JAN 2022 - International Petfood magazine

JANUARY 2022

COP26

& the “Greening Finance” roadmap - Improving petfood drying efficiency - Process Design - from recipe to retail - Conditioning & pelleting: A focus on finding the right process & choosing the correct ingredients

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Perendale Publishers Ltd 7 St George’s Terrace St James’ Square, Cheltenham, Glos, GL50 3PT, United Kingdom Tel: +44 1242 267700 Publisher Roger Gilbert rogerg@perendale.co.uk Managing Editor Peter Parker peterp@perendale.co.uk International Editors Dr Kangsen Mai (Chinese edition) mai@perendale.com

January 2022

Prof Antonio Garza (Spanish edition) antoniog@perendale.com Erik Hempel (Norwegian edition) erikh@perendale.com Technical Editor Joe Kearns joek@perendale.com Nutrition Editor Prof Simon Davies simond@perendale.com Editorial team Andrew Wilkinson andreww@perendale.co.uk Caitlin Gittins caitling@perendale.co.uk Levana Hall levanah@perendale.co.uk International Marketing Team Darren Parris Tel: +44 7854 436407 darrenp@perendale.co.uk Latin America Marketing Team Clarissa Garza de Yta Tel: +52 669 120 0140 clarissag@perendale.com Egyptian Marketing Team Mohamed Baromh Tel: +20 100 358 3839 mohamedb@perendale.com India Marketing Team Dr T.D. Babu +91 9884114721 tdbabu@aquafeed.org

REGULAR ITEMS 8

Industry News 26 Training

29 Troubleshooting

30 Production focus 32 Industry Events

38 The Market Place 40 The Interview

42

Industry Faces

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www.internationalpetfood.com International Petfood - Volume 4 - Issue 1 ©Copyright 2022 Perendale Publishers Ltd. All rights reserved.

No part of this publication may be reproduced in any form or by any means without prior permission of the copyright owner.

More information can be found at www.perendale.com ISSN 2754-4680

6 Roger Gilbert 7

Joseph P Kearns

8 Professor Simon Davies

LATAM FOCUS

LATAM MEXICO ECUADOR MEXICO ECUADOR PERU & CHILE

8 page 10 page 24 page 28 page 30 page 11 page

Regional focus and welcome to new Regional General Manager.

Imported tilapia in Mexico, finding a solution to an old problem Shrimp Health management ,

by Dostofarm Supply problems during a pandemic, by Dr Zendejas Growing with Ecuador's shrimp industry, by Famsun IFFO report: Peru & Chile amongst just three countries reporting production increases in 2021

FEATURES 14 COP26 & the “Greening Finance” roadmap 18 Improving petfood drying efficiency

20 Process Design - from recipe to retail 22 Conditioning & pelleting: A focus on finding the right process & choosing the correct ingredients

THE PUBLISHER Pet ownership is continuing to surge around Welcome to the All new, All re-vamped and All the world and while the demand for high quality re-branded edition of our magazine AllExtruded petfoods that meet and fulfill the nutritional needs under its new brand name - International Petfood! of the animal, we must also consider the carbon Moving AllExtruded from a bi-monthly footprint that petfood production produces. magazine schedule to a more frequent monthly For example, in this first edition of 2022, we schedule has allowed us to expand on content, and look at the outcome of COP26 (held in Glasgow, focus exclusively on pet food production.

Roger Gilbert Publisher – International Petfood Scotland in November 2021) and what that means We will continue to publish International for millers and those manufacturing feeds for Petfood magazine both in English and Spanish, as animals. It’s a topic we will be addressing on we have done so in AllExtruded for the past four a regular basis along with alternative proteins for inclusion in years and provide digital support for each language as per our petfoods and health issues impacted by nutrition. other titles within the Perendale Publishers Ltd group. We aim to ensure our readers and advertisers can gain access to our content in a seamless and readily available way that only print-cumOur editors digital publishing can offer.

International Petfood Editor is Joe Kearns. Mr Kearns has spent Re-branding indicates our commitment to the petfood sector. his working life in the development of extrusion technology at International Petfood is a magazine that reflects the importance Wenger Manufacturing in the USA and is highly regarded in food has within the pet-owning sector and the attention food petfood production globally - in 2000 his company calculated manufacturers should be paying to both pet health and pet that over 80 percent of the world’s petfood production was being nutrition during the production process. produced on Wenger extruders.

The introduction of Covid 19 restrictions over the past two Mr Kearns will provide a wealth of knowledge and bring forward years has meant that we have spent more time at home with our a range of features relating to the production of petfoods that will pets, increasing our awareness of pet health and nutrition. help producers achieve their goal of greater viability and efficiency, As a result, we feel it is vital that International Petfood higher quality and functionality and the solving of technical and addresses these important areas of pet support - an area we are other manufacturing problems in the production process. most familiar with in the production of petfoods.

Complimenting Mr Kearns, we are also proud to announce Hence, the reason why we have chosen to re-brand the that Professor Simon Davies of the UK, who is not only a magazine under its new title and to introduce a monthly globally recognised expert in fish nutrition but possess sound publishing schedule that meets our readers’ needs for more knowledge and expertise in petfood nutrition which will benefit knowledge and information. our readership.

Professor Davies will be contributing a column each month plus overseeing the line-up of feature material associated with Our intended purpose pet nutrition and health. We will have a range of other columnists Unlike other petfood magazines, we will not deviate from our including Dr Mian Riaz of Texas A&M University. intended purpose – of exploring and reporting on the production It is a great pleasure for Perendale Publishers Limited to processes involved in producing petfoods. We will be honing be taking our magazine AllExtruded to the next level! From in on processing equipment, formulations and the markets with quarterly to monthly in both English and Spanish and under its a keen focus on the species, their health and nutrition and the new name of International Petfood. Welcome to this edition! environmental impact maintaining pets have.

New training course for petfood producers Progressus AgriSchools of Thailand and International Petfood magazine, published

by Perendale Publishers Limited of the UK, are pleased to announce the launch of the Pet Food Milling School for 2022.

The Pet Food Milling Course will join two other established 12-week courses on milling and aquafeed offered by Credo, the two partners’ online school management team.

"Becoming a reputable petfood manufacturer that provides nutritional, quality and safe food to pets is a hard status to achieve,” says Yiannis Christodoulou the founder and Executive Director of Progressus AgriSchools.

Joining the school to hear and learn

from a select group of petfood industry experts and trainers, who are prepared to discuss all there is to know about petfood manufacturing, is a unique opportunity that will address that goal, he adds.

Following the format of the other two courses, the Pet Food Milling Course will run over 12 weeks offering one two-hour online Session each week and culminate in a Certificate of Attainment that will help to convey the topics studied by the attendee.

Amongst a variety of topics to be covered, the School will deliver learnings on food production processes, equipment and instruments required for petfood manufacturing with a focus on areas such as extrusion, packaging, mixers and coating.

6 | January 2022 - International Petfood

EDO

CR

ONLINE PETFOOD SCHOOL

“It will also include an in-depth look into processing conditions and how those can be optimised while keeping to stringent food quality and safety standards required by the regulatory bodies and petfood retailers," says Mr Christodoulou.

“We look forward to welcoming all those who have a keen interest in the manufacturer of petfoods.”

Details of the course will be available from mid-February 2022 on the OMS web site at: www.onlinemillingschool.com

THE EDITOR elevated fresh meat inputs or other liquids.

Petfoods have become a truly internationally produced, shipped and marketed product, covering many styles and types. Production of petfood has Possibilities & efficiencies enjoyed amazing growth as well as advancements Single screw component design, introduction in production methods over the years, which has of twin screws into the market, dies yielding made this industry a truly remarkable one to work shapes and colours of all sizes and it does not in. appear to be slowing down any at all. When you Joseph P Kearns The advancements over time has been exciting bring in the topic of controls the possibilities Editor, International Petfood Magazine not only from the mechanical point of view but the and efficiencies add a dimension never expected. broad range of petfood styles and types that these The industry did go through a push back on machines can be controlled to produce. computer control, but it has been embraced because simply Alltech reported recently 2020 had an increase in petfood put they work and do things that are too hard to do manually production of eight percent up to about 29.33 million metric efficiently and timely. tons worldwide. It is exciting to see the continued growth in this I started hanging around extruders when the operator had total sector. control, he set everything by hand and even felt the ingredients It is such an honour to be asked to edit the International Petfood out of the preconditioner and out of the extruder, whilst also Magazine. Thanks to Roger Gilbert for the opportunity as well as making adjustments to water and steam, maybe the dry flow the involvement in the Online Milling School for AquaFeeds and rate. He could shut down and change the die or change the soon for Petfoods. extruder parts but other than this there was not much to be done, Perhaps a brief history of how I ended up in this position is in no options. order. At 19 years old I took a position with Wenger International It was the glory years of the brown and round petfoods, make as a draftsman, which included plant layout work. it expand, see if it stretches in your fingers for cook effect, This required a summer stint in the Wenger MFG’s Tech Center quick density check and off to the dryer. If you can imagine in Sabetha, Kansas in the early 70’s, as I needed to know how everything the operator did back then is now practically to clean and the space needed around machines in order to draw covered by control systems, the speed and accuracy have been plant designs. the differences. We need to consider that most likely every type of production method is in use now in the industry when considering the world.

An onslaught of technical developments Dryers and downstream equipment were never really looked at At this point, luck had it that the extrusion of petfood was too hard as the extruder must be the problem? Truly the system an accepted process and was already ongoing – although the was advanced from the front to the back, until the extrusion was real advancements were just starting. Desires to differentiate practically perfect the needed dryer developments were not seen. from competitors and nutritional advancements brought on an There are many different dryer possibilities but the major two onslaught of technical developments. are horizontal and vertical. Both have advanced greatly and are Dry feeding systems, preconditioning, the actual extruder moving forward on energy efficiency topics. Coating has been barrels, the dies and knives just to mention the extruders. Dryers an interesting process to watch develop. The accuracies have changed to match needs, covering mainly moisture evenness and greatly improved on the percentage of liquid to dry addition in efficiencies, whilst coating equipment has also greatly advanced. all plant phases.

The advancements in all the related industries also kept pace with appropriate fans, pumps, conveyors of many designs, boilers, lab equipment and just about every part, nut and bolt in Thought provoking topics & ideas these production machines.

