside the tube. Since sweeps show the first signs of wear, proper installation can reduce the wear and significantly prolong tube and cable life, simplifying maintenance. 'With a supervised install, processors can ensure that their conveyor is assembled correctly to enable seamless startup, reliable production, optimal output, and greater longevity for the system and its parts. Our reputation is on the line to get it right from the start,' says Derby. In addition, a supervised installation includes a full report outlining actions to correct any issues found. Due to the attention to detail, a supervised installation also preserves the standard warranty for the system's components. Of course, operators also play a critical role in conveyor performance. For this reason, having experts onsite can be one of the best ways to train the operators and maintenance crew on properly running, cleaning, and maintaining the system.    Reliable Production Requires Expert Commissioning When the installation is complete, the next step is to schedule commissioning. The average commissioning visit for a single-system installation usually lasts an entire day.  The onsite commissioning process readies the conveyor for total production and identifies any immediately correctable issues to keep the startup on schedule. At this point, the system must be installed entirely, including all mechanical and electrical components. The conveyor material must also be ready for introduction to the system. This is where a botched installation by a third party can come to light without supervised installation by the OEM. 'We are often asked to 'fix' poor installations by third-party contractors. We have had to tear whole systems apart. This frequently requires a complete rebuild and replacement of damaged parts, which adds cost, creates downtime, and delays startup,' says Derby. In the case of AHS's commissioning service, the technician conducts an inspection using a camera that runs through the entire system layout to ensure that everything is correctly assembled and ready for testing. The technician then performs a test run of the product, from the inlet feed through the sweeps to the discharge outlet, and verifies that it flows at the desired speed. 'Tailoring the conveyor to the material conveyed can require adjustments to fine-tune the process. With the commissioning, the goal is to increase efficiency, production volume, and reliability,' says Derby. He adds that 'checking the system's health' also uncovers any issues that might arise, which technicians can address to prevent production downtime. He points out that commissioning also extends Cablevey's standard warranty. As a final step in the commissioning process, the technician issues a report for the processor that documents all findings from the full-system inspection. Completing conveyor installation, commissioning, and start-up is only the start of the OEM's and processor's relationship since the system's lifespan can be decades. In addition to traveling on-site for emergency service calls, the company offers an annual service visit to conduct a detailed system inspection and address any issues, identify worn parts, ensure predictive maintenance is being conducted, and provide any additional training needed. This complete system audit aims to extend the conveyor's lifespan and prevent unexpected downtime. 'Our mission is to provide conveying equipment and ensure it performs as required, with minimal downtime and maintenance. Once a pet food processor buys a system, they become part of our family. We will continue to support them every way we can, even as their needs evolve,' concludes Derby. By Del Williams is a technical writer based in Torrance, California. Source All Pet Food

27/11/2023

Mobile 'Smart Cart' Automates Food Conveyor CIP for Pet Food Manufacturers

To promote food safety and sanitary compliance, pet food manufacturers are increasingly seeking the ability to clean-in-place (CIP), an automated method of cleaning the interior surfaces of tubular drag conveyors without disassembly. Now, with the advent of mobile tools like an innovative 'smart cart' that quick-connects to any tubular conveyor and enables simple, customizable 'single button cleaning recipes,' CIP is becoming easier, faster, less labor-intensive, more repeatable, and almost fully automated. Tubular drag conveyor systems gently move product through a sealed, enclosed tube using a drag cable and circular discs pulled through on a loop, so they are ideal for delicate items. Designed to handle a variety of different forms and sizes, from kibble to seeds or pellets and nutrients, tubular conveyors maintain both quality and proper proportions. In a wet CIP process, the system is flooded with water, flushed, rinsed, cleansed, and thoroughly sanitized. Although the process is very effective, streamlining its automation and simplifying the process for all a facility's tubular drag conveyors has been a priority for leading innovators in the industry. 'The standard system required port hookups to water lines and installing piping. The processor also had to make decisions, such as which water temperatures to utilize, or whether to use a cleaning solvent - and the correct amount to add manually,' says John Adair, Engineering and Quality Director for Cablevey Conveyors, an Oskaloosa, Iowa-based conveyor manufacturer that has designed, engineered, and serviced enclosed cable and disc tube conveyors for 50 years, and is in more than 65 countries. To simplify the wet cleaning process, Adair and his engineering team at Cablevey have developed a small, mobile 'smart cart' with integrated water line hookups that a single technician can easily take to any tubular drag conveyor in a facility. The cart is specifically designed to be a fraction of the size of similar carts on the market to facilitate mobility. When the cart is in position and connected to water lines, the CIP process is automated and controlled by a programmable logic controller (PLC) that reduces the need for manual labor and virtually eliminates the risk of improper cleaning. 'Once it is set up, all you do is press a button, and it will bring in the required amount of water at the correct temperature with the necessary amount of solvent for cleaning,' says Adair. The smart cart is designed to store and utilize pre-programmed CIP recipes to flush various residual materials from the tubular drag cable conveyors in a facility before new production runs. The cleaning recipes enable even those with very little training to use the cart, which is helpful in today's tight labor market and allows the technician to move on to other tasks once the cleaning process begins. The use of easily executable recipes ensures a superior, repeatable clean that essentially 'error-proofs' the process. This is particularly important when the technician may be new or less familiar with the production equipment. 'Depending on the product conveyed, sometimes all you need is a wet rinse or a specific cleaning solvent. All that information is saved, so after the first cleaning, it can be automatically repeated. Just push a button to start the appropriate recipe, whether you have one conveyor running multiple products or dozens of conveyors running various products,' says Adair. To meet strict compliance standards, the smart cart also documents all critical CIP information, such as water volume and temperature, chemicals used, and cleaning time by date, in an easily retrievable data log. Since decreasing production downtime between conveyor cleanings is a priority for pet food manufacturers, Cablevey provides new capabilities with the cart that expedites the CIP process. Currently, the CIP process floods the tubular conveyor system but is not designed to clean the discs specifically. 'Operators would manually clean each disc and advance the system disc by disc when the discs had to be cleaned of particularly viscous substances,' says Adair.   Once it is set up, all you do is press a button and it will bring in the required amount of water at the correct temperature with the necessary amount of solvent for cleaning.   Now, as an option on the cart, a disc washer can be integrated with the conveyor turnaround to spray a pressurized cleansing solution on the discs. This helps to remove stickier substances that could remain after routine CIP cleaning. 'The disc washer sprays high-pressure water directly on the discs, so it acts like an automatic car wash. At the push of a button, the discs and cable are run through, and spray cleaned, which reduces CIP time and eliminates the need to manually clean the discs,' says Adair. To further reduce downtime, Cablevey also offers a new sanitary blower option. 'After the wet CIP process, a sanitary blower attachment on the smart cart can dry the discs and other parts of the system 75% faster than typical air drying,' says Adair. He points out that the faster the conveyor is cleaned and dried after a product change, the sooner it can be put back into service, which improves profitability. According to Adair, Cablevey's Mobile Smart Cart was already available since it was officially unveiled at Pack Expo, a premier packaging and processing show held at the Las Vegas Convention Center in September. The event featured full-scale setups of machinery in action. The company also offered traveling demo smart cars to customers in September for free so clients could test drive the units. Pet food manufacturers can now purchase the demonstration unit used in their facilities, with hands-on training available immediately. While the pet food manufacturing industry is aware that automated CIP can improve conveyor system production uptime, barriers to implementation have slowed adoption. Utilizing a mobile smart cart with integrated water hookups will help manufacturers easily implement CIP in tubular drag conveyors throughout their facilities: expediting conveyor cleaning, production changeover, and sanitary compliance. By: Del Williams - Technical writer based in Torrance - California Source: All Pet Food Magazine

23/06/2026

The Role of Bagging in the New Generation of Pet Food Ingredients

This shift impacts product development as well as the industrial processes that handle these materials. As raw materials become more complex and valuable, every stage of production must ensure proper handling, preservation, and traceability.

In this context, bagging and end-of-line operations are becoming increasingly strategic within production plants.
New Ingredients, New Handling Challenges
Modern pet food formulations incorporate ingredients with highly diverse physical characteristics: plant-based proteins, functional meals, blends with varying particle sizes, and dehydrated ingredients with high nutritional value.

These raw materials may behave very differently during handling, requiring adapted bagging solutions. Among the most relevant factors are:
  Variations in bulk density. Presence of fine particles or dust during filling. Fragile or handling-sensitive ingredients.
  In these cases, dosing and weighing systems must ensure controlled flow and gentle product handling, avoiding losses, breakage, or segregation that could affect final product quality.
Having equipment that adapts to these characteristics is essential to maintain process efficiency and protect product integrity.
Weighing Accuracy: Protecting Product Value
As formulations incorporate higher value-added ingredients, precision in the bagging process becomes critical.

Even small weight deviations can represent significant economic losses when working with high-cost raw materials or tightly balanced nutritional blends. For this reason, bagging lines must integrate dynamic weighing systems and digital control to maintain high accuracy, even at high production speeds.

In this field, PAYPER has established itself as a global reference in dynamic weighing of bulk solid products. All its automatic bagging machines incorporate the MSX weighing controller, designed to ensure exceptional accuracy in demanding industrial processes.

This system enables optimized product dosing, reduced variability between bags, and maximized raw material utilization—key factors when handling high-value ingredients.
Quality Control and Product Safety
Product quality and safety are top priorities in the pet food sector, where production standards are increasingly aligned with those of the food industry.

For this reason, modern bagging lines can incorporate various inspection and control systems, such as metal detectors, checkweighers, and automatic rejection systems. These solutions allow for the identification of process deviations and ensure that only bags meeting all quality parameters proceed along the production line.

In the case of PAYPER, these technologies can be integrated into complete end-of-line solutions, covering everything from dosing and weighing to bagging, palletizing, and final pallet protection. This integrated approach optimizes coordination between equipment and ensures smooth and efficient operation across the entire line.
Automation and Advanced Line Control
As production plants increase in capacity and complexity, managing bagging lines requires advanced control and monitoring tools.

In this context, PAYPER has developed Pulsar, an all-in-one digital platform designed to centralize the management of the entire bagging line. This tool allows manufacturers to monitor equipment performance, analyze production data, and optimize line configuration in a simple and intuitive way.

Through this system, manufacturers gain a comprehensive view of the process, enabling them to identify deviations and improve operational efficiency.

In addition, Pulsar facilitates maintenance management and access to key technical information, allowing potential issues to be anticipated and interventions to be planned before unplanned downtime occurs.
Technical Service and Operational Continuity
In high-capacity production environments, operational continuity is critical. Any unexpected downtime can directly impact plant efficiency and supply capacity.

For this reason, access to specialized technical service and predictive maintenance tools has become essential for manufacturers.

Digital solutions such as Pulsar enable equipment condition monitoring, spare parts management, and maintenance support, helping reduce downtime and improve line availability.

This approach combines advanced technology with specialized technical support to ensure maximum reliability in plant operations.
Bagging in the Face of New Pet Food Challenges
The evolution of the pet food sector demands increasingly precise, flexible, and automated solutions. In this context, expertise in design and bagging systems optimization becomes a key factor in meeting new market requirements.

In an environment where ingredients are becoming more innovative and higher in value, bagging is no longer just a logistical step—it becomes an essential part of the product's value. Ensuring precision, quality control, traceability, and proper final presentation allow this value to be preserved from production through to distribution.

This evolution—closely linked to operational efficiency and production optimization—is also reflected in the industry's leading international events. In this context, PAYPER actively participates in trade fairs, such as Interpack (stand 12C06), Fenagra (stand C19), and Foro Mascotas (D6-B), where it showcases its solutions and engages directly with key industry players.

In addition, the company continues to strengthen its international presence in key markets, such as Central America and Brazil, where it operates with local structures to provide close, tailored support to the specific needs of the sector. By PAYPER
Source: All Pet Food Magazinw

05/06/2026

When Does it Make Sense to Automate a Bagging Process? 

What is an automatic bagging machine?
An automatic bagging machine is a packaging machine whose ultimate objective is the same: to measure out precise quantities of solid products and place them into bags. The main difference is that the automatic bagging machine does this without human intervention. In other words, in an automatic system, the machine handles all stages: picking up the empty bag, opening it, positioning it, filling it, sealing it and moving it on to the palletiser. It is worth noting that weighing and dosing are automatic in both semi-automatic and automatic systems. The difference lies in the handling of the bag.   In these cases, the operator moves from performing repetitive physical tasks to carrying out supervisory duties and replenishing consumables. This technological leap involves greater mechanical and control complexity, but also a profound transformation in the dynamics of the workstation and the production capacity of the line.   Advantages and disadvantages of automatic bagging machines.   Benefits of automatic bagging machines. Full automation of bagging transforms the operational logic of the workstation. This continuity reduces variability and allows for consistent rhythms to be maintained even during sustained production runs. By stabilising the bagging point, line performance is optimised, which has a direct impact on productivity and planning capacity.   Another key aspect is the reorganisation of the operator's role. Instead of physically intervening in every cycle, a single person can supervise the system and manage the supply of consumables (empty sacks, sewing thread or other items), devoting more time to process control than to mechanical execution. From a health and safety perspective, automation also offers clear advantages. By reducing direct handling of the product and the bag, exposure to dust, repetitive physical strain or unnecessary contact with sensitive materials is significantly reduced. The result is a cleaner and safer working environment. Finally, monitoring the position of the bag throughout its journey ensures greater precision in filling and sealing. This continuous monitoring reduces errors, improves the quality of the finish and brings greater consistency to the entire process.   Limitations of automatic bagging machines. However, full automation also entails certain technical and financial requirements. The initial investment is higher than that of a semi-automatic bagging machine, which can delay the return on investment if the production volume does not justify the technological leap. Therefore, the decision must be based on actual data regarding production capacity, labour costs and growth projections.   From a physical standpoint, automatic bagging machines typically require more floor space, as they incorporate additional modules for bag retrieval, opening and positioning. Although compact configurations are available [JV1]  , the impact on the layout must be assessed in detail within the overall end-of-line project. It is also important to consider the human factor. An automatic system requires a qualified operator to ensure the line operates correctly. Experience shows that the optimal performance of a system depends largely on the technical knowledge of the team operating it.   Finally, the greater mechanical and control complexity implies proper planning of preventive maintenance. More mechanisms and drives mean more critical points that must be managed correctly throughout the machine's lifecycle. This aspect is not necessarily a drawback, but it is a factor that must be taken into account in the overall project analysis.   In which cases is it advisable to install an automatic bagging machine?   There is no universal threshold determining when an automatic bagging machine is essential. The decision depends on a combination of production, economic and strategic factors. One of the clearest factors is production volume. When demand is in the medium to high range of bags per hour, automation enables consistent output rates that ensure a return on investment through high productivity.   The labour context also plays a role. In regions where labour is scarce or costly, automation can accelerate the return on investment by reducing operational dependency. In food or hygiene applications, where the aim is to minimise operator contact with the product being bagged as much as possible. Similarly, when working with toxic, abrasive or dusty products, automation serves as a safety measure for workers. There is also a strategic component. Full automation of bagging conveys an image of efficiency and control that many companies consider part of their industrial positioning.   If the investment is to be made in phases: is it better to automate bagging or palletising first?   This is a common question when the budget does not allow for the complete automation of the end-of-line process in a single stage. At first glance, it seems logical to automate palletising first: manually moving a 25 kg full sack is more demanding than placing an empty sack. And, in many cases, that argument makes sense.   However, the decision should not be based solely on physical effort. The bagging rate determines the palletising rate, never the other way round. If the bottleneck lies in dosing and filling, automating palletising will not solve the underlying problem. Furthermore, when the product requires strict hygiene conditions or poses risks to the operator, automating bagging can have a greater impact than automating palletising. Each project must analyse where the greatest loss of efficiency occurs, what operational risks exist and what the plant's medium-term objective is.   At TMI, we help you automate with a clear strategy.   Automating bagging is a matter of industrial coherence. In some cases, a well-designed semi-automatic solution is sufficient and cost-effective. In others, sustained production, operational safety or growth strategy fully justify an automatic bagging machine. The manufacturer's role is to assess the customer's production reality and propose the most suitable solution in terms of performance, investment and future prospects, and that is what we do at TMI.   By: David Padullés, Sales Director at TMI Source: TMI