APR 2022 - International Petfood magazine

April 2022

PETFOOD SAFETY - Joint management & obesity in dogs - Developing effective natural nutritional support for joint ailments & weight management in canines - Insects in petfood - The continuing growth of the use of insect derived ingredients in petfood applications - Petfood technology in action - Achieving peak petfood packaging performance www.internationalpetfood.com www.perendale.com

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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 Technical Editor Joe Kearns joek@perendale.com

April 2022

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 Cristina María Roldán Otero Tel: +44 1242 267700 cristinaot@perendale.co.uk Turkey, Eurasia and Middle East Marketing Team Mehmet Ugur Gürkaynak Tel: +90 537 3646457 mehmetg@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 Asia Marketing Team Dante Feng Tel: +886 0227930286 dantef@perendale.com Nigeria Marketing Team Nathan Nwosu Tel: +234 8132 478092 nathann@perendale.com

REGULAR ITEMS 8

Industry News 30 Training

31 Troubleshooting

32 Production focus 34 Industry Events

37 The Market Place 38

Industry Profile 40 The Interview

42

Industry Faces

Design Manager James Taylor jamest@perendale.co.uk Circulation & Events Manager Tuti Tan Tel: +44 1242 267706 tutit@perendale.co.uk Development Manager Antoine Tanguy antoinet@perendale.co.uk International Petfood - Volume 4 ©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

www.internationalpetfood.com

COLUMNS 7

6 Roger Gilbert Joseph P Kearns

8 Professor Simon Davies

FEATURES 10 Petfood safety 14 Joint management & obesity in dogs

16 Insects in petfood 18 Insect based feed specialists continues impressive rate of expansion 20 Petfood technology in action 24 Achieving peak petfood packaging performance 28 The bamboo chain conveyor

THE PUBLISHER We have our two editors - Joe Kearns, who is In recognition of petfood producers throughout widely experienced in all things related to petfood the Ukraine - and the daunting task they are faced production - and Dr Simon Davies who has spent with at this time - we have devoted our cover in a lifetime in education and research that has support of their cause by reflecting their country’s involved all terrestrial and water-borne creatures, flag in carrying a picture of a Betta Splendin. has a special interest in pets, their nutrition and The Betta Splendin we have chosen is splendid their health. Their comments are well worth the by name and splendid by nature.

Roger Gilbert Publisher – International Petfood time taken to read and digest!

Its colours reflects the harsh reality the country Besides a range of news to whet-your-appetite, faces against a dark background to highlight we focus on the issue of petfood safety (see page the true spirit and determination shown by this 12) before looking at joint and obesity in dogs. country’s citizens in resisting and hopefully overcoming a larger, Dr Juan Jacierre of Layn Natural Ingredients, USA, looks into the aggressive and hostile advisory, in the form of an unwanted and role petfood plays in relieving these and associated problems. cruel invader.

Talking of diet, we are all fascinated by the rapid growth of Not only are people suffering terribly in the Ukraine as we go to insect-based protein supplies becoming available for pets and press, but their pets are also suffering and the conditions for both what this might mean for more sustainable protein supplies - and is unlikely to change in the near future. It’s a dynamic and fluid its likely impact on pet health; given that many pets do eat insects situation which could get much worse given that no one knows as part of a natural diet. That story (see page 18) comes to us when or if Putin’s recklessness and anger will be expended and from Aman Paul, the director of product development at Protix in the war will come to an end.

The Netherlands.

It is heartening to see so many countries, led both both their But to my mind a feature to focus on in this issue is ‘Petfood governments and their people, in coming to the aid of Ukrainians Technology in Action’ written by our editor Joe Kearns. He while at the same time trying to avoid escalating the conflict visited Wenger Petfood Technology’s Open House in late beyond the country's borders.

March, where he was given a tour of the very latest in extrusion processes as related to petfood production. Joe also takes us In this issue through this month's column of problem solving a few pages It’s difficult to ignore Ukraine and turn our attention to more later: 'Trouble-shooting for Dryers' (see page 40). mundane activities, but we should try. And with that in mind I There is so much to read in this edition that I can’t highlight draw your attention to a comprehensive range of features and everything. Suffice to say, take your time. Enjoy the read. Find stories we publish in this edition; topics that often do not make it those things that will help you. And let me know if there are into more traditional pet magazines. These are stories written for those who should be aware of their content and apply suggestions subject you’d like our team to focus on in future.

In the meantime we will all be keeping a nightly watch to their everyday work situations. on developments in Eastern Europe and praying that this International Petfood magazine, which is monthly and in unimaginable situation comes to a swift end with Ukraine two languages - English and Spanish - might be small in page remaining fully intact and independent. numbers but powerful in content.

Our last edition

Did you miss our March 2022 edition? If so, then don’t panic, as you can still read the stories we published in March on our App - either by downloading it from Apple Store or Google Play of from; https:// magstand.com/petfood – with the latter option providing the option to see all back editions on your desktop computer. https://magstand.com/petfood What you might have previously missed:

The diet of the laboratory rat

Throughout the world, the go-to breed has long been favoured for nutritional research is the domesticated Norway rat, or Rattus norvegicus.

In 2020 there were an estimated 10,000 rats being kept as pets in the UK, with the number in the US also steadily increasing. The fear is that the needs and stressors of rats are filtering through to the owners, meaning that many of these pets may not be receiving appropriate levels of care.

This situation places the often much maligned laboratory rat in what some might describe as an advantageous situation – click on the link below to find out why. https://issuu.com/watching/docs/ipf2203_w1/12

Are we overcooking our kibbles?

Extrusion is still the most common process to produce petfoods worldwide. Some important benefits include that it is a continuous and efficient process, it provides commercial sterilisation of the food, it cooks, it binds and it unifies all ingredients in a kibble, providing complete nutrition in every bite.

Written by Isabella Corsato Alvarenga, DVM PhD this article seeks to an approach to retaining resistant starches in dog nutrition when using this process in the petfood production process.

To read more, go to: https://issuu.com/watching/docs/ipf2203_w1/18

The Interview – Matt Zeigler

As the old Mark Twain penned adage goes, ‘Find a job you enjoy doing, and you will never have to work a day in your life’- a saying that seems very appropriate when discussing Matt Zeigler.

Growing up in the animal food manufacturing industry, becoming a Food Process Engineer was somewhat in his blood. So, when it came to the aspects of dealing with Agriculture Products and Processes, he simply enjoys it.

To find out more about Mr Zeigler’s climb to the top and his hopes and fears for the future, be sure to follow the link below: https://issuu.com/watching/docs/ipf2203_w1/40

6 | April 2022 - International Petfood

THE EDITOR and product characteristics to be met over time.

Small animal petfoods include aquarium fishfoods Liquids need to also be strained to remove any and this is the topic of the month. The data available oversized particles also capable of die blocking. shows that this sector of the industry, aquarium feed, The insurance of proper particle size is greatly is in third place behind dog and cats in terms of enhanced by the use of rotary filters right before volume of feed sold. It is a distant third place but is the extruder to remove any oversized particles. growing steadily.

I am sure a similar quality is required for drum There is data on the internet but not many Joseph P Kearns dryers. Standard extrusion application is used with specifics. Just looking at the fish side of aquarium Editor, International Petfood Magazine proper preconditioning and extrusion for cooking use, there are about one billion aquarium fish sold and product specifications, floating, sinking, slow per year. From here, assumptions need to be made if you are interested in the overall tons of aquarium feed sold per year sinking etc, basically density control.

Keep in mind of all feeds made for pets these kinds of feeds as no firm data is published. have the light turned on, owner is up close with face right on the A quick market review did show aquarium feeds can cost in glass watching everything. It must be assumed that the detail to the area of US 0.10 to 0.66 per gram. These are packaged in the knife and die setup is good as each pellet will be watched and approximately two grams and up pack sizes for the extruded and quality will be noticed. It should be noted that wet small extruded flaked varieties. Generally, aquarium feeds are sold as live, frozen pellets have been flaked with a set of rolls much like corn flakes or processed. Live varieties include worms, larvae, brine shrimp are made. (artemia) and others.

The interesting note is the flakes using this approach on small This discussion is on the processed version of aquarium feeds. diameter pellets seem to dry so quickly that a dryer is possibly Usually there are just a few styles of aquarium feed produced with extruded pellets and drum dried flakes being the predominate types. not needed. It would be very difficult to handle flakes in an air movement style dryer.

There is a special system to make small diameter feeds using A relatively low hourly volume extrusion but in a non-traditional sense. The feed is not forced to In general, an overview of drum dried flaked aquarium feeds start high temperatures during the process. All being the same through with a relatively low hourly volume, 50 kg/hr. and up. In all cases preconditioning but at this point the feed is formed in a cooled slow these feeds include macronutrients, trace elements and vitamins, speed extruder. the rest is a secret!

The die is etched with down to about 0.1mm holes for the Ok, most would use standard type feed ingredients with the smallest of feed diameters. The die yields fine strands of product special additives for the varieties needed. Beta carotene and/or that’s like angel hair pasta, which is then conveyed to a Spherespirulina, for example, are ingredients used to promote the colours izer. This unit has a rotating textured disc which breaks and developed in marine aquarium fish. The process has finely ground rounds the strands into small diameter particles. Our industry ingredients mixed and elevated in moisture to the 70 to 80 percent colleagues at Extru-Tech Inc of Sabetha, Kansas, USA offers such M range. systems.

The drum is heated by steam or electrical input to elevate the drum surface. The solution is spread over the heated drum while rotating. While aquarium feeds are very thin in thickness the The goal in drying is to dry evenly operation of the drum dryer is greatly assisted by controlling the Ok, in either case the pellets need to be dried. Sphere-ized pellets ingredient feed rate, film or product thickness, rotational speed of have a special dryer as the feeds are so small in diameter, fluid bed the drum as well as its temperature. Moisture is evaporated leaving drying. Direct extruded pellets, usually about a 0.5 mm die hole (or a dried sheet on the drum which is scrapped off by a knife system. larger) yields right at a 0.6mm product diameter. These diameters Flakes collected, possibly mixed for colour varieties and then are able to stay on the high temperature fine mesh polyester belts in packaged. horizontal dryers. Flexibility of air flow control, temperature and belt speed allow for the parameters to be controlled in the drying process.

Mostly extruded Systems exist allowing for low temperature drying, at or below Pellet style aquarium feeds are mostly extruded in order to 80°C, for heat sensitive materials. The goal in drying is to dry maintain water quality in the system due to pellet degradation. evenly, yielding a safe storable, shippable product with a good shelf The last decade has shown tremendous development of machinery life. making small diameter feeds, typically what is required for So now you have made a volume of feed that needs packaging, aquariums. Systems or equipment is available for high capacities in 50-gram bags or jars or smaller? At 1000 kg/hr that is at least as the difference in these feeds and production starter aquatic feeds 20,000 packages an hour. This requires some special high speed is very low. A wide range is available, and in most cases, the standpackaging lines for handling or placing in such small packs. It alone aquarium feed producer will generally have smaller capacity should be noted that this same 1000 kg/hr volume has a retail value equipment, approximately one tonne an hour for the less then 2mm depending on exact product in the US$100,000.00 to 660,000.00 feeds. potentially, granted there is packaging shipping and other costs All the extrusion rules for making small diameter feeds apply also. with grinding and sifting the dry material and filtering the liquids No doubt feed costs are a great portion of the nearly US$5billion being top of the list. In general, 1/3 of the die hole diameter is the a year annual expenditure on aquarium products in the USA. maximum diameter for the dry feed particles before the extruder.

Europe and Asia lead the countries on popularity of aquariums, So, if you wish to use a 0.5 mm die hole, as an example, the making the global totals in the US$13 billion range annually. feed ingredients need to be 165 microns for extended operation International Petfood - April 2022 | 7

PETFOOD NEWS

Scottish biotech firm unveils labgrown petfood project

Professor Simon Davies Nutrition Editor, International Petfood

Enriching the diets of cats and dogs with omega-3 long chain fatty acids from marine sources We all know that cats enjoy fish and are very attracted to diets containing fish products of a variety of sources such as cod, tuna, and salmon. The latter, oily fish are rich in the desirable fats or oils that contain essential fatty acids (omega 3’s) for health and wellbeing.

There is now wide interest in providing these omega-3 fatty acids from a variety of sources beyond traditional fish sources due to questions of sustainability and costs. It is my belief that much more work is required to improve our understanding of the importance of fats and essential fatty acids in dog and cat diets particularly. It is something quite overlooked in many aspects including veterinary medicine and clinical nutrition.

Fatty acid terminology is complicated and involves nomenclatures describing their molecular structure. The fatty acids known as EPA (Eicosapentaenoic acid) and DHA (docosahexaenoic acid) are highly unsaturated fatty acids (HUFAs) that can be only partially synthesized in the body from the essential omega-3 fatty acid known as alpha-linolenic acid (ALA) that is typically found in flax or linseed meal oil. These molecules are vitally important to the functioning of the immune system and to promote anti-inflammatory pathways in tissues and organs.

Although, dogs can convert alpha-linolenic acid (ALA) to EPA and DHA to limited extent, the process is quite inefficient in dogs and nearly non-existent in cats due to the lack of specific enzymes to effectively synthesise these specific fatty acids.

Further, typical diets of domestic canines and felines tend to be higher in the omega-6 series fatty acids present in plant oils added to contemporary diets. Higher levels of omega-6 can compete with the pathways associated with omega-3 and so it is vitally important to obtain the correct omega-6: omega-3 balance in the diet. Terrestrial animal derived by-products are not good sources of these omega-3 fatty acids either.

Therefore, dogs and cats both need foods fortified in EPA and DHA, and this must be reflected in their formulated diets. Optimal dietary omega levels greatly aid canine and feline skin and coat quality, skeletal health, and immune function. I have direct experience of this essentiality and benefits from numerous case study reports dealing with both canine and feline health related issues.

To meet the demand for essential fatty acids more petfood companies are ensuring that diets for both cats and dogs contain sufficient essential oils or fats in their formulations. Dry, moist, and wet foods will be fortified with suitable ingredients. Recently there has been much interest in novel marine ingredients for dog and cat food with more regard for sustainability with questions on the supply and sourcing of fish in particular.

In addition, we see more potential being realised for inclusion of novel marine ingredients such as phytoplankton, krill and both marine macroalgae (seaweeds) and microalgae e.g., spirulina and chlorella. These materials are more expensive than traditional ingredients but have distinct advantages as being sources of phospholipids (containing essential HUFAs), emulsifiers, and are often very high in carotenoids and in particular astaxanthin that has a powerful antioxidant property in vivo protecting cells from oxidative stress and enhancing the immune system.

Such marine ingredients are also rich in the fat-soluble vitamins and vitamins A, D, E and K are of prime importance in numerous metabolic pathways in dogs and cats. Together they work in a synergistic and harmonious way promoting maintenance, growth and development from the pup, kitten to full grown animal.

They would be of strategic importance in older animals to mitigate the effects of aging and later onset disease risks. In my role as an animal nutrition scientist, I have come to greatly value marine based ingredients and their functional properties for cats and dogs.

The oceans are a vast and wonderful environment, and we observe increasing marine biotechnology and discovery producing an array of natural functional products for the petfood manufacturer to consider. Increasing research is showing their attributes for our companion friends to benefit.

Now, some companies are scaling up algal biomass production to meet demands in the petfood market and this will be a positive step towards adding functional value to petfood products.

8 | April 2022 - International Petfood

A

Scotland-based food biotechnology firm says it is extending the reach of its animal stemcell technology with the launch of a venture that will produce and sell high-end, eco-friendly dog food using lab-grown meat.

Roslin Technologies has debuted the British initiative – known as Good Dog Food – with Agronomics, an investor that focuses on cellular agriculture, to develop healthy, eco-friendly petfood products that are made using cultivated meat.

This is not a complete switch of focus for the Scottish outfit though. The company notes that the new offering is entering the market when it already supplies its cell lines to cultivated meat producers for use in lab-grown meat products such as sausages, burgers, and chicken nuggets.

As reported by The Scotsman, the two parties involved in the venture say it has come about based on the belief that many pet owners are looking for more sustainable alternatives, food-wise, while cultivated meat is grown from cells without the need to raise and slaughter animals and could have a “significantly” lower environmental impact.

Roslin Technologies says its relationship with the University of Edinburgh – the firm is based at its Roslin Innovation Centre – provides the tie-up with access to animal science and top research facilities and capabilities.

Turning to Agronomics, this is billed as bringing a network of “passionate” investors and cultivated meat experts that will help build the venture.

PETFOOD NEWS

Insect-based petfood & treat company helps dog charities

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n insect-based petfood and treat company, demonstrates its commitment to pets in need by making a donation of 420 boxes of its own dog food to two charities. With the donation valuing at UK£8400, charities Greyhound Protection UK and Candy’s Hound Rescue International both received the dog food from Percuro.

Greyhound Protection UK was established in 2012 and is a non-profit organisation dedicated to rescuing and rehoming greyhounds in need, to raise awareness about the racing industry. Its sister rescue, Candy’s Hound Rescue International, rescues and rehabilitates dogs taken from the meat trade, breeding programmes and other terrible situations from countries with few animal protection laws.

“This is absolutely wonderful. A massive thank you to Percuro pet food for their incredibly generous support. We are dedicated to the rescue and rehoming of greyhounds

PIJAC celebrates 50th anniversary by changing its name

T

he Pet Advocacy Network, formerly known as the Pet Industry Joint Advisory Council (PIJAC), last night announced a comprehensive rebranding with a new name, logo and website that reflects its evolution over the past 50 years as the legislative and regulatory voice of the responsible pet care community.

The association made the announcement at its 50th anniversary celebration reception, held in conjunction with the Global Pet Expo tradeshow in Orlando, USA. “’Pet Advocacy Network’ embodies who we are, what we do and why we do it,” says Mike Bober, president and CEO, Pet Advocacy Network.

“This new name purposefully aligns with our role as a connector for the responsible pet care community to lawmakers, governing bodies and coalitions in the U.S. and worldwide advocating for the well-being of pets and the value of animal companionship.”

Research for the Pet Advocacy Network’s rebranding efforts started in early 2021 with a comprehensive communications audit, interviews with key stakeholders, and a survey of select pet care community audiences.

The results revealed that the name PIJAC no longer resonated with audiences and did not effectively represent who the organisation is or what it does. “The name PIJAC served us well for our first 50 years, but it was apparent after the research was conducted that it was time to make a change for the future,” says John Mack III, Pet Advocacy Network board chair and founder and CEO of Reptiles by Mack in Xenia, Ohio.

“Becoming the Pet Advocacy Network best represents our mission to advocate for animal well-being and responsible pet ownership, access to healthy pets and environmental stewardship.”

Pet Advocacy Network’s new logo was designed with intentional symbolism. The brand colours were chosen to

requiring help and feeding the dogs at our rescue centre is a major expense," says owner of Greyhound Protection UK, Kerry Lawrence.

“A petfood donation of this magnitude will make a huge difference to our non-profit organisation and the dogs love the taste of Percuro's insect-based, ethically farmed formulation," she adds.

"Corporate social responsibility is an integral component of our ethical brand. We are delighted to give back to the dog welfare community and demonstrate our support to Kerry's charitable organisation which is dedicated to the rescue and rehoming of greyhounds in need,” comments Denise Saber, Percuro's founder.

Percuro’s donation is invaluable in a time of “rising running costs,” to ensure that the dogs being housed at the charities receive the nutrition they need.

“Food insecurity is at an all-time high for dog rescues and it's gratifying to see these magnificent, gentle dogs thrive on our eco-friendly petfood with its hypoallergenic ingredients specially selected for the health and well-being of a dog's body and mind,” Percuro's founder concludes. represent the different environments where the animals that become beloved pets live and are arranged in a way that corresponds with each environment, with light blue representing air, green representing land and dark blue representing the sea.

The new logo was constructed to represent a stylised animal face, suggesting eyes, a nose, ears and whiskers.

The individual sections of the logo mark resemble hearts, birds or ornamental fish. In addition to its new name and logo, the Pet Advocacy Network unveiled its new website, PetAdvocacy.org.

A refreshed, modern design Visitors to the site will see a refreshed, modern design and streamlined navigation. The pet care community also will appreciate a more efficient member registration and donation process and an easy-to-navigate library of expertbacked resources including animal care guides and retailer best management practices.

Additional website features include an updated advocacy section to view state and federal legislation and local ordinances that the Pet Advocacy Network is tracking. The Pet Advocacy Network continuously monitors information sources to learn about proposed government bills and actions that could help or harm their members’ businesses, and acts, as needed, to advance or stop prospective legislation or regulations before they become law.

This work is especially crucial as the percentage of US households containing at least one pet continues to rise while legislative and regulatory challenges to restrict opportunities for pet ownership or impede access to pet care products and services intensify.

The Pet Advocacy Network kicked off its year-long 50th anniversary celebration in December 2021 with a series of social media posts depicting 50 memorable moments from the organization’s history of positive pet and pet care advancements.

In addition to the event held at Global Pet Expo, there also will be another celebratory event at SuperZoo in August, 2022.

International Petfood - April 2022 | 9

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PETFOOD SAFETY Ensuring petfood safety is a major concern for producers and processors alike.

All mills, including the Siemer Milling Company, are regularly subjected to close scrutiny during audits carried out by customers and agencies.

Having adequate processes and the right software to track and record maintenance work carried out on their machinery takes the pain out of this essential task.

M

aintaining clean, safe food and a clean, safe work environment are important in processing food for human consumption as well as for animal consumption. Many of the rules and guidelines for maintaining sanitation and preventing workplace hazards are the same between both of these environments.

Taking precautions to create a sanitary petfood processing plant and prevent workplace hazards also has similar benefits; a good reputation, avoiding expensive fines, reducing downtime and improving efficiency.

At the Siemer Milling Company, a feeling for quality and a sense of responsibility are deeply ingrained in the company’s DNA. Owned in part by the Siemer family and in part by the employees, the USA based milling company can look back on over 138 years of history.

Operating in three locations – in Teutopolis, Illinois, Hopkinsville, Kentucky and West Harrison, Indiana – today it employs 170 people and produces 750,000 tons of quality processed wheat products every year.

In order to ensure the highest standards, the company implements stringent quality and safety policies. The business also operates a test kitchen to further support its work.

“Quality and safety are at the very core of everything we do.

Our customers expect it, and so do their customers along the

Using advanced maintenance tools in petfood processing to ensure good sanitation and prevent workplace hazards

by Bühler, Switzerland

value chain down to the end-consumer,” says Sunil Maheshwari, Vice President of Siemer Specialty Ingredients and West Harrison Plant Manager, Siemer Milling Company.

Guaranteeing food safety in a complex business

In order to produce to the highest standards, machines need to run smoothly. The sophisticated equipment at each of the company’s milling plants needs continuous calibration to correctly and efficiently process over 750,000 tons of locally grown wheat annually.

This can only be achieved with rigid maintenance discipline and the necessary expertise. In the best case, machines run efficiently without costly breakdowns and essential parts are replaced as needed.

“As a preventative measure we shut down once a week for a few hours to assess any problems. When it gets really busy during harvest time, we shut down twice a month.

“All of our flour is made to order, and a very tight schedule is maintained between production and shipment. Every load is processed and shipped out as quickly as possible. Unscheduled disruptions can therefore have a very negative effect on the entire process flow,” says Mr Maheshwari.

Food safety is, however, the main concern. With increasing market pressure and margins becoming tighter, optimal maintenance helps to improve the bottom line. Maintenance has always been a constant in the milling business. As a benchmark, around two to five percent of the value of the installed assets is dedicated to it.

The evolution of maintenance

Maintenance has evolved for many businesses over the past few years. New technology – IT in particular – has enabled operators to optimise maintenance tasks and take the entire process to the next level. At the same time, expectations have also changed,

10 | April 2022 - International Petfood

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those of both customers and official food safety auditors.

Today, comprehensive paper trails are required that cover all aspects of the processes determining food quality and safety.

“Food safety audits have become tougher and tougher all over the world - and quite rightly so. Safety is of critical importance to our business,” says Mr Maheshwari. “If a machine is maintained, we want to know every detail about the procedure: who was in charge, what was done, which parts were examined and replaced.

“All calibrations undertaken in a mill for optimal performance require similar diligent procedures,” he adds.

Keeping on top of maintenance

With scores of machines made by different manufacturers, each with thousands of parts, it is a mammoth task to keep on top of the maintenance process. That is why, in 2015, the company investigated purchasing specialised software to assist in this operation.

After researching the market, Siemer Milling Company opted for Bühler’s ProPlant software. The key advantage that it offered was its ability to cover the entire business – each department and each different type and make of machinery.

The ProPlant Service Management System is a software that enables operators to organise the maintenance schedule of a plant.

It can be deployed for plants operating Bühler and non-Bühler equipment.

It merges complex data from various sources and delivers the information that operators need to manage maintenance and repairs. Before software like ProPlant was available, maintenance tasks were noted and tracked with pen and paper resulting in a very inefficient, time-consuming and error-prone process.

G e n t l e

C l e a n

With ProPlant, generating a job card for each task and then generating a list of all the work that has to be done is simple. The software also provides a record of every check or change made to each piece of machinery.

The software consists of four modules, which are Installation Asset Data Management, Preventive and Corrective Maintenance, Inventory Management, and Document Management. The multiple plant installation securely connects operations in different locations via the Internet to a management computer at any location. Data is safely backed up on a backup server.

Beyond the standard set-up, changes can be made to adapt the system to each customer’s requirements. The system is highly customisable to suit the individual needs of customers whether they use Bühler or non-Bühler equipment.

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PETFOOD NEWS Some customers add facility management to the system. For example, a job card can be created to schedule changing the office air conditioning filters.

aspect of our processes without software as potent as ProPlant would be unthinkable.”

Achieving consistently high audit scores

Siemer Milling Company currently uses ProPlant for its milling equipment tasks and auditing requirements as well as for calibrating its milling scales. Some of the equipment is from Bühler, other machinery is from other suppliers. Regardless of the manufacturer, ProPlant is able to track all sanitation tasks and documentation as well as employee time spent on specified tasks.

“Pressure to implement the system successfully was strong as we urgently needed to make our lives easier. And we succeeded.

However, there are still areas which haven’t been integrated into the system.

“There are just so many ideas where we can make improvements,” says Mr Maheshwari. This is the next step to further improve efficiency and utilise the system’s full potential, for example, by processing data from other areas of the business.

“We would like to include data on our trucks, our forklifts and other equipment. Ideally, we would use the system as a one-stop shop solution that can handle all our maintenance management requirements,” says Mr Maheshwari.

The Bühler team is already working on improvements and upgrading the software, with the vision of one day pushing the development towards predictive maintenance via the intermediate step called condition-based maintenance, where decisions about maintenance are based on the actual condition of the equipment.

For Roman Inauen, Customer Service Sales Support, Milling Solutions, there are several key elements in this process: “To move one level up from preventive to predictive maintenance we use both historical and live sensor data from machinery and entire plants to make accurate predictions about the status of equipment.

This enables us to comprehensively plan the exchange of parts before costly breakdowns occur. The other key element of this is connectivity.”

For Maheshwari and his colleagues at Siemer Milling Company, the potential is huge. “We are keen to build on what we have already achieved with ProPlant,” he says. “Collaborating with Bühler team has been very rewarding.”

The benefits of ProPlant are significant in terms of increased plant availability but also in terms of how customer and agency audits are run. Customers and official food safety agencies have a vested interested in ensuring that food processing companies adhere to standards.

Once a year, Siemer Milling Company opens its doors to BRC (British Retail Consortium) auditors. In between these visits the company’s national and international customers also send their own teams of experts to thoroughly scrutinise the milling operation.

Audits are an essential part of safeguarding quality within the milling industry. Achieving a good rating is important.

“Customers demand excellent ratings as they depend on safe and high-quality produce to keep up their own standards,” says Mr Maheshwari, whilst adding that “we are proud to have prime ratings at Siemer Milling Company.”

The BRC auditing process used to take two days, but every year new areas have been added. Currently an audit takes over two days. All the managers are involved as well as the food safety team – a significant effort in terms of time and manpower.

Customer audits are shorter but still take a whole day.

“The deployment of ProPlant has made a huge difference to how we conduct audits. The visiting auditors were visibly impressed and complimented us on the system. It significantly speeds up the entire auditing process,” says Mr Maheshwari.

ProPlant displays the complete history of an individual machine or processing line making the audit more transparent and easier for auditors and in-house teams alike.

“It’s very user-friendly, with just three clicks all the relevant information is there, right on the screen before us,” says Mr Maheshwari. “Auditors require a complete and detailed picture.

With ProPlant we can prove that we not only talk the talk but walk the walk.

“Operating with such detail and seamless control over every

Pushing for further digitalisation

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Joint management & obesity in dogs

Developing effective natural nutritional support for joint ailments & weight management in canines

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by Dr Juan Javierre, Senior Nutrition Scientist, Layn Natural Ingredients, USA

he two most prevalent problems dogs suffer from in middle age to seniority are joint ailments and overweight/ obesity, and very often they are concurrent. These two conditions can tax heavily on the canine’s quality of life which can also impact the lives of their owners.

Joints are complex structures made up from bone, cartilage, ligaments, and other soft tissues that allow mobility and add flexibility to the skeleton. Joints can suffer sporadic inflammation (arthritis), or a chronic articular degradation of cartilage, a painful condition known as osteoarthritis (OA).

According to recent papers, 20 percent of dogs older than one year and over 90 percent of dogs older than five years suffer from this disease. Normal cartilage, a complex material composed of a solid collagen and proteoglycan matrix saturated with water, is synthesised by chondrocytes, and functionally supports joint range of motion. Sporadic inflammatory arthritis associated to trauma or infections are usually short-lived.

Severe impact on a dog’s quality of life

Osteoarthritis, however, is a pervasive condition where the articular cartilage deteriorates, followed by bone remodeling, changes in periarticular tissues, and variable-grade inflammation.

This leads to gait alterations, discomfort and pain, and can ultimately have severe impacts on a dog’s quality of life.

Causes of OA range from genetics to breed size to obesity, with age and repetitive stress upon the cartilage as the main factors.

There is no known cure for this ailment. However, research has shown some polyphenol-rich botanical extracts can prevent the appearance, or reduce the severity of OA, because they can control three of its mechanisms: cartilage degradation, oxidation status, and inflammation.

Most often, damaged cartilage cannot be repaired, or existing repair procedures are complex with an uncertain outcome.

In-vitro and in-vivo research with the polyphenol icariin, a glycoside of the flavonoid kaempferide has shown its ability to stimulate mesenchymal bone marrow stem cells differentiating into chondrocytes and osteocytes and laying the foundation for cartilage and bone repair.

Other research shows icariin can also stimulate chondrocyte growth under poor articulate oxygen and nutrient conditions, and growth of 3D cartilage structures as well. Researchers have also identified the cell pathways icariin modulates to achieve this effect, namely Nrf2/ARE, and MAPK. Other pathways are activated by excess Reactive Oxygen Species (ROS) within the chondrocyte. ROS in the cell operate by activating the NF-κB pathway, which trans-locates key elements into the cell DNA, forcing expression of inflammatory cytokines.

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Research has shown that polyphenol-rich botanical extracts including green tea, pomegranate and mango leaf can help keep oxidative stress in check, reduce inflammation and support healthy metabolic activity. For example, pomegranate is rich in polyphenols such as ellagic acid, gallic acid and punicalagins.

There are many papers dealing with the metabolic antioxidant properties of these extracts and demonstrating that these potent polyphenols have the ability to help neutralise ROS, thus inhibiting the NF-κB pathway. This reduces the expression of inflammatory cytokines such as TNF-α, IL1-β, IL-6, which can result in positive effects such as a reduction in swelling, inflammation and pain.

The third pathogeny of OA is inflammation itself, which also appears in sporadic arthritis. Mango leaf extract contains, among other molecules, the polyphenol xantone mangiferin. Mangiferin has been shown to possess specific anti-inflammatory activity, and its molecular mechanisms have been elucidated, and research has shown protective effects in-vitro and in-vivo osteoarthritis in experimental animals.

There is no magic bullet against obesity

While botanical extracts can help to support articulate challenges, they can also support healthy weight. Excess weight in pets can also have impacts on joint health. If an inappropriate diet and lack of exercise are major factors in canine obesity, it would be natural that weight management should involve just increasing energy expenditure and controlling food intake.

Unfortunately, research has shown obesity is more than just weight increase. Two extra factors complicate the issue, namely oxidative stress and sub-clinical chronic inflammation.

Obesity involves excess fatty acids circulating through, and stored in, the liver and other tissues. These free fatty acids increase ROS at levels above those the body antioxidant system can neutralize them. This causes secretion of pro-inflammatory cytokines that end up in insulin resistance by the adipocyte.

Further, increased pro-inflammatory cytokines level cause widespread sub-clinical inflammation that result in osteoarthritis or diabetes.

There is no magic bullet against obesity. The use of especially formulated diet, high in protein and low in calories; the change of feeding patterns, by serving small food portions several times through the day instead of large amounts once; promoting exercise; restraining excess rewards, especially those rich in energy; disposing off food scraps off the table instead of giving it to pet, all are good weight control strategies that, unfortunately, do not address the root cause of obesity complications.

Earlier studies have shown that green tea extracts provided to obese dogs decreased insulin resistance, improved triglyceride profile, and modified genes linked to metabolisation of lipids and glucose, alleviating the metabolic status of dogs.

More recently, researchers have confirmed green tea extracts improve the metabolic status of obese dogs, by reducing the expression of inflammatory cytokines that results in a lower level of liver inflammation induced by high fat diets.

Also, they identified the metabolic pathways linking metabolic oxidation with inflammation, confirming the cause of obesityrelated metabolic dysfunction in obese dogs is an exacerbated state of oxidative stress.

When using green tea extracts for obesity/overweight management, it is critical to ensure that these extracts are caffeine-free. Caffeine and other methylxantines such as theobromine and theophylline are toxic for dogs, and they can cause behavioural and cardio-respiratory syndromes that may require urgent intervention.

Promising tools

Function-targeted botanical extracts containing active polyphenols are promising tools to help support two serious conditions in mid-age and older canines – joint damage and obesity. The TruGro CARE Joint Health and Weight Management solutions from Layn Natural Ingredients are efficient options for pet supplement and treat brands that contain these proven, potent polyphenols.

Joint comfort and healthy weight contribute to a happier and healthy life for pets and help alleviate the concern and stress of pet owners when dogs enter the senior stages.

About the Author:

Juan Javierre is Nutrition Scientist at Layn Natural Ingredients.

He is a Doctor of Veterinary Medicine, as well as a nutritionist and researcher. Juan has over 30 years of experience in animal and pet nutrition in Europe, the Americas, Southeast Asia and China. (juan.javierre@layn-usa.com; www.layncorp.com)

International Petfood - April 2022 | 15

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Insects

The continuing growth of the use of insect derived ingredients in petfood applications

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in petfood

by Aman Paul, Director of Product Development, Protix, The Netherlands

nsect derived ingredients are gaining recent acceptance in petfood formulations. Insects have received attention due to their ability to grow on large variety of organic side streams and unique composition that could be correlated to nutritional and health promoting benefits.

European legislators have already approved the use of insect ingredients (with no species restriction) in pet food formulations. They are covered under the animal by-product legislations ‘Regulation (EC) 1069/2009’ and ‘Regulation (EC) 142/2011’, being classified as category 3 material.

In August 2021, Association of American Feed Control Officials (AAFCO) approved the use of BSF protein in dog foods and treats in USA. Whereas, approval of BSF oil by AAFCO for petfood applications is expected in 2022.

In 2015, Trovet was the first brand to launch insect-based petfood in Europe. Since then, several start-ups, mid-sized local and big multinational players have launched insect-based petfood in European markets.

According to a recent report published by Rabobank “Several factors support the growth of insect protein as a petfood ingredient: 1) Growing premiumisation and the humanisation trend in the petfood market as pet owners increasingly give their pets more natural and high-protein meals and treats 2) Sustainability benefits of insect protein for environmentally conscious consumers 3) Insects have hypoallergenic features, which is particularly important for cats and dogs with sensitivities and allergies”.

Considered for mass production

Amongst all the insect species, only two insect species have been considered for mass production, they are black soldier fly larvae (BSF) and mealworms. The commercial production of these insects is mainly saturated in Europe.

However, there are also few commercially active companies in North America. Most companies produce insect meal and insect fats. Commercially available partially defatted insect meal has between 50 to 60% crude proteins. Insect meal is highly digestible in dogs as well as cats.

Additionally, several authors have reported functional benefits of BSF proteins. These proteins have immune response modulation activity demonstrated in vitro as well as in vivo. BSF proteins are also known to have antimicrobial activity against Clostridium perfringens, which can cause severe pathogenicity in pets.

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Additionally, scientists are currently trying to develop new functional claims around insect proteins. One such example is arthritis prevention. However, more work is needed to proof such functional benefits in vivo. Finally, BSF meal also contains chitin. The role of insect chitin to modulate pet health is yet to be investigated.

Strong antimicrobial properties

BSF fat has ≥ 96% digestibility and high acceptability in dogs.

BSF fat contains up to 50% lauric acid. Large majority of this fatty acid is present in the form of trilaurin. Trilaurin is digested in the guts of dogs and cats by sn-1,3 lipase to produce two molecules of lauric acid and a monolaurin.

Both lauric acid and monolaurin are known to have strong

antimicrobial properties against wide range of pathogenic bacteria. Whereas, trilaurin, also being an medium chain triglyceride an improve the brain health of ageing dogs.

Some companies are already adding other sources of medium chain triglyceride in formulations targeted towards senior dogs.

Current annual production of insect meal stands around 10,000 metric tons. Insect companies are scaling up fast. The production is expected to reach 500,000 metric tons by 2030. As the insect industry matures, demand for insect proteins in the petfood industry is expected to touch 350,000 metric tons in future.

Finally, insect industry should continue to unlock new functionalities of insect ingredients to support organic growth of the insect-based petfood market.

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INSECT BASED FEED SPECIALISTS CONTINUES IMPRESSIVE RATE OF EXPANSION roducers of protein and natural insect fertilisers Ÿnsect announces the opening of its first mealworm farm in the US. This follows the news that Jord joined its production platform.

Jord Producers, based in Nebraska, has been incorporated into Ÿnsect’s production portfolio, signifying the global leader’s entry into North American

mealworm production.

The move comes off the back of Ÿnsect’s introduction to the US market in November 2021, when they announced they would be supplying high value-added protein to Seattle WA start-up Pure Simple True LLC, selling ultra-premium and luxury food for dogs under the brand Bernie’s.

With the world’s largest vertical insect farm in France, Ÿnsect transforms Buffalo and Molitor mealworms into premium, highvalue, sustainable ingredients to feed animals, fish, plants and humans. Having raised more than US$500 million (UK£378.7M) from renowned investment funds, banks, and public institutions, Ÿnsect exports its products worldwide.

The addition of Jord Producers (one of the US' biggest mealworm producers) to Ynsect's production platform not only reflects the company's continued expansion into the US market, but also their entry into the backyard chicken feed market.

As Americans spent more time at home during the pandemic, the backyard chicken market saw significant growth. By 2026, the US market is predicted to reach approximately US$400M (UK£303M) according by a recent study by Arthur D. Little, a consultancy.

Over the last two years, the number of Americans rearing chickens has increased to around 26 million (8% of the population), allowing them to enjoy fresh eggs, keep their gardens free of pests, as well as the enjoying company of a new pet. Emerton studies showed that mealworms are the insect of choice among US backyard chicken owners, with 82 percent preferring mealworms versus other insects.

Recent trials conducted by Ÿnsect have shown increased performance on egg size. Ÿnsect is looking forward to providing its high-quality products for this market under its own brand.

“We’re very excited to continue establishing our presence in the US, which is a priority market for Ÿnsect as we expand globally. As an impact company, sustainability and support

for the environment is at the top of our agenda. We were obviously very impressed with Cheryl's entrepreneurial skills as she has become a pioneer in this industry in the heart of the Midwest,” comments Antoine Hubert, CEO and Co-Founder of Ÿnsect.

“She co-founded Jord within the best agricultural region in the US, allowing easy, local access to raw materials. It was therefore an obvious choice for us.”

Significant benefits

Mealworms like those produced at Jord offer significant benefits to livestock and pets alike: very high protein content (72% protein), highly digestible, hypoallergenic and the potential to decrease skin diseases.

Mealworms contain all the amino acids a chicken needs for optimal development, and incorporation into chickens’ diets has been linked to increased health, with decreased pathogens and improved resistance to stress.

Cheryl Powers, CEO of Jord Producers, adds, “Having built Jord Producers from scratch over the last four years with cofounders Kris Vrooman and Amber Klassen, becoming experts in raising and distributing live and whole dried larvae to the backyard chicken market, Jord Producers is delighted to join the Ÿnsect family. We’re confident that move will help us take the production of high-quality mealworms – something we’re so passionate about – to the next level.”

With the incorporation of Jord Producers in Nebraska, Ÿnsect’s production portfolio grows to three vertical farms and one hatchery. The integration of Jord Producers will eventually allow Ÿnsect to significantly increase volumes of mealworm larvae production and will also help pave the way into further entries into the petfood market, with ingredients like protein meal and oil expected to be approved for production in the near future in North America.

By using Ÿnsect’s ingredients instead of other types of protein for petfood, manufacturers benefit from using 98 percent less land and 45 percent fewer resources than traditional livestock farming.

Furthermore, Ÿnsect is dedicated to promoting sustainable manufacturing.

The company utilises a circular-economy model through its new vertical farms to create value chains fully aligned with the Paris COP21 Agreements +1.5°C scenario, and the EU Fit for 55 target.

18 | April 2022 - International Petfood

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Proven Performance

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Petfood technology in action

A report from an ‘open house’ held at Wenger Petfood Technology on March 22, 2022

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by Joe Kearns, Editor, International Petfood magazine

enger Manufacturing held an open house at their newly renovated Technical Center in Sabetha, Kansas, USA, which centred on demonstrations and discussions on an advanced version of the

Thermal Twin Screw Extruder.

The event, titled ‘Production of Petfoods of the Future Now’, allowed participants to spend the day discussing and observing the production of petfoods with this advanced technology.

The schedule included a demonstration of a high meat kibble with 45% meat added (% of dry feed) followed by a demo with 110% (% of dry feed) meat inclusion. Discussion of the process, review of how this technology affects drying, a Q&A period and a facility tour rounded out the day.

Noteworthy is the fact that no steam was used inside the process, zero added in the conditioning cylinder or directly into the extruder barrel. A thermal fluid was used in the head jackets that surround the screws and hollow core screws in this twinscrew design for heating and cooking.

A number of heating elements allowed for temperature control in the various areas of the extruder. This was the cleanest demonstration ever seen, no mess, no steam or dust anywhere.

A historic look at the process

The discussion of high meat use in petfoods resulted in a historic look at the process. This would include the use of a pelleting machine initially, single screw extruders, twin screw extruders, thermal twin screws and now thermal screw twin extruders. Over years of development the increased use of high meat in petfood actually follow the evolution of the process.

Preconditioning was a big factor, single cylinders, double cylinders, differential diameter cylinders and now high intensity preconditioners (HIP) have allowed for meat level increases at each design change. The HIP design is the lowest coefficient of variance, 2-3, of any cylinder available yielding an approximate 30 or 40 percent cook at the cylinder exit. The DDC design has a CV of about five and cooks in the 25% range with steam usage.

This HIP design allows for intense mixing offering elevated levels of meat and fat usage. A combination of speed control and shaft rotational direction is a primary importance in these kinds of products.

A dynamic shift

The meat is pumped into the cylinder with positive displacement pumps and it carries all the water for the process, the meat solution is heated to about 40 to 50°C before the cylinder.

The material then enters the extruder barrel where a dynamic shift occurs, no intentional cooking from friction as only thermal cooking is used. At 45 percent meat inclusion as a percentage of the dry ingredient flow the first demonstration resulted in 450kg meat combined with 1000kg dry ingredients.

The second demo had 1100kg of meat with 1000kg of dry feed. It is defined in this manner, meat addition as a percentage of dry flow as there are two distinct flow streams, meat and dry ingredients.

The material entered the twin screw barrel which was 25.5 to

1 L/D and exited through a back-pressure valve for flow control to the die. It was noted that when using frictional cook versus thermal cook the energy usage ratio is 40Kw electrical input is equal to seven percent steam usage, however this system had no steam injection but the energy to produce in total is much less.

The water needed is in the meat and is what greatly increases the thermal conductivity of the mix as it passes through the extruder barrel. A 70% moisture meat at 450kg/hr you are inputting 315kg of water as in the first demonstration.

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International Petfood - April 2022 | 21

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The dry feed material has water, about 10 to 12% or 100 to 120kg of water yielding a total in the 30% range out of the extruder die.

The second test with 1100kg of meat added to 1000kg of dry has a moisture content in the 40% range. This method of petfood production does lower the energy usage per ton dramatically. It also shows increased nutrient retention, offers a smoother kibble surface and an increase in product palatability.

The industry keeps advancing

Drying obviously needs to be reviewed when such a high moisture kibble exits the extruder, with the term convection roaster (CVR) was used to define this development. Much like biscuit drying or toasting. These CVR systems remove water, decrease bulk density, reduce kibble hardness and also improves palatability.

Palatability improvement as these products were selected to be consumed 2.75 to 1 and first selection was 3 to 1. The drying is basically, like an oven, higher heat and lower air flow. Dryer controls are considered to be more important due to the increase moisture levels and the need to maintain a max moisture in the final bag.

The tour of the new facilities was impressive with attention given to the need of current plant designs now required. Clean, roomy, advance pneumatic conveying for raw materials and finished product with attention to details were obvious, with separate rooms for individual processes such as coating.

Approximately 30 people attended the event, and most were from the USA and South America. The event was eye opening as making petfoods with such high meat levels included was amazing.

It was stated the possibility to achieve 200 percent of the dry feed is within reach with this technology; that is, 2000kg of meat for every 1000kg of dry feed.

The industry keeps advancing!

22 | April 2022 - International Petfood

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ACHIEVING PEAK PETFOOD PACKAGING PERFORMANCE

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by Statec Binder, Austria

ACCURATE AND EFFICIENT SOLUTIONS FOR A SURPRISINGLY WIDE RANGE OF APPLICATIONS

hether for a large producer or a smaller firm in the industry, or if a fully automatic or manual machine is required – this company believes it is able to deliver the right system to each of its customers, matching their high standards and requirements.

Bagging machines made by Austrian machine manufactures Statec Binder are used for the packaging of flour, grains, animal feed and pet food, seeds and other bulk materials all over the world.

Found within its product portfolio, Circupac is a packaging system that can be found throughout the global food sector. This high-performance bagging carousel is developed specifically for flour and powdery products.

The special feature of this particular packaging machine is its continuously rotating carousel, which allows the entire process to be carried out without a startstop system to achieve a maximum output.

In 2018, one of the world’s largest flour producers granted the company the chance to prove the high-performance capacity of this bagging system. The customer’s requirements of 1200 demanded bags per hour, each bag containing 25kg flour, proved to be quite challenging for many manufacturers.

Therefore, increasing its output significantly was the customer’s main priority, so it needed to move from semi-automatic bagging systems to fully automated lines. Several manufacturers were shortlisted as potential partners for the project and following a period of consideration, the flour producer finally made the decision.

High performance & accuracy

Statec Binder was able to win the bidding process, with the high performance of its machines and weighing 24 | April 2022 - International Petfood

and dosing accuracy amongst the most decisive factors. Additionally, the technical implementation and the project setup encouraged the company to place its trust in the Austria based specialists.

Three fully automatic Circupac bagging carousels and three high-performance Principal-R robot palletisers were ordered.

Additionally, quality control equipment such as checkweighers and metal detectors were also supplied.

As part of the packaging line, a long conveyor system was installed to guarantee a smooth transition from the bagging to the palletising process. A special feature of this system is the bag detection equipment, which can identify the category of the bag according to the bag’s imprint, and then convey it to the corresponding robot palletiser.

The customer further attached great importance to a clean layer pattern, which is easily achieved with the Principal-R. Moreover, via a control system, the customer can always monitor the performance of each machine along with its productivity and efficiency.

In addition to the Circupac and the Principal-R, other Statec Binder bagging and palletising solutions can also be used

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in the food sector, as well as in the packaging of animal feed and pet food. Depending on the specific product requirements and the desired output, the company offers three open-mouth bagging machines to choose from including the Principac, the Certopac and the Acropac.

Bagging machines from this series are used successfully for the fast packaging of bulk materials successfully used worldwide for the packaging of food and feed products.

The fully automatic high-performance bagging machine Certopac can pack any type of free-flowing bulk material in pillow bags and gusset bags with a filling weight between five and 80kg at high speed.

In addition to the standard version, the packaging machine is also available as Certopac- S and Certopac-L, with the differences between the two versions including bag magazines (rotating bag magazine or push magazine) and the different filling weights and sizes of the bags. The Certopac-S, abbreviated for Certopac-Small, has brought great success for Statec Binder in recent years.

The problem with paper

The machine was developed especially for the packaging of maize meal in the South African market. In the past, the dusty product was packaged in large paper bags with a filling weight of up to 80 kg.

However, the packaging requirements for maize meal, including bag sizes and used materials, have changed considerably. As a result, the bagging of the product in large bags, which used to be quite common, was no longer preferred by the purchasing population.

In addition, using paper as a bagging material became more and more of a problem. This is because producers had to deal with many complaints and returns, as the material often broke during transport.

“As a company, we reacted with the development of the Certopac-S. With the technical features of this machine, we were able to perfectly address these trends in South Africa at the right time," says Josef Lorger, Managing Director at Statec Binder.

The Certopac-S uses polypropylene (PP) as a bag material to ensure sufficient resistance, and at the same time packs maize meal in small bag sizes, usually with a filling weight of only five kilograms. The company was thus the first manufacturer on the South African market to develop a product especially for maize meal.

"Thanks to our rapid response to market requirements, Statec Binder has achieved a great deal of recognition in all

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International Petfood - April 2022 | 25

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of South Africa with our machine. We are now THE supplier for this industry with an extremely high market share for automatic packaging with PP bags," says Josef Lorger.

The potential for the Certopac-S is great, since maize meal is an important product not only in South Africa, but on the entire African continent. The demand is expected to remain high in the future.

However, the company has more packaging solutions to offer.

Standing as the most efficient machine out of the broad product portfolio of Statec Binder, the Principac is a packaging system prepared for a wide range of applications.

This system is designed specifically for those who want to make the move from manual or semi-automatic packaging to fully automatic packaging or require rather low capacity, Statec Binder offers the machine Acropac.

The fast packaging of bulk materials

Moreover, also Form-Fill-Seal (FFS) packaging solutions are offered for these industries. The FFS machine System-T is particularly suitable for the fast packaging of bulk materials and can fabricate pillow bags and gusset bags with a filling weight between five and 50kg. On the other hand, the System-F, a fully automatic vertical FFS machine allows easy and quick adjustability and only requires little space.

Statec Binder further ensures precise weighing and dosing in product feeding by equipping bagging machines with highperformance net weighers. Moreover, the company ensures a secure and precise bag closure through Statec Binder bag closing systems.

For instance, the patented bag closing system “Over Tape Bag Sealer” is especially suitable for PP bags. The hot air of the machine, which is produced by a heating unit, seals the bags airtight and makes sure that they are completely odourless.

The packaging process of animal feed and food products is optimally complemented by fully automatic high-performance palletising systems. Besides the robotic palletising solution Principal-R, customers can also choose from high-level and portal palletisers.

Thanks to proven technology as well as continuous developments and optimisations, the company serves as an internationally recognised partner to many. Expert consulting services, a high level of service competence and support for any concern provide additional reasons for this. The fullest satisfaction of the customers has always the highest priority.

Numerous fully automatic bagging and palletising systems for the processing of flour, food products as well as animal feed in woven PP, PE and paper bags have already been installed and commissioned on all five continents.

Providing assistance & answers

The company’s specialists are always available to provide assistance and answers to questions, from dealing with orders of spare parts and their delivery, ongoing inspections and maintenance of machines and individual customer training programs, to tailor-made service agreements.

Statec Binder focuses on a high level of communication, fast availability and proximity to the customer within its partnerships, which is why a large number of the company’s representatives offer not only consultation, but also support customers with maintenance services and inspections directly and immediately on site.

26 | April 2022 - International Petfood

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Flexibility and adaptability

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by Cimbria, Italy

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The bamboo chain conveyor

Simultaneously reducing micro plastic contamination & carbon emissions on the production lines of the petfood, feed, food & aqua industries ith the creation of a new eco-attentive product for multiple usage, one company is taking another step towards aligning itself more closely with the best interests of the environment.

As a company with 75 years of experience in the field of high-tech technologies and services applied to seed processing, Cimbria has been focussing the attention of its own internal R&D department keenly on the development of sustainable solutions.

This decision has been taken with the aim of harnessing the potential exciting opportunities created by our global industry, which is currently undergoing rapid change.

As often happens, innovations are borne out of the need to solve a specific customer need. In this case, for the company it was a question of acting towards more sustainable practices in the supply chain of feed processing.

However as there are many other production lines within the petfood, feed, food & aqua industry, all of these facets are disrupted by the presence of micro plastics in the finished product.

and flexural strengths.

Thus, plastic components in contact with raw materials during the distribution process, were replaced with bamboo wooden parts (pictured), making this the first conveyor on the market produced with the reduction of micro plastics in the food supply chain in mind.

By replacing the plastic with bamboo the functionality of the product is maintained, as bamboo has been chosen for its incredible resistance, its tensile strength which is higher than steel. Bamboo is also incredibly lightweight.

As a matter of fact, the bamboo chain conveyor offers a range of features which make it ideal for these industries, because of its loading capacity, versatility and speed. Last but not least the Bamboo Chain conveyor creates a better working wellbeing, thanks to its smoother operation and lower noise.

The bamboo chain conveyor is the demonstration that sustainability is not only a good intention or a vision for the future of a company, it is a business approach which is necessary to remain competitive and preserve value in the long-term.

The use of bamboo in the petfood processing line opens new opportunities for future product developments, showing that sometimes, sustainability is also a key driver of innovation and creativity for businesses.

Selecting the perfect material

The bamboo conveyor is just one of many belts within the Cimbria portfolio, with the range applicable to a variety of applications. Its specific solutions for the milling business include horizontal or slightly inclined conveyors for the transportation of cereals to silos.

The range of chain conveyors also includes models that are specifically constructed to suit various raw materials and tasks, with dimensions and capacities customisable on individual requirements.

Strength is ensured by the chain, which is manufactured in special steel with welded flights, and fitted with hardened steel bushes. Durability is ensured by galvanised steel sheets covering.

Flexibility is made by easy assembling sections of 500 -1000 2000 – 3000mm, with many other standard features complete the range such as drive station and intermediate sections.

Other standard features include a 10mm wear plate on the bottom plate, drive terminal with hollow shaft gear, and motors and gears from well-known and acknowledged supplier in energy classes IE2 and IE3.

In order to remedy this situation, with the vision of changing the game for the entire industry, Cimbria decided to focus its research and development department on searching for an alternative solution to the plastic materials used in chain conveyors. After numerous analysis and product tests, the team picked up the bamboo wood as the perfect material for its tensile Bamboo is a sustainable material because: •

It is classified as grass, has the ability to absorb up to seven times more C02 than conventional forest trees.

•

It has complex roots providing nourishment to the soil after years of different cultivation.

•

It can be planted in poor quality soils, without replacing essential food crops.

•

It does not require a huge quantity of irrigation or pesticides because it is very resistant.

•

It grows very fast and regenerates itself, increasing the yield and extending the life of the plantation for tens of years.

•

It is very lightweight and therefore easy and economical to carry and transport.

A range of chain conveyors

28 | April 2022 - International Petfood

F

TRAINING

Industry Training Online Milling Schools return for Spring 2022 editions

April 2022 sees the long-awaited return of both the Online Aquafeed Production School and Livestock Feed Milling Management courses for their Spring 2022 Editions.

Upon their return, the new, improved and updated online broadcