Pet Food production system
Dry Pet Food Production: A Guide to the Industrial Process
Pet food production, according to a recent analysis by GrandViewResearch, will reach a value of USD 103.3 billion in 2023.
It is expected to grow at a CAGR (2024-2030) of 4.4%, touching approximately USD 139 billion by 2030.
The growing demand is driven by an increased focus on pet health and more responsible consumption choices.
In parallel, the pet food machinery market is booming.
It is estimated to reach USD 7.98 billion by 2030, growing at an annual rate of 6.1%.
This evolution is driven by automation and the need to produce high quality food with greater efficiency.
In this dynamic scenario, investing in modern plants for the production of dry pet food is not only an opportunity, but a strategic choice.
Massini Industries, with its MIAL brand, stands out for its ability to design state-of-the-art, modular and fully automated plants.
In this article we will analyze:
- Production phases of dry pet food
- Pet food packaging
- Why choose Mial – Massini Industries
Production phases of dry pet food
The process for producing dry pet food involves numerous steps and phases, each of which is linked to the previous one.
These include:
- Plant design
- Raw material storage
- Transportation systems
- Grinding and Mixing
- Conditioning and Pre-Baking
- Pet Food Extrusion
- Drying and Cooling
- Coating
Plant design
The first step in setting up a dry pet food plant is to define the technical specifications.
These take into account production volumes, the type of food (extruded or pelleted), and market characteristics (lines for single-protein, grain free, etc.).
The layout is customised to optimise raw material flows, internal logistics and possible future expansion.
MIAL supports the customer from the initial consultation phase, designing tailor-made solutions based on international regulations and specific production requirements.
Raw Material Storage
Raw materials include animal by-products in the form of meals (chicken meal, lamb meal), cereals, pulses, vegetable oils, additives, vitamins and minerals.
Their proper storage is essential to ensure food safety and formulation stability.
Storage facilities may include:
- Raw material silos
- Finished product silos
- Stainless steel tanks for oils and liquids
MIAL offers modular solutions for storage of various types with attention to cross contamination, with integrated traceability systems and high-precision dosing units.
Conveying systems
There are various transport systems for pet food. The choice of which model to use depended on the need to ensure flexibility, constant transport and product protection.
MIAL’s conveyor systems, designed and manufactured in-house, have a high degree of customisation and can therefore easily adapt to different customer requirements.
Among the most common are:
- Tubular Chain Conveyors
- Open Screw Conveyor
- Paddle Drag Conveyor
- Redler
- Bucket Elevators
- Pendulum Bucket Elevator
Uniformity and grain size control
Milling and Mixing
Dry raw materials are milled to a uniform grain size.
This is an essential requirement for the homogeneity of the finished product and the correct gelatinization of the starches.
This is followed by the mixing stage, in which the ingredients are combined according to the nutritional recipe with the highest level of homogeneity.
MIAL uses high-speed paddle mixers, PLC controls and the possibility of continuous or batch mixing, optimising operating time and costs.
MIAL’s modular solutions make it possible to optimise the space available to the customer by limiting clutter.
The key technology for product quality
Pet Food Extrusion
The compound enters a pre-extruder, where it is mixed with steam and hot water. This step serves to soften the ingredients and start the cooking process, facilitating extrusion.
The use of NIR (Near-Infrared Reflectance) sensors allows real-time monitoring of moisture content, automatically adjusting liquid intake and improving overall yield.
Extrusion is the crucial moment in production. The dough is pressed and cooked in an extruder (single or twin screw) and then pushed through a die.
At the outlet, the pressure difference generates the expansion of the dough, forming the kibble, which is immediately cut to the desired length.
Mial Extruders
Advanced extruders, such as those integrated by MIAL, allow control of:
- Temperature and pressure
- Cutting speed
- Kibble density and shape
Inside the extruders, fresh meat can be added to obtain high quality products.
Stability and Long Shelf Life
Drying and Cooling
Freshly formed kibble contains a high amount of moisture and must be dried to ensure shelf-life and microbiological stability.
Drying takes place in belt tunnels or multi-stage chambers until a residual moisture content of <<10% is reached.
Subsequent cooling brings the product to room temperature, increasing the shelf-life.
Palatability and functional integration
Coating
Coating is the stage where oils, fats and flavours, as well as nutritional supplements, are added. This process improves palatability and may include:
- Chicken or salmon oils
- Natural preservatives
- Supplements such as probiotics or omega-3
MIAL implements drum or spray coating systems with optical viewers that ensure uniform kibble coverage and a high level of quality.
Pet food packaging
Dry pet food is packaged in bags of up to 25 kg. MF TECNO packaging systems, a MASSINI INDUSTRIES brand, include complete packaging systems including:
- High productivity vertical or automatic bagging machines
- Case packers and shrink wrappers
- Robotic palletisers or tertiary packaging
Why Choose MIAL - Massini Industries
MIAL, a brand of Massini Industries, is the ideal partner for designing and building high performance dry pet food plants. Relying on MIAL means relying on a company with more than 50 years of experience in the livestock sector.
This allows:
- To rely on a single contact person who is fully responsible for the entire project. This leads to optimisation of the entire process.
- Customised and scalable installations. The entire in-house design allows the different needs and requirements of the customer to be met in order to realise tailor-made solutions.
- Complete integration of all production steps.
- Automation 4.0 with remote control and real-time monitoring.
- Continuous technical support, also post-installation thanks to dedicated assistance and long-term collaboration.
- Turnkey projects with complete layout management.
- High productivity vertical or automatic bagging machines
- Case packers and shrink wrappers
- Robotic palletisers or tertiary packaging
Conclusion
Setting up a dry pet food production plant requires multidisciplinary skills, advanced technologies and specialised partners. From the selection of the ingredients to the delivery of the packaged product, each stage affects the quality and competitiveness of the final product.
If you want to invest in an efficient, safe and high standard plant, MIAL – Massini Industries is the right choice to turn your vision into a successful production reality.