Marketing and packaging of products are also interesting topics Back in the mid 70’s the kibble, dry or semi moist petfood along with the unusual production of petfood for fish, reptiles and system was extremely manual. Maybe if you were lucky you had other small animals. a relay based ingredient selection system which was half-way After 45 years of traveling in 85 different countries working on automatic. Practically everything else in the plant was manual and extrusion cooking projects, the idea is to present and prepare an needed to be controlled manually.

International Petfood magazine with thought provoking topics and The operators were and should be classified as artists, as it was ideas that cover the entire range of production scenarios. an art to run these plants smoothly and efficiently. It was even We can’t cover them all, but we will offer a variety of topics more impressive to see the artists inside a machinery production which relate to the industry from different viewpoints. The company face challenges and modify the equipment to succeed possibilities are almost endless with all the different types of in the goals, including how to manipulate the four areas of equipment and services needed for the many different styles of production: ingredients, equipment setup, operation of the petfood production. equipment and final product specifications.

We intend to have articles on plant design, standalone processes Of course, the ingredients and final product specs were set or the in most systems such as mixing, conveying, grinding, weighing, limits were pushed, which drove equipment modifications. There micro ingredients, extrusion, drying, coating, cooling, packing were many significant equipment advancements, feeding by and others. controlled loss in weight for the dry ingredients, water and steam If the readership has any specific interest in select topics drop us input controls coupled with preconditioning designs allowing a line, we will look into it.

International Petfood - January 2022 | 7

PETFOOD NEWS

Innovation hub eyes agrifood tech solutions for feeding pets & people Professor Simon Davies Nutrition Editor, International Petfood

A Nutritionist’s Viewpoint

Welcome to this new publication concerning the petfood industry and the wellbeing and health of our companion animals. Globally this industry currently amounts to some US$98.9 billion (2021) and expected to attain US$136.4 billion by 2026, as we provide nutrition for our dogs, cats, rabbits and many more species including equine (horses, ponies) and ornamental fish.

As a trained animal nutritionist, I have for years realised the significance in providing the best nutrition for our domestic animals and the array of key nutrients that sustain metabolism, promote growth and development and are also essential for the maintenance of the immune system and building resistance to infection and disease.

Indeed, pet nutrition has been transformed by research and much progress been made in leading universities and institutions devoted to the subject.

Scientists have been engaged with veterinarians to better understand the fundamental nutrient requirements of cats and dogs for instance where we have now obtained a better picture of specific macronutrient requirements at different stages of growth and body development.

We have data on protein and essential amino acid levels for provision of optimum tissue and organ development from the young to the older animal. The understanding of micro-nutrients for key metabolic processes has given us much more insight into trace elements and vitamin needs of the companion animal.

We have for example numerous scientific studies on the role of omega-3 fatty acids, vitamins A, E, & D, selenium, zinc, calcium and phosphorus on skeletal health of cats and dogs and horses.

Recently various prebiotics and probiotics have been highlighted in their modulation of the gut microbiome leading to the role of such functional feed additives in dietary health management.

Special formulations exist for puppies and kittens and for the mature dog and cat as well as breeding animals and bespoke for certain conditions and health status. We have diets that range in energy density accommodating the specific needs to allow for the highly energetic younger or working animal and for animals that may be sick, elderly and exhibiting various pathologies.

Indeed our feline and canine friends are at the attention of specialised manufacturers that provide complementary foods as treats and snacks to formulated main meals. We must remember that diets vary too considerably in their physical format from wet and canned diets to moist feeds in sealed pouches to dry extruded diets.

The technology of petfood manufacture is also keeping in step with nutrition progress.

The petfood market is highly competitive and the consumer will always be a key factor in marketing strategy. These days the public are very keen to know the sourcing of the raw materials in pet foods and ask questions concerning sustainability of supply much more than in the past.

Therefore the transparency of the food chain is becoming an important issue together with packaging and waste considerations.

There are many interesting topics to discuss and in the coming issues much to learn.

Agrifood technology start-ups based at a UK based innovation hub are beginning to think very differently about the products and service models for the future of agriculture.

Based at the Royal Agricultural University, Farm491 support entrepreneurs as they advance their business with potential for impact in the agricultural sector, with the hope of finding and healthy and sustainable food options for people and their pets.

This shift of focus comes as a result of input from Ben Jones, a highly influential entrepreneur who with a group of close friends, founded, built and then sold two successful businesses, for a total of UK£250m, to Unilever and Nestle.

These two businesses - the healthy snack company, Graze and a bespoke dog food business, Tails, filled niche gaps that the group had previously identified.

Mr Jones says that he sees huge potential for agrifood tech and since moving to his base in Gloucestershire from London, he has expressed his wish to support the huge potential that he sees for start-ups in the farming and food sector.

The factors that have made his own start-ups succeed will be crucial for tech companies competing for market position and funding. “Things that have been important to us in founding our own businesses have been staying curious and embracing naivety,” he says.

“For Tails, a chance insight from an animal nutritionist sparked the business idea, which was that from a variety of basic kibble recipes, we could feed every dog in the UK, whatever their dietary need.

“When we started Graze, we had no experience in food, but saw a gap in the healthy snack market which, at the time, was dominated by ‘tricksy’ marketing of ‘healthy’ snacks that were laden with sugar,” he adds.

He describes his business partnership as an alchemy between friends who are still exactly the same as they were when they were kids at school.

“Importantly, there is complete trust between us, we instinctively know where our competences lie and there is never any ego in the room. Added to this, we all shared the same vision.”

Mr Jones’ experience to date will give members of the Farm491 community exceptional advice on how to gear a business to lucrative market needs, to clearly define the offer and to raise adequate finance for the phases of growth.

8 | January 2022 - International Petfood

PETFOOD NEWS

Global ingredient manufacturer celebrates 25 years in rosemary The Kemin team is incredibly excited to celebrate 25 years of its rosemary line for use in foods, and it is proud to offer its partners solutions that come from its sustainable, vertically integrated rosemary program.

Rosemary is used in dog foods in its whole form, which has a number of uses in herbal medicine, but more often its oil is used as a natural preservative. Rosemary oil (or as it is also known, rosemary extract) is a powerful antioxidant which is able to slow down the oxidisation process that turns fats rancid.

Kemin has asserted itself as one of the largest vertically integrated producers of sustainably grown rosemary and boasts a traceable supply chain, from cuttings to final product. Before the establishment of its vertically integrated rosemary, it was previously harvested wild in southern Europe and north Africa.

"Being one of the first suppliers in the marketplace, we have dramatically evolved our offerings and continuously improved the production of these specialty crops over the last 25 years," says Dr John Greaves, Vice President of Specialty Crops, Kemin Industries.

"We quickly realised wild harvesting was not sustainable, and we needed to put a rosemary cropping system in place to improve biomass through plant breeding.

“Kemin developed one of the first rosemary-breeding programs, which took the plant from a Mediterranean evergreen shrub to a

high-performance phytochemical manufacturing plant," Dr Greaves explained.

Sustainability in ingredients continues to be driven by consumer demand.

The company’s rosemary is SCS Sustainably Grown, certified

by SCS Global which recognises leadership in environmental stewardship, social responsibility and economic stability.

"As we look to the future, Kemin continues to invest in innovation as our scientists and growers work together to discover new molecules for new natural antioxidants,” says Dr Greaves, detailing the future of the company.

“We are actively developing new botanical sources of antioxidant molecules to complement rosemary-based formulations and are continually working with extraction and formulation methods to produce the most effective rosemary products," he concludes.

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PETFOOD NEWS

Company launches its first insect based dog food in the US Insect-based petfood has more than 50 percent acceptance among US pet owners according to Emerton Market research.

Moreover, this study has shown that mealworm specifically has the best acceptance among cat and dog owners in the US compared with other insect species. Ÿnsect’s high-value and sustainable protein, a core ingredient for up-and-coming dog treat brand, Bernie’s, is entering the US market, with the launch of the ultra-premium and luxury food brand for dogs, which was launched in September 2021.

This partnership is an important step for the industry and paves the way for a healthier, more natural, and environmentally friendly diet for our pet friends.

Premium, high-value, sustainable ingredients

With the world’s largest vertical insect farm in France, and a new farm to follow in the US, Ÿnsect transforms Molitor and Buffalo mealworms into premium, high-value, sustainable ingredients to feed animals, fish, plants and humans.

Having raised around US$425 million from recognised investment funds, banks, and public institutions, Ÿnsect exports its products worldwide. The collaboration with Pure Simple True LLC to add Molitor larvae protein into Bernie’s soft treat Tender Medallions is a significant step towards further Ÿnsect development in the United States.

“We are very pleased to launch with Bernie’s our first insectbased product in the USA. Insects are not only a sustainable solution to feed the world, but also a high-value ingredient for pet health,” comments Antoine Hubert, CEO of Ynsect.

“Independent studies have shown that mealworm protein is highly digestible (with an 86 percent peptic digestibility), hypoallergenic and can even decrease skin diseases. This collaboration is another important step in Ynsect-US strategy,” he adds.

Pure Simple True LLC Ultra-Premium Brand for Dogs

Founded in 2020, Pure Simple True LLC announced the launch of the Bernie’s brand on the booming Direct-ToConsumer channel on September 3, 2021.

Its products are formulated with human-grade whole superfoods, such as Wild Alaska Pollock, locally sourced grassfed beef liver, MSC-certified cod liver and worm mill larvae protein.

The result is a portfolio of ultra-premium, sustainable foods for dogs, packaged in recycled glass jars and bottles. The Dog Food e-commerce start-up opted for a vertical model and it

owns and controls its own production and supply chains, which is not yet the norm in the Pet Food e-commerce channel.

The company balances growth with sustainable scalability, integrating operations from the beginning. The new operations platform, called Bernie’s Cookhouse, is based in the Seattle industrial district.

It is equipped with retorting capabilities for complete wet petfood production, as well as a fulfilment centre. The location also allows Bernie's to access very high quality, unprocessed raw seafood materials, which are key to the brand.

The brand has not yet raised any venture capital and is not aimed at growing at a loss for the sake of being bigger and faster. Their goal is to play the long game and moving partially offline is part of the plan.

The brick-and-mortar retail industry still offers a potential for sustainable growth and Bernie’s brand is an excellent match for small and mid-size pet food stores, providing a clear element of differentiation and answering some unmet market expectations.

"Pet parents are increasingly expecting highly nutritious and sustainable products for their companion animals. At Pure Simple True, LLC we are thrilled to share with Ynsect a commitment to bring to consumers these high-end products,” comments Jean-François Herve, CEO of Pure Simple True.

“The launch of Tender Medallions is the result of a partnership lead by a common vision of the food system, and a shared vision of a more sustainable nutrition,” he adds.

Ingredients for dry & wet petfood

Ÿnsect produces a wide range of ingredients for dry and wet treat and petfood applications. Fully traceable, its products are composed of petfood-grade ingredients and are 100 percent antibiotic-free.

The ingredient contained in Bernie’s dog treat is a superpremium protein, benefiting dogs’ health and wellness. Made of 72 percent protein and four percent ash, it is naturally rich in peptides and has a low molecular weight.

The ingredient is proven to be hypoallergenic and to help reduce skin lesions and food intolerances in dogs.

It also displays exceptional digestibility qualities and has the best amino acid score among insect species. The protein comes with some freshness perks: low Total Volatile Nitrogen and biogenic amines.

Using the company’s ingredient instead of other types of protein for pet food is sustainable, as insect production use 98 percent less land and 45 percent fewer resources than traditional livestock farming.

10 | January 2022 - International Petfood

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PETFOOD NEWS

New plant produces sustainable barley protein ingredient for petfood A provider of diverse supply chain solutions for the grain, animal feed, petfood, aquaculture and food industries has recently celebrated the opening of a new facility in Jerome, Idaho, US. Owned and operated by Scoular, the newly opened plant will produce Emerge, which is an industry first as a concentrated barley protein. It was developed to meet growing demand for plant-based and sustainable ingredients in both petfood and aqua feed. It is also both traceable and non-GMO. It currently stands as the only barley protein for feed customers and is created through a process that concentrates a protein naturally located in whole barley kernels. The result of this is a nutrient rich ingredient with uses in petfood and aqua feed.

“Scoular is proud to develop this innovative feed product and partner with Idaho’s barley farmers and pet food and aqua feed

Adisseo announces price increase Established over decades, Adisseo has a strong reputation as a supplier of innovative feed additives for livestock, aqua and petfood.

As the livestock industry - including Adisseo - is negatively affected by the ongoing and unprecedented supply chain disruption, as well as significant and sustained price increases in raw materials, logistics, packaging and energy costs, the comoany has no other choice than to make a difficult decision.

In order to maintain its supply of products and services to its customers, whilst maintaining safety, quality, and customer service standards in this inflationary environment, Adisseo has informed its clients it will increase the prices for its whole specialties’ product portfolio, starting January 1st, 2022.

All existing supply agreements and contracts will be honoured at the current terms and conditions.

The company’s sales managers contacted and informed its customers personally on the price adjustment for our specialty’s product portfolio. Adisseo technical team is available to support customers and help them to extract the maximum value from Adisseo’s products, services, and technologies.

Earlier this year the company announced Calysseo, a joint venture between Adisseo and Calysta, is building a first facility in Chongqing, China, which is expected to become the world’s first commercial-scale production facility of single-cell protein.

Delegates gathered at the site for a ceremony to mark the beginning of construction, which will deliver 20,000 tonnes of FeedKind protein in its first phase.

FeedKind, is made using very little water and no agricultural land by fermenting natural gas, an abundant source of energy, to create a safe, nutritious, traceable and affordable protein.

It is non-GMO, price competitive with existing sources of protein and produced to the highest quality standards and has been commercially validated through extensive customer trials in aquaculture, agriculture and petfood.

manufacturers to add value throughout the supply chain,” says Scoular CEO Paul Maass. “Scoular has a long history of success with our Jerome, Idaho, teams and customers, and we are thrilled to make additional investments in this region.”

In a ribbon-cutting ceremony to commemorate its opening, Paul was joined by David Faith, Chairman of Scoular’s Board of Directors, Laura Wilder, Executive Director of the Idaho Barley Commission and Mike Williams, the City Administrator of Jerome. The facility expects to begin commercial production in January, 2022.

The facility begins commercial production this year. Along with State of Idaho and City of Jerome, key project partners include the Jerome 20/20 Economic Development Organization, Scott Jackson Trucking, Starr Corporation and Bratney Companies.

Brace of companies announces continuation of cooperation It is with “great pleasure” that Cablevey Conveyors announces the renewal of its partnership with Matsuda.

With 20 years of experience in the sector, Matsuda Pet is only growing and developing its productivity and high-quality product, with this growth supported by its three production plants that are located throughout Brazil.

In 2020, Matusda Pet introduced a new production line, which resulted in a doubling the company’s pet food yield. Cablevey collaborated with them by furnishing the project with an array of sophisticated conveying solutions.

Bringing 50 years of experience in their conveying system to the partnership, Cabelvey has supplied over 1000 products in 66 different countries during this ha;f century of operation.

The company also has a lot to offer in the way of petfood production machinery, including versatile, clean and compact alternatives to bucket elevators, screw conveyors, and others.

The consensus shared from all partners is that this pooling of resources will continue to be beneficial to both and ensure optimal production, quality and customer satisfaction for many more years to come.

12 | January 2022 - International Petfood

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F

COP26

& the “Greening Finance” roadmap It’s time to start taking sustainability much more seriously

B

by Andrew Wilkinson, International Petfood magazine

ringing together 120 world leaders, all with the aim of speeding up progress towards the climate change goals set out in the Paris Agreement back in 2015, November 2021 saw the drama of COP26 unfold

in Glasgow, UK. On the final day of COP26, or the 26th UN Climate Change Conference of the Parties to give its full name, climate negotiators concluded two weeks of intense talks that ended with a consensus reached on urgently accelerating climate action.

This agreement, combined with increased ambition and action from countries, means that a 1.5°C reduction in global temperature still remains within our reach, but is only deliverable through “concerted and immediate global efforts.”

Five key points from COP26

1: Appreciation was expressed for informal agreements: This includes the increased targets and actions announced and the commitments made to work together and with non-party stakeholders to accelerate sectoral action by 2030.

2: Come back stronger next year: Parties were asked to revisit and strengthen their 2030 targets and align with the Paris Agreement temperature goal by the end of 2022.

3: Fossil fuel phaseout: Parties are to accelerate the transition towards low-emission energy systems and phase-down unabated coal power and inefficient fossil fuel subsidies, 4: Called out on climate finance: The Paris agreement made it clear that rich countries had an obligation to help them pay for the transition to clean energy and for adapting to climate impacts. The goal of them contributing US$100 billion per year by 2020 has not yet been met.

5: Loss and damage finance scheme: Urges developed countries to provide reparations to developing countries for those climate impacts that can’t be adapted to. This remains almost entirely unfunded and unstaffed.

14 | January 2022 - International Petfood

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Greening Finance: A roadmap to sustainable investing

With all countries agreeing to revisit and strengthen their current 2030 emissions targets, the main hope is that this pact will speed up the pace of climate action, with further meetings scheduled over the coming years.

In November 2020, the UK government announced that it intends to make disclosure requirements mandatory across its economy by 2025.

The Greening Finance roadmap outlines plans for new sustainabilityrelated disclosures and implements a Green Taxonomy to evaluate corporate environmental behaviour and to counter so-called greenwashing.

This scheme parallels one currently being introduced in the EU, with the ultimate objective being to establish a globally consistent reporting standard for environmental sustainability.

Starting with “economically significant” companies, organisations will be required to make disclosures on their carbon reduction plans, with certain firms required to publish plans that align with the UK Government’s net zero commitment, or provide an explanation as to why they have not done so.

The Green Taxonomy element will set out criteria that specific economic activities must meet to be considered environmentally sustainable and has six environmental objectives, which are: • Climate change mitigation • Climate change adaption • Sustainable use and protection of water and marine resources • Transition to a circular economy • Pollution prevention and control • Protection and restoration of biodiversity and ecosystems

What does this mean for our industry?

The quick answer to the question of what this means to our industry is, well, not much.

Other than serving as a timely reminder that we should all be adopting more sustainable working practices, there was very little in this that was specific to our industry.

However, with the UK Government set to phase in the Greening Finance Roadmap, a set of measures set to be replicated by governments throughout the developed world, the pressure is really on us to update our working practices and look for ways of reducing the carbon footprint of our respective organisations.

So as our governments have not acted on our behalf, we are going to have to make the difference under our own volition. But

The Roadmap will initially focus on developing the first two objectives (climate change mitigation and climate change adaption), before turning to the remaining four objectives in 2023.

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just where do we start?

Well one plausible course of action would be to seek out a company that has been “doing it” for many years already, a company that has already won awards for sustainability, find outwhat they are doing and then try to do something similar.

One such organisation that is setting the gold standard in sustainable food processing is a double award winner found in the UK county of Suffolk.

As a global supplier of brewing and distilling malts and malted ingredients to the food & drinks industry, sustainability is the common objective that links all aspects of Muntons business activities.

In fact, the company describes minimising the impact of its business activity on the environment wherever and whenever possible as its key objective. A decade ago, the company was one of the first malting and milling plants to install an energy efficient kiln heating system at its Stowmarket site.

This latest project forms an integral part of the company’s strategic pledge to be carbon neutral by 2050, and this, along with an existing system at its Bridlington site, is set to take the company over 60 percent of the way towards that goal.

Since receiving the awards, the mill has been fielding inquiries from other companies keen to follow in their carbonfree footsteps. And it has been the job of its Director of Technical Sustainability Dr Nigel Davies to satisfy these requests.

International Petfood magazine recently met with him to ask about the advice that he would give to companies that are looking to become more sustainable.

According to Dr Davies, contained within the following 10 steps is a constructive and foolproof framework for starting your organisation's journey towards reducing its environmental footprint.

10 steps to reducing your organisation’s environmental footprint:

1 2 3 4 5 6 7 8 9 10

Get your board interested in sustainability: Tell them that this is about business risk management, that it’s about operational cost reduction and try to get them to use the "Triple Bottom Line” business model of People, Planet and Profit.

Calculate your carbon footprint: You need to use a model which takes everything into account: scopes 1 and 2 in the factory and scope 3 - the impact of materials coming in and going out.

Don’t spend too long worrying about the accuracy though, as you may miss the opportunities to change. Action does not need 100% certainty. Some of the most forward looking and sustainable companies move ahead with 70-80% certainty and are not afraid if something does not work as well as expected.

Make a carbon map across your supply chain: This step will help you to understand which supply chain areas have the greatest carbon intensity. Be ready for an adverse reaction if your supply chain partner thinks you are blaming them for their carbon intensity and make sure they understand that you want to work with them towards a common goal: the spirit of the United Nations Sustainable Development Goal 17 is partnership.

Set a science based target (SBT): look at what you've done so far and see how your current savings match up with the target required to minimise the human impact on climate change. There could be a four-to-five fold higher target to achieve a SBT but those that set such an ambitious target find it drives innovation, regulatory resilience and gives a competitive advantage.

Join the 2000 companies globally who have agreed it’s a good initiative and the 50 percent of those who are bold enough to have already progressed to setting a target. It will align you with the Race to Zero and fast track your GHG reduction programme. The target has to be set no more than five years backwards in time and has to be achieved within a 15 year window.

Align your investment plans with your carbon roadmap. Be mindful that 63 percent of Chief Executives who have elected to take a science based target say that it has driven innovation within their operation. You can achieve remarkable changes in GHG emissions with existing technology whilst we wait for new options to become available.

Engage with your capital project team : These are the people who are going to liaise with your contractors to actually install new equipment and oversee projects and they'll be involved with local planners, the environment agency and other important stakeholders inside and outside the business.

Use the United Nations Sustainability Goals to broaden your outlook on sustainability. Don’t just agree they are a good idea. Be very specific about how your operations address each of the 17.

Don't think of offsets first: Hunt down the technology that’s available now, there is a lot out there. If you have done all you can and still have a small residual amount to offset choose offsets within your supply chain if possible and always those which capture new additional carbon from the atmosphere and are not just previously captured carbon now allocated to you through a financial transaction.

Intention needs action: All of the previous steps count for nought without action. Action can come from any part of the organisation.

Don’t fall into the trap of thinking it is only the young who drive sustainability.

At a recent conference Dr Nigel Davies described it as a silver bullet - a reference to seniority and experience in the right hands being able to drive transformational change in sustainability, as is evident through Muntons winning many awards for sustainability leadership and GHG reduction.

Appoint a consultant with a good track record of sustainability improvement: If you are still unsure of what to do, a sustainability consultant will be able to help you to align board strategy with action and demystify the jargon, barriers and fears that can at times stifle sustainable improvement. All of us in the UK now have to act fast to generate robust carbon plans as legislation is proposed from 2023.

International Petfood - January 2022 | 17

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Improving petfood drying efficiency

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by Merry Ortberg, Design and Engineering Division, Famsun-USA reliable dryer can cut down on unplanned down time and associated yield losses. Issues that may cause this downtime are belts breaking on the recirculation fans.

The installation of direct drive fans completely eliminates this problem.

Also shutting down the feeder to make a bed depth adjustment can take a lot of time if the feeder cannot be adjusted without stopping the dryer. A dryer producing 10 tonnes per hour that experiences four hours of unplanned downtime in a week is losing 40 tonnes a week.

This missed opportunity may create the need for over-time and result in reduced customer satisfaction if the product isn’t available to restock store shelves.

Sanitary design reduces cleaning time

Cross contamination and sanitation are high priority issues in petfood production. Producers need to look for a dryer built with a sanitary design to reduce cleaning time. A sanitary design includes minimised flat horizontal surfaces, crevices or other collection points.

Turning horizontal tube members at a 45 degree angle is an example of a way of decreasing cleaning time. Total access should be provided with doors and hatches all around for

18 | January 2022 - International Petfood

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inspection. If the dryer is not designed like this, extra downtime could be needed for cleaning.

Wasting energy due to lack of knowledge or controls is also costing producers. You could be throwing money out the stack by exhausting too much heated air. The dampers on the dryer can control the humidity of the drying air.

Always having the air at the proper humidity setting controls the drying rate to pick up the most water from the product. By either manually adjusting the dampers or using a humidity sensor and actuated dampers, a 10 percent energy saving can be achieved.

Higher level controls are also available that know when the dryer is not receiving product and put it into an idle mode where savings of up to 30 percent can be reached during that period of downtime.

There are many factors that affect the dryer’s performance, but if you pay attention to dryer design and operation, your improvement efforts can have a positive effect on your overall performance and product quality.

Improve petfood processing efficiency

If you are looking to improve petfood processing efficiency, you can take an objective look at a production line and determine that the dryer can be a significant source of opportunity. Dryers are a significant source of yield loss, the largest consumer of thermal energy and is often a major source of downtime. Luckily, if you focus on improvement, the process lines overall yield, energy consumption, and operational efficiency can be positively enhanced.

One often overlooked area for yield improvement is overdrying. For example, let’s say your target moisture is 10 percent based on a water activity limit of no greater than 0.65. If the finished product out of the dryer has a variation of +/- 3 percent, you must dry the product to seven percent on average to ensure that no product is over the specified 10 percent moisture limit.

If the 0.65 water activity limit is surpassed, then you are at risk of mould growth and an even greater potential for loss. The moisture deviation results are an approximate three percent loss in production. If you are producing 50,000 tonnes per year, a three percent loss in production from this line represents 1500 tonnes per year lost. A well designed, maintained and operated dryer is able to dry the product to within a +/- 0.5 percent moisture.

Increasing moisture uniformity

Efforts to improve moisture uniformity can include adjustment of the feeding device. Proper, level feeding is the first key to good moisture uniformity. If a level bed is achieved, then you must check to see if the outgoing bed remains level or if something in the dryer is causing a disturbance to the bed.

After these things are checked a more detailed evaluation must be performed by studying the results and looking for patterns to determine the next steps to take. Another form of over-drying occurs when the average moisture for the entire run is below target.

This form of yield loss can add up quickly, whilst also consuming more energy and a reduced production rate. It typically occurs when the operators are too focused on other matters, especially during very short runs, and are not properly

controlling the process parameters.

Downtime is necessary for maintenance and cleaning, but it must be a key consideration of the operation that should be broken down into planned and unplanned. Production management often specifies or plans how long the dryer should be down each week for critical items like maintenance, product change-overs and sanitation. But when the actual downtime exceeds the allotted time, then this is considered a run-time loss, which cuts into productivity and plant capacity.

Unplanned downtime often creates the majority of the run- time losses. Consider a dryer fault for example, it not only disrupts the drying operation, it shuts down the entire line.

If we were to simply consider how much out of specification material is diverted at every start-up and shutdown of the extruder, only then can the true scope of this opportunity be fully understood, with these potential losses adding up quickly.

INTERNATIONAL

PETFOOD

International Petfood comes to you either in print or digitally.

Whichever way you want to receive, please sign up on our MagStand for your personal copy which will give you access, from your desktop, to our back-issue library.

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International Petfood - January 2022 | 19

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Process from recipe Design to retail

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by Tim Broeke, Project Sales Engineer, KSE Process Technology, Holland he design of a petfood production facility has one main goal: how to get all the raw materials into the end product.

Of course this goal must be achieved in an accurate, time- and cost-efficient and flexible fashion with the desired capacity and footprint, whilst respecting any contamination groups. And last but

not least, within budget.

So there’s of course a lot more than just the one goal while designing the ideal process. That always makes for an interesting discussion on how to approach the design, since everyone in the production process has his or her own approach and requirements.

Perhaps the three most important are nutritionist requirements, production requirements, and (of course) commercial requirements.

Anticipating & satisfying all requirements Nutritionists need a wide variety of raw materials to be available 24/7 to dose a large selection of recipes automatically – of course with minimum manual interferences and maximum accuracy. This allows the nutritionist to produce specialised formulas without manual dosing, and a lot of different materials readily available.

Developments in nutritional science are leading to the production of more efficient feed additives. They are also however increasing the demand for faster, more accurate and cleaner dosing, transport and mixing equipment. There are nowadays more ingredients, and often in small doses.

Process requirements depend strongly on the type of production

facility. Whereas one facility may focus on output and efficiency, another might focus on maximum flexibility in customer-specific production to serve demanding (niche) markets.

This may allow longer batch times, but require more ingredients per dosing installation, and the ability to dose small and large components from a single silo. Flow characteristics of ingredients are often poor, and hygroscopic materials need to be treated carefully. This indicates different design parameters for storage and dosing equipment.

Studying the process will tell you the best equipment and batch size for a specific project. You can gain insight by analysing the required production capacity for each of a selection of representative recipes. This can be a complex calculation, though.

Process related variables include number of ingredients, batch cycle times, collection and internal transport times, and mixing times. Broader considerations include working hours, physical space, seasonal production peaks, and available budget.

Once you’ve decided on the key process equipment and how to set up the process itself, next is to fit all equipment within the available footprint and height. In existing buildings, adding or extending production lines is often a challenge and needs creative design by experienced process engineers.

Commercial requirements include delivering a range of products with as short a lead time as possible, with low capital and operating costs, and without compromising quality.

According to KSE, the best starting points for a process design or redesign are a thorough analysis of (realistic) wishes, with a good balance of nice-to-have features and future-proof design.

Don’t overdo the nice-to-have and future-proof parts, though.

The optional extras might tick all the boxes, but not fit the budget.

20 | January 2022 - International Petfood

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Conditioning & pelleting

A focus on finding the right process & choosing the correct ingredients

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by Arthur vom Hofe, Segment Manager Feed & Oilseed, CPM Europe BV, the Netherlands

very pellet mill operator has the same wish; the machine just needs to run, make good quality pellets at high capacity and for every type of feed or formulation. As a pellet mill supplier, CPM are often asked to give its opinion about the most ideal way to condition meal before pelleting for aquafeed.

Our answer is always simple and revealing - unfortunately this kind of magical solution just does not exist.

Generally, it is understood that conditioning increases pellet mill capacity and pellet quality, whilst reducing energy consumption and wear costs. On top of this it can also improve the conversion rate for the animal, provide a hygienic treatment of the feed and may allow the use of lower cost ingredients.

However, the selection of the conditioning method is dependent on a wide range of process parameters. In order to make the right selection, you have to look to the input (chosen formulation) and the output parameters (required pellet quality). Failing to do so can result in a very costly machine with a negative impact on the production process.

Looking into more detail of the conditioning process (Preparation of the meal before pelleting) we can recognise three different treatments. It all starts in the grinding-mixing line where we produce a mix with a specific particle size. This particular aspect has a great influence on the pelleting process and the animal nutrition, however we will not elaborate on this subject in this article.

Here we will focus on the thermal treatment (adding energy by steam) and the mechanical treatment (adding electrical energy by kneading shearing and compressing).

Choosing either thermal or mechanical energy

Depending on the characteristics of the material mix the emphasis is more to the thermal side, mechanical side or combination of both in the conditioning process. In our experience, starch, fibre and fat content are parameters which greatly influence the outcome of this selection.

All pellet-conditioning systems make use of the parameters temperature, moisture and time. Pressure is applied in the pellet mill die. While at high starch formulations the time is usually less than two minutes, we recognise for high fibre formulations a retention time longer than six minutes to soften the fibres and to absorb the liquids.

High fat formulations are the most complex to transfer to good quality pellets and there we see systems which also use pressure and shear to condition the material before it is shaped in the pellet mill die. Figure 1 shows the relation of all parameters to the process in the most simple terms in one graph.

Conditioning for a relatively short time

Formulations with a good combination of maize and wheat (typical poultry) are relatively easy to pelletise. They can be conditioned with the addition of steam for a relatively short time.

If the wheat content is minimalised and more maize is used the retention time requirement is increased and more mechanical energy is used in the pelleting process.

Through the years we have seen conditioners of different sizes entering the market. But all conditioners have basically the same requirements.

First of all, they need to be (steam) efficient as with the increasing price of energy, it is essential to select a conditioner where special precautions are made to keep the total cost of ownership as low as possible.

Beneficial auxiliary systems are systems preventing steam escaping from the inlet of the conditioner and systems

22 | January 2022 - International Petfood

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which inject the steam in or under the product so that steam consumption efficiency is optimised. A “spider” at the outlet will equalise the material flow to the pellet mill.

To minimise maintenance costs, bearings should not be mounted directly on the conditioner shell but with some distance and they should also be sealed so they are protected from the hot and dusty environment inside the conditioner.

The mixing of liquids traditionally requires a high speed but short mixing time whilst steam conditioning requires more retention time and a longer conditioning time at low speed.

This resulted in stacked conditioning systems with a combination of both, offering optimal liquids mixing and improved retention time for steam absorption.

A new conditioning technology

The California Pellet Mill (CPM) brings a new conditioning technology to the market. This makes it possible to fill the conditioner up to 70 percent and it provides extensive mixing of product particles with liquids and steam.

The improved conditioning machine provides higher possible temperatures, achieving better quality pellets and lower energy and operational costs, whilst also providing a high standard of blending for molasses and other liquids.

The design principle is based on the premise that the material is moving forwards and backwards through the conditioner and is rubbing against itself, with this then increasing liquid and steam absorption.

On top of this it has excellent product clean out characteristics after each run, a factor which improves the level hygiene and reduces cross contamination.

Hygiene is a key subject in conditioning

Whilst we are on the subject of hygiene, this became a key subject in conditioning. Breeder feeds are nowadays processed under strict conditions and this have resulted in a whole range of hygienic conditioning equipment with very specific demands.

A hygienic conditioner must be easy to clean, so it has to be easily accessible with a large ‘cleaning out’ door. Under no circumstance product should escape which has not reached the required temperature. In combination with an improved temperature control the ‘hot-start’ function provides this feature even for the first product coming out of the conditioner.

An additional benefit of the hot-start function is that the pellet mill reacts much more forgiving on the warm meal, which results that the nominal capacity can be reached within minutes from start. This improves the pelleting line efficiency importantly especially when frequent product change overs are required.

After the product is heated it needs to be kept for a certain set time at the required temperature. A hygieniser is used to keep the product (first in first out) usually between two-to-six minutes.

Special precautions are made to prevent heat losses and excellent self-cleaning characteristics.

For high fibre formulations more retention time (>6 minutes) is required for the material to absorb added liquids.

Liquids and some steam is added in the first mixer. After that the material is kept for a long time (>6 minutes) in a retention bin

International Petfood - January 2022 | 23

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so that liquids can be absorbed.

Before pelleting additional steam is added in a second mixer.

Adding too much steam in the first conditioner will result in large amount of un-processable material in the retention bin.

Pellet mill requirements

Generally speaking, a pellet mill is selected based upon its perceived ability to reliably produce pellets of a certain quality at a certain capacity. But there is more; in a sustainable environment energy efficiency is becoming more and more essential, which is also true for the pellet mill selection.

Using gear drive machines driven by a highly efficient motor is a step towards reducing the carbon footprint and reducing operational costs on top of that. Figure 2 includes information that relates to the use of energy in the pelleting process.

Thermal energy is added in the form of steam in the conditioner, whilst mechanical energy is added in the pellet mill die. However, the optimal amount of mechanical energy varies with the processed formulation.

It is therefore required to be able to adjust the amount of mechanical energy. This can be done with the CPM Lineator remote roll gap adjustment. With increasing distance between the die and rolls more electrical energy is consumed by the pellet mill and pellet quality is increased.

If pellet quality allows it, then the roll gap can be decreased leading to saved energy (see Figure 3). The remote control of the roll gap provides an increased safety level, which also reduces downtime.

What is also important to realise is that during the starting up of the pellet mill, roll distance can only be limited to prevent roll slippage but once running the gap can then be increased.

This reduces steel to steel contact between die and roll and saves importantly on die life. And since the die stays longer in shape it also saves energy and gains capacity.

To find the find the maximum allowable roll gap is always a challenge. The roll slip will increase with the distance until a pellet mill choke occurs. In an effort to remedy this issue, CPM have introduced a roll slip measurement system.

Figure 4 illustrates that with increasing temperature of the product coming into the pellet mill, the roll slip is increasing till a choke occurs at in this case 80°C, whilst Figure 5 shows that the slip can be controlled by varying the roll distance.

In this way the pellet mill is operating exactly on its optimal working point. But that is not all the system prevents pellet mill chokes, reduces downtime which increases effective production capacity.

It can also determine the exact zero position of the rollers and with that prevent steel to steel contact with the die, which will result in reduced wear costs.

Reducing mechanical energy

In the case that even with an optimal thermal conditioning system and large roll gap you can’t get enough mechanical energy into the pelleting process the retention time of the die can play an additional role.

This figure shows that a higher retention time of the product in the die increases the energy consumption and with that increases the pellet quality.

Basically, it means that for ensuring both pellet quality and pellet mill capacity the most flexible choice is selecting a larger pellet mill with a relatively thin die and adjusting the energy input by varying the distance between the rollers and the die.

If pellet quality still is a challenge while using relative thick

dies (ratio 1:20). What means, less steam addition (lower pelleting temperature), reduced pelleting capacity, higher wear and energy costs and increased production costs.

Apart from that, thick dies are sensitive for surface wear and many other curses. In this instance, a next step can be considered.

If at first you don’t succeed…

Something that we consider to be a quite simple solution is double pelleting. If it is hard to do it in one big step, then do it in two smaller steps! Back to thinner dies, increased flexibility, low cost raw materials and lower production costs.

This pelleting principle is extremely successful on high fibre (ruminant) formulations, in areas where low cost raw materials have replaced grains and soya.

When compared to the energy input by the use of the lineator roll adjustment, the mechanical energy input is increased further by the use of the additional pellet mill, or alternatively other precompactors.

With the increasing amount of fat, a higher amount of thermal and mechanical energy is required to still get a good quality pellet.

That said, you should always be very mindful that the first step to quality improvement of high fat formulations is post pelleting fat coating.

Expander pelleting

An expander is a tube with cantilevered shaft fitted with proportioning, mixing and kneading elements. The hydraulically adjustable cone at the outlet together with the outlet ring forms the annular gap. By means of adjusting the cone, the pressure, the intensity of kneading, the product heating, and the energy consumption can be controlled.

Figure 7 shows three different formulations that have been produced. The odd tests are single pelleting tests and the even test numbers are produced on an expander pelleting set up.

At high fat and liquid formulations, where it is hard to get energy in, the expander improves pellet quality. But running the expander on lower fat and liquid formulations results in higher energy and wear costs, as well as a less user friendly and controllable process.

There is no ‘one size fits all’ solution

Going over the characteristics of the different conditioning systems we can conclude that there is no one size fits all solution.

The selection is depending on process parameters like the binding properties of raw material, and desired pellet quality. What works for him doesn’t necessarily work for her and an incorrect selection may result is a very costly machine which have a negative impact on the production process.

What may be the safest conclusion to arrive at is that the key to the art of conditioning is to fully understand the science.

About the author: Arthur vom Hofe - CPM Europe BV

Arthur vom Hofe is working as Segment Manager - Feed & Oilseed at CPM Europe BV, a California Pellet Mill subsidiary in Zaandam - the Netherlands, where he has worked for more than 30 years.

Mr vom Hofe has been involved in the front line since the early nineties, when representing the company for pelleting and particle size reduction equipment. Throughout this time, he has gained valuable experience of feed production processes across the world.

24 | January 2022 - International Petfood

EXTRUDER AND EXPANDER TECHNOLOGY YOU CAN TRUST Extruder AL300 Almex offers a wide range of single screw extruders and expanders which are used for different applications.

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TRAINING

Industry Training IAOM & GEAPS to share knowledge as well as member rates

“We are thrilled about the new avenue of cooperation between IAOM and GEAPS. It's a chance for our members to gain access to the extensive catalogue of GEAPS educational offerings, and for GEAPS members to enrol in IAOM's comprehensive online and resident courses, says IAOM President Randy Garvert, Ardent Mills.

“We anticipate that this will pave the way for our organisations to increase our collaboration going forward,” he adds.

“For two organisations with missions so closely aligned, it makes sense that we would work together to provide all of our members with access to the best educational programming available,” he concludes.

This special promotion is planned to run until March 31, 2022.

31st Annual Short Course Feeds and Pet Food Extrusion

drying, grinding, conditioning and feed mixing equipment.

Further subjects covered include current practices for production of pet foods, preparing full-fat soy meal; recycling by-products and secondary resources; spraying and coating fats, digests and preservatives; use of encapsulated ingredients and preparation of premixes are reviewed.

This course offers an extensive look into the principles and characteristics of feed processing, as well as support systems for effective processing 4.5-day short course with leading instructors from around the world.

Participants completing the course will be awarded a Certificate and are eligible for 30 Professional Development Hours (PDHs).

Reservations are accepted on a first-come basis. For more information, programs and application forms, contact: Mian N Riaz, PhD, CFS, Texas A&M University Tel: +1 979 845 2774 Email: mnriaz@tamu.edu

The International Association of Operative Millers (IAOM) and the Grain Elevator and Processing Society (GEAPS) are pleased to announce an education collaboration.

For a limited time, GEAPS members will be able to enrol in IAOM's courses at their member rates; IAOM members are invited to enrol in GEAPS Distance Education classes at the reduced member rate.

“We are excited to work with IAOM to further our mission of advancing industry knowledge,' says GEAPS Executive Director Steve Records. “Training Season is the perfect time to take advantage of all of the great courses available through GEAPS and IAOM.”

As several events continue to be postponed, moved online, or cancelled altogether as a result of Covid-19 concerns in the United States, Texas A&M University (TAMU) announces its 31st Annual Practical Short Course on Feeds & Pet Food Extrusion.

A one-week Practical Short Course on Feeds & Pet Food Extrusion, this event will be presented from January 31- February 4, 2022, at Texas A&M University in hybrid format by staff, industry representatives, and consultants.

The decision to hold the event in hybrid format was made in order to cater for those who like to attend face to face, and for those who still cannot travel because of Covid-19.

The program will cover information on different extrusion systems such as Dry extruder, Expander, Single and Twin-Screw extruder, designing new feed mills and selecting conveying,

26 | January 2022 - International Petfood

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TROUBLESHOOTING

Petfood production troubleshooting Part 1:

Density

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by Joe Kearns, Editor, International Petfood magazine

he number one consideration in dry petfood production is product density.

For discussion let’s assume the formula is good for the product spec with the needed starch level for the required expansion, the machines are in relatively good shape, tolerances in range and the correct die with open area needed for the capacity to be run.

The typical approximate open area is in the 250 mm sq/ ton produced per hour range for expanded petfood.

If the density is too light, then steam injection in the barrel usually helps. Be careful not to add too much as this might leave you with product that is too wet.

So, take care to adjust it accordingly.

You can also change the amount of water added in the preconditioner. Typically, moisture out of conditioner can be in the low 20% to mid 30%. Water aids in creating cook in the conditioner to create more friction in the extruder barrel - as water acts like a lubricant and generally reduces friction and expansion.

Next is steam added to the preconditioner, and wherther an increase or decrease as needed, with the same care needed as when water injected into the extruder barrel. The basis of normal running conditions usually starts with 80% of the steam and

water added in the conditioner and 20% of the steam and water added in the extruder barrel.

Achieving maximum capacity

Most extruders now allow for heating and cooling of the head jackets. Cooling and or heating can influence expansion at the end of the extruder barrel, cooling less expansion while heating promotes more expansion.

If you increase the feeder screw rate slowly you might see increased pressure behind the die thus more expansion, the opposite is also true. If your die design allows it then the open area can be chenged to either increase or decrease expansion.

You should also keep in mind that you want as many holes as possible and get your density for maximum capacity. If your equipment has a method of adjusting density control, then adjustments to these devices if operated in their midrange points offer expansion control in either lighter or heavier ranges.

Another newly developed technology also allows for cook level changes in the preconditioners, where speed controls on the advanced DDC designs is possible.Variable speed control of the main drive also offers a possibility in increase or reduction of energy input or increased or decreased cook which is basically a method of density control.

Automation now allows for reading of the density level after the extruder before the dryer where feedback can adjust running parameters or auto control of energy inputs for density adjustment, thus automatic density control.

International Petfood - January 2022 | 29

PRODUCTION FOCUS Innovations this month January 2022 Following a two-year break, IPPE Expo is taking place at the end of January 2022 with Milling and Grain magazine in attendance at stand B8304.

In preparation for this long awaited industry extravaganza, we’ve put together a showcase of products from companies exhibiting at the show, ranging from processing equipment to nutritional products.

If you would like your product or service to appear on this page in a future edition of International Petfood magazine, then please contact us at editorial@perendale.co.uk

Quantum Series Orifice Gate, from Vortex Global Designed with the aim of eliminating production inefficiencies and frequent valve maintenance in mind, the Quantum Series Orifice Gate from Vortex, is designed to specifically handle dry bulk solids in gravity flow, dilute phase, or vacuum conveying.

Vortex's Orifice Gate also features a full-flange, weather-resistant design with improved sealing performance, higher durability, easier maintenance, and fewer replacement parts.

This product also features measures that are designed to eliminate sealing problems associated with traditional knife gates or butterfly valves. can be applied to control, shutoff, or meter material flow of non-abrasive to moderately abrasive powders, granules, or pellets.

Maintenance on the Quantum Series Orifice Gate, when necessary, is quick and easy – and can be performed directly on the conveying line. It also offers a wide variety of modifications to accommodate a range of temperatures, corrosive, humid, and hazardous environments. www.vortexglobal.com

GEA Ray Pilot Plant Freeze Dryer GEA’s Ray Pilot Plant is a batch-based freeze dryer which enables a highly efficient and economical batch freeze drying process, for meat products.

It provides tailored solutions for freeze dried petfood products, such as raw meat, cooked meat, kibbles and petfood treats.

Operated via a touchscreen, the Ray PP is designed for hygienic processing and consequently is easy to clean and maintain.

Once the product is placed in the chamber, the process is automatic, and all crucial parameters (such as product temperature and loss of weight) are monitored and stored to provide full documentation.

The pilot plant comes in two sizes, ‘Ray PP 1’ and ‘Ray PP 2’. The Ray PP 2 can produce twice as much at 8kg per day but consumes much more energy.

Its key benefits are uniform drying, flexible operation, online monitoring, batch reporting, and many others. www.gea.com

Yang from Lallemand Animal Nutrition Yang, a yeast derivative product, has been formulated to help strengthen animals’ natural defences. It can be used in a number of animal species: pets, equine, ruminant, swine, and more.

Its benefits in pets have been proven to improve the gut microbioata and increase dogs’ natural defence. By modulating the animal’s immunity and limiting colonisation of the gut by undesirable bacteria, Yang ensures the animal has good digestion and maintains good performance during periods of stress. Stress can weaken animal immunity and be detrimental to health and performance.

This feed additive is also compatible with other feed ingredients and stable in all feed types: mash, pellets, and liquids.

It comes packaged in 25kg bags and can be kept 24 months from the date of production when unopened. www.lallemandanimalnutrition.com

The Thermal Twin extruder, by Wenger Wenger’s thermal twin extruders enable petfood manufacturers to go beyond the traditional, dry expanded food and offer high carb, baked, soft, moist and high meat content pet food. It also allows specialty treats, retort-stable wet food, engineered ingredients and textured vegetable products to be manufactured.

This product features a specialised screw profile design which delivers high volumetric capacity and the capability of operating using a wide range of thermal to mechanical energy ranges, from 1:1 to 2:1.

It creates a new energy source through the increased use of steam injection, by utilising angled steam injector ports. This results in 4 times more steam injection in extrusion zones and up to 12 percent evenly distributed over the barrel length.

The extruder is also coupled with a high intensity preconditioner (HIP) which provides less moisture variation and increased cook. www.wenger.com

Conditioner CM from Andritz The CM conditioner is a large-volume conditioner with a largediameter shaft and individually adjustable stainless steel paddles, to ensure maximum filling and mixing efficiency.

The shaft is mounted in pedestal bearings containing grease seals, in order to ensure its long lifetime. The stainless steel trough facilitates easily accessible cleaning and service hatches.

The conditioner can be utilised for pelletising and extrusion. When using the conditioner for pelletising it has an integrated steam manifold which distributes the steam evenly to the product, whilst it also has two separate injection points for adding molasses.

In the case of extrusion, the steam manifold has adjustable steam valves to manually adjust it.

The ability of the conditioner to mix raw materials and liquids effectively make it suitable for a wide range of mixing processes in both pelleting and extrusion plants. www.andritz.com

30 | January 2022 - International Petfood

Hamex Semi Automatic Hammer Mill from Dinnissen Thanks to the robust design and relatively low speed of the hammer mill, it ensures minimal noise, guaranteeing a pleasant experience for the operator.

The semi-automatic screen exchange system enables the user to change screens whilst the rotor is still rotating, which saves ten minutes per screen change.

The semi-automatic version runs at a lower speed than the Hamex hammer mill, at a speed of around 1800rpm. However, the tip speed of the hammers has remained the same, so the user is able to achieve a comparable grinding with low energy consumption.

It is also equipped with large inspection hatches, providing quick and easy access for inspection and cleaning and maintenance.

Primary advantages of all Hamex hammer mills include robust construction and long life; accessibility so worn parts can be replaced easily; variable direction of rotation and good production. www.dinnissen.eu

Feed Innovation Award 2022 If you know of or have a newly introduced innovation for the production of animal feeds, including petfoods then consider proposing it for inclusion in this year’s Feed Innovations Award to be held at the Victam International 2022 exposition, which takes place in Utrecht, The Netherlands from May 31-June 02, 2022.

Email tutit@perendale.co.uk for an application form.

Deadline for submissions: February 25, 2022.

For more information: https://mymag.info/e/1290

Product Spotlight - The Holmen NHP100 Portable Pellet Durability Tester

T

he Holmen NHP100 is Tekpro Limited’s entry level pellet durability tester used for calculating the Pellet Durability Index, also known as the PDI, of feed pellets or extrusions by simulating pellet transportation environment from mill to trough.

Mesh pellet hopper

Pellets

Airflow The complete Holmen range of Pellet Testers represent the culmination of over 20 years involvement within the pellet manufacturing industry.

The range consists of four models including the ever popular Holmen NHP100, which is supplied complete with a 2.5mm diameter mesh Holmen Testers Increasing In Demand Globally hopper as standard, although other mesh sizes are also available to suit The basic NHP100 is a popular machine for smaller aqua, poultry, kibbles, extrusions and larger cattle feed types. companies, but quality focused feed mills typically now prefer the NHP200, this is due to its ease of use and the repeatable Versatile Pellet Test Machine accuracy of the test process. For larger companies who The Holmen NHP100 portable pellet durability tester is a truly manufacture pellets in bulk, Tekpro can also provide the versatile entry level machine. Being portable it can be easily Holmen NHP300, together with inline samplers to test directly transported between different testing locations, requiring only to be after the press, before too much product has been produced, placed on a flat stable surface to provide basic results for the operator. this can significantly help reduce the need for rework, and It works by loading a pre-sieved sample of pellets into the test optimise production efficiency. chamber which cascades them in an air stream causing the pellets to collide with each other and the perforated hard surfaces within the test The NHP100 has always been a very popular machine since chamber. When testing is complete the pellets are removed for manual it’s original launch, but as feed mills further strive for greater weighing. The 'pellet durability index' (PDI) is the difference between levels of automation and consistent repeatability of processes, pellet weight before and after the test recorded as a percentage. The both the Holmen NHP200 semi automatic and NHP300 inline tester provides the ability to manually calculate test results with pellet durability testers from Tekpro have significantly limited repeatable accuracy. The operation is totally manual with a increased in demand from all around the globe. basic timer function only, unlike the manufacturers more advanced Holmen NHP200 where test length is adjusted according to pellet For further free information, visit www.tekpro.com/mag diameter.

Industry Events 2022

January

2022

22-27 IPPE 2022 Atlanta, Georgia, USA https://www.ippexpo.org/

May 2-4 Petfood Forum 2022 Kansas City, Missouri, USA www.petfoodforumevents.com 24-27 Interzoo 2022 Nuremberg, Germany https://www.interzoo.com/en

31-4 31st Annual Practical Short Course on Feeds and Petfood Extrusion College Station, Texas, USA https://web.cvent.com/event/2801534f-0c2f-4646-be9c-1081107c95cf/?RefId=T EES+Edge+Website 2021

February

At Interzoo, the spotlight will be on innovative products, brands, and services as well as exciting developments and trends from all around the world.

Themes like equestrian sports, pet food technology, shop fittings, packaging, IT systems, e-commerce, trade literature, etc. are represented as well as traditional products for dogs, cats, small mammals, birds, ornamental fish, reptiles and amphibians.

At the last and so far largest edition in 2018, around 39,000 trade visitors from 126 countries gathered information on the latest products and services for pets from 1,990 exhibitors from 66 countries including global players as well as young companies and start-ups.

More than three quarters of the visitors are specialists from the trade, for example from pet stores, from drugstores, do-it-yourself stores and garden centres, the retail food trade and the Internet trade. Only eligible trade visitors are admitted to Interzoo.

Interzoo is used for image building by manufacturers and traders and all the stakeholders involved.

With over 390 media representatives from 29 countries and extensive media reporting, the trade fair offers a powerful PR platform.

31-2 Build my Feed Mill: VICTAM and Animal Health and Nutrition Asia Utrecht, The Netherlands https://vivhealthandnutrition.nl/visit/conference-program/ 2022

21-23 Animal Health, Nutrition and Technology Europe 2022 London, UK https://www.kisacoresearch.com/events/ah-europe-2022

August 17-21 Pet Fair Asia 2022 Shanghai, China www.petfairasia.com

22 February – May 24 Online Aquafeed Production School Online https://www.onlinemillingschool.com/omsaquafeed 2022

March 23-25 Global Pet Expo 2022 Orlando, Florida, USA https://globalpetexpo.org/Default.asp

2022

October 26-28 Pet Fair South East Asia 2022 Bangkok, Thailand www.petfair-sea.com

2022

November 17-20 China International Pet Show (CIPS) 2022 Guangzhou, China http://en.cipscom.com/CIPS.htm

32 | January 2022 - International Aquafeed

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Industry Events

AFIA Pet Food Conference 2022 The conference attracts more than 350 attendees from the petfood manufacturing industry to ingredient suppliers, offering an excellent opportunity to network with a diverse audience since 2007.

This program is designed for petfood and pet treat manufacturers and those supporting the industry, such as ingredient manufacturers and equipment suppliers. There are opportunities for students as well.

The American Feed Industry Association’s (AFIA) annual Pet Food Conference covers a variety of topics from regulatory issues to the technical aspects of petfood production to product claims, marketing and nutrition. You will also learn about how federal regulations will affect petfood in 2022, human-grade pet food labels, human resource issues and more.

Session speakers include:

• Nathan Bingaman, D1 Resources Inc; • Dave Edwards, Ph.D FDA Centre for Veterinary Medicine; • George Ferguson, North Carolina Department of Agriculture & Consumer Services; • Matt Frederking, Mid America Pet Food; • Col John T Hoffman, Food Protection & Defence Institute; • Carolyn Kennedy, EAS Consulting Group; • Thembi Machaba, Freshpet; Erin Mies, People Spark Consulting; • Todd Renner, Federal Bureau of Investigations; • Gina Tumbarello, AFIA. To find out more information about this event, be sure to visit its website at: https://www.afia.org/events/pfc-2022/

34 | January 2022 - International Petfood

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International Petfood - January 2022 | 35

Industry Events

College Student Program

IPPE 2022 What to expect

by Levana Hall, Milling and Grain magazine

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Come along and meet the International Petfood team at IPPE - stand B8304

he International Production & Processing Expo (IPPE) - being held January 25-27 in Atlanta, Georgia, USA - is a collaboration of three shows; International Feed Expo, International Meat Expo and the International Poultry Expo.

Showcasing the latest technology, equipment, supplies and services used in the production and processing of eggs, meat and poultry, the event also serves those involved in animal food manufacturing.

Sponsored by the American Feed Industry Association, North American Meat Institute, and US Poultry & Egg Association, IPPE is the annual flagship event for the meat, poultry and feed industries. This single event offers the largest variety of education and interactive exhibits for everyone from feed to fork, in the egg, poultry and meat industries.

Attendees include representatives from all over the world, including operation and plant managers, purchasing agents, engineers, and researchers from the world's top feed, meat processing and packing, and poultry companies.

Exhibitors are enthusiastic

The 2022 International Production & Processing Expo has already surpassed 507,000 square feet of exhibit space and has secured more than 1000 exhibitors.

“We are excited about offering an in-person 2022 IPPE and are encouraged by our strong exhibitor participation,” remarks the show’s organisers. “It demonstrates that our exhibitors are enthusiastic about reconnecting and showcasing the latest technologies and services that will continue to drive the industry forward.”

IPPE will feature several forums, conferences, talks, and programs, taking on a wide variety of topics, covering over 160+ hours of educational sessions. There is also the Innovation Station/ New Product Showcase running every day, providing attendees with an outstanding opportunity to see the newest products or innovations offered by exhibitors.

TECHTalks will be taking place each day of the event, where short educational presentations by exhibitors will be delivered throughout the day. These presentations will address topics such as food safety, animal welfare, sustainability, and feed production, to name just a few.

As well as the educational programs, throughout the IPPE event the College Student Program will be taking place, connecting students to professionals in the poultry industry, such as HR managers and recruiters. The three-day program is funded by the USPOULTRY Foundation. Interview sessions will be held Tuesday afternoon, all day Wednesday, and Thursday until noon.

In addition to benefiting the industry, the program is an excellent learning opportunity for the students to see the latest technology and advancements in today's production and processing industry

IPPE Young Leaders Program

With the recent celebration of the 10th year of the annual IPPE Young Leaders Under 30 Program, the launch of the 2022 program is already underway. The IPPE Young Leaders Under 30 Program targets young professionals who work for companies directly involved in the production and processing of poultry and meat or in the production of animal food and pet food who normally would not have the opportunity to attend IPPE. The goal of the program is to engage and invest in the next generation of young professionals, between the ages of 21 and 29, while celebrating their status as up and coming leaders in their companies.

To celebrate the Young Leaders there will be a breakfast, plaque presentation, and keynote speaker session for them on the third day of the event.

If you are lucky enough to be attending IPPE 2021, then the team from Milling and Grain magazine will be happy to see you at stand B8304.

See you there!

Day One – January 24

• International Poultry Scientific Forum, 0800 – 1700 • Latin American Poultry Summit, 0830 – 1900

Day Two – January 25 • • • • •

AFIA Pet Food Conference, 0700 – 1530 International Poultry Scientific Forum, 0800 – 1400 Feed Strategy Conference: Poultry, 0800 – 1200 Animal Agriculture Sustainability Summit, 0900 – 1200 TECHTalks will also be running from 1030 – 1600

Day Three – January 26 • • • •

The Future of Workforce & Workforce Issues, 0830 – 1000 Feed Education Program, 0800 – 1000 Poultry Market Intelligence Forum, 0900 – 1200 Business Continuity in Times of Disruption: Lessons Learned in the Feed Industry, 0930 – 1200 • TECHTalks, run alongside these sessions, 0930 – 1620

Day Four – January 27

• Environmental Commitments & Considerations, 0830-1000 • International Rendering Symposium, 1200 – 1700 • TECHTalks, run throughout the morning, from 0930 – 1220

Day Five – January 28

• International Rendering Symposium, 0800 – 1200

36 | January 2022 - International Petfood

24 – 27 May 2022 | Nuremberg, Germany

37. International Trade Fair for Pet Supplies

TOGETHER AGAIN AT THE WORLD’S LEADING TRADE FAIR IN NUREMBERG With this unique overview of the market, you will benefit from countless ideas for structuring your product range, the most important trends, and innovations.

And from valuable business contacts – all with a very personal touch at Interzoo.

Join us – personally and successful Follow us!

Admission granted to authorised trade visitors only.

INTERZOO.COM Organizer

Honorary sponsor

Organization

The Market Place lists leading manufacturers of equipment used for the production of petfood.

To be included in the Market Place please contact Tuti Tan at tutit@perendale.co.uk.

Bagging systems

Coolers & driers

Bühler AG +41 71 955 11 11 www.buhlergroup.com

Bühler AG +41 71 955 11 11 www.buhlergroup.com

FAWEMA +49 2263 716-0 www.fawema.com

Consergra s.l +34 938 772207 www.consergra.com

Statec Binder +43 3112 38 5800 www.statec-binder.com

FrigorTec GmbH +49 7520 91482-0 www.frigortec.com

Bulk storage

FAMSUN +86 85828888 www.famsungroup.com

AGI www.aggrowth.com

Van Aarsen International +31 475 579 444 www.aarsen.com

Behlen +1 402 564 3111 www.behlengrainsystems.com

Yemmak +90 266 7338363 www.yemmak.com

Behn + Bates +49 251 9796 252 www.behnbates.com Brock +1 866 658 4191 www.brockgrain.com Bühler AG +41 71 955 11 11 www.buhlergroup.com Ozpolat Makina Gida +90 342 337 1217 www.ozpolatmakina.com.tr Silo Construction & Engineering +32 51723128 www.sce.be Silos Cordoba +34 957 325 165 www.siloscordoba.com Symaga +34 926640475 www.symaga.com Sukup +1 641 892 4222 www.sukup.com The Essmueller +1 800 325 7175 www.essmueller.com TSC Silos +31 543 473979 www.tsc-silos.com Van Aarsen International +31 475 579 444 www.aarsen.com

Computer software Inteqnion +31 543 49 44 66 www.inteqnion.com Van Aarsen International +31 475 579 444 www.aarsen.com

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Dosing Bühler AG +41 71 955 11 11 www.buhlergroup.com Van Aarsen International +31 475 579 444 www.aarsen.com

Elevator buckets 4B Braime +44 113 246 1800 www.go4b.com Tapco Inc +1 314 739 9191 www.tapcoinc.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Elevator & conveyor components 4B Braime +44 113 246 1800 www.go4b.com Bühler AG +41 71 955 11 11 www.buhlergroup.com Henry Simon +44 0161 804 2800 www.henrysimonmilling.com

Van Aarsen International +31 475 579 444 www.aarsen.com

Extruders Almex +31 575 572666 www.almex.nl Andritz +45 72 160300 www.andritz.com Bühler AG +41 71 955 11 11 www.buhlergroup.com IDAH +866 39 902701 www.idah.com Wenger Manufacturing +1 785-284-2133 www.wenger.com Yemmak +90 266 7338363 www.yemmak.com Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Feed milling PLP +39 05 23 89 16 29 www.plp-systems.com VAV Conveyor Components & Solutions +31 7140 23701 www.vav-nl.com vibronet-Gräf GmbH & Co.KG +49 6441 62031 www.vibronet.com Yemmak +90 266 7338363 www.yemmak.com Zheng Chang +86 2164184200 www.zhengchang.com

Feed Mill Automation Bühler AG +41 71 955 11 11 www.buhlergroup.com Van Aarsen International +31 475 579 444 www.aarsen.com

Laboratory equipment

Tapco Inc +1 314 739 9191 www.tapcoinc.com

Bastak +90 312 395 67 87 www.bastak.com.tr

Yemtar Feed Mill Machines +90 266 733 8550 www.yemtar.com

Bühler AG +41 71 955 11 11 www.buhlergroup.com

38 | January 2022 - International Petfood

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International Petfood - January 2022 | 39

the interview

LaVon Gene Wenger

LaVon Gene Wenger officially joined the company that was started by his father, Lou, and Joe Wenger, Lou’s brother in 1955, accompanying his father in the engineering, refining and innovating of the equipment. Within a few years, he developed the first petfood extruder – the Wenger X-50.

Born October 29, 1935, in Sabetha, Kansas, to Louis & Tillie Wenger, Mr Wenger graduated from Sabetha High School, before then going on to study engineering for two years at Kansas State College (now Kansas State University).

He then married the love of his life, Erma Strahm, with whom he has raised three children, Marc, Shari, and Brad.

In 1977, he became President of Wenger Manufacturing; a title which he held for many years. He currently holds the title of Chairman Emeritus.

How did the Wenger company originally develop, what are the key events that you believe shaped the company that we know today?

In the early 30’s, the Wenger brothers had a feed mill they operated. This was during the Dust Bowl.

They came up with the idea that if they ground straw and mixed molasses with it, the straw would be digestible to the cattle. My father Lou came up with the idea to have a continuous high speed molasses mixer.

This was made from a hot water heater from the junk yard, thrashing machine beater shaft, and Model-T bearings; it turned at high speeds which blended the molasses into the ground straw.

Farmers would bring in their straw, the feed mill would grind it, and it was fed into the high-speed molasses mixer with high levels of black strap molasses. The story goes that many tank loads of molasses were used during this Dust Bowl period.

Other feed mills in the area saw this success, and then my father used a barn at the edge of town to start manufacturing these molasses mixers. During WWII, the use of molasses for feed was shut down.

My father then started fixing farm machinery to keep them running during the war.

Once the company was running, I understand that you then became interested in the extrusion process?

After WWII, molasses became available again and a high molasses extruder was developed from the Buffalo meat grinder. That was the start of the extrusion concept, but only a forming operation – not extrusion cooking.

Were you the first to identify that extrusion might be suitable as a feed manufacturing process?

By using technology developed from the high molasses extruder, we modified it by adding extruder sections on to one another and added a cone screw to develop pressure and shear. The objective at that time was to make floating trout feed. There was not such a thing as expanded kibble pet food at the start.

What was the response from industry and how difficult was it to gain support for the concept of extrusion in the feed industry?

Shortly after we set up the first cooking extruder in the back of the production plant in which we made

expanded products (but nothing more than a hog feed formula we got at a feed mill), we had an expanded cooked product coming out of the die.

Within months of the first test run, kibbled expanded dog chow came out on the market. Wenger had a market immediately. Everybody wanted to copy kibbled dog chow and Wenger’s had the only commercial cooking extruder to make it.

While there were many trials and tribulations – and various mechanical design issues – the potential was there. The right product at the right time.

Was petfood or aqua feeds important at that time and when did you find that extrusion technology would be suitable for petfood processing and what were the major hurdles?

As previously stated, we started making aqua feed, but it ended up being irrelevant and petfood was the product. We learned early on that dogs couldn’t digest raw starch and it had to be cooked.

A major hurdle was designing extruders that would stand up under the high mechanical shear and temperatures.

Also, the extruder thrust bearings were a challenge under the pressures required. There was no method of identifying the problem except simple trial & error.

Did others follow Wenger in the development of extrusion technology and did that help or hinder the global acceptance of the technology?

Obviously, we had competitors come in early in the game. But by Wenger’s staying focused and concentrating on extrusion cooking, we were successful in maintaining our position in the market.

We wore a lot of competitors out by consistently bringing out new technology.

Did Wenger have to conduct much research, and if so, did that involve outside assistance such as universities?

Wenger’s were the first to have a research centre in which we demonstrated our extrusion cooking technology to clients from around the world.

Universities were not of much assistance.

While we worked with them on occasion, it was never a major asset. Nobody wrote the book on extrusion cooking. Universities were mainly in a catch-up mode.

40 | January 2022 - International Petfood

Extrusion has developed significantly over the years, what were some of the key developments in your view? Has extrusion technology reached its pinnacle in terms of its development and processing ability, can it do more and if so, in what areas?

Product preconditioning prior to extrusion was a key development and Wenger’s kept finetuning the technology. While cooking extrusion technology is starting to level off over the development curve, there are still advancements.

There are numerous developments presently being explored. However, it is important that we keep these confidential for obvious reasons.

THE INDUSTRY FACES Experienced executive joins Bühler Group’s board of directors Former President and CEO of DSM Nutritional Products, Christoph Goppelsroeder, has been unanimously elected to Bühler Group’s Board of Directors at an extraordinary general shareholders’ meeting.

With his appointment, the Board of Directors is gaining an experienced executive who has played a crucial role in innovation and who puts customer needs first.

Swiss national Mr Goppelsroeder began his career at The Boston Consulting Group. From 1994 to 2003, he held management positions at Roche Vitamins in Switzerland, Belgium, and the US. He joined DSM in 2003 through their acquisition of Roche’s Vitamins business. He was then appointed President and CEO of DSM Nutritional Products in 2013, and Member of its Executive Committee.

He led the division on a robust growth path, both organically as well as through acquisitions. He retired on April 1, 2021.

Carnivore Meat Company appoints new distribution sales coordinator The Carnivore Meat Company announces the hiring of Alexander Umland as its distribution sales coordinator.

In his new role Mr Umland will help to fulfill and process orders, as well as collecting sales data from distributors, maintain retail store data and providing customer support.

“We are very excited that Alexander will be joining Carnivore Meat Company’s team,” says Jessica Pigeon, customer service manager with Carnivore Meat Company. “He has invaluable experience in sales, procurement and enterprise resource planning that will benefit the company greatly.”

Mr Umland has held previous positions in procurement, supply chain and logistics. He earned his associates degree from the McHenry County College in Crystal Lake, Illinois, US. “I am very happy to see and contribute to the can-do attitude that Carnivore Meat Company displays in all aspects of business,” adds Mr Umland.

Zinpro appoints new Global Digital Marketing Director Zinpro has welcomed Michael Tolmie as its new global digital marketing director. Mr Tolmie will lead the development of a stronger digital ecosystem to communicate with customers across the globe.

Mr Tolmie holds a bachelor’s degree in integrated marketing communications from the University of Wisconsin – Madison and an MBA from the University of Phoenix. He also brings two decades of experience in building strong teams and integrated digital strategies to the animal nutrition providers.

“We are very excited to have Michael on board to help us stay on the cutting edge of the everchanging digital business frontier,” says Rob Sheffer, Zinpro president and CEO. “As a company, we are committed to leveraging technology as we build stronger, more meaningful connections between our industry experts and customers around the world, and Michael is well positioned to lead us in that effort.”

Darling Ingredients promotes new Executive VP of Speciality division Darling Ingredients Inc announces the promotion of Sandy Dudley to Executive Vice President, Renewables and US Specialty Operations effective immediately.

In this new role, Ms Dudley will continue to oversee our renewable fuel strategy as well as spearhead Darling's US Specialty Operations, which include the production of nutrients for wet pet food, organic fertilisers, bakery feeds and our refining operations.

She most recently served as Senior Vice President of Renewables and Strategy, leading the collaboration for DGD's swift growth in renewable diesel production. "Sandy's extensive knowledge gives her a unique and valuable perspective, which has advanced Darling as a leader in sustainable ingredients," comments Randall C Stuewe, Chairman and CEO of Darling Ingredients.

"Her contributions have benefited Darling's business around the world, and we look forward to her business acumen continuing to drive results in this new leadership position."

42 | January 2022 - International Petfood

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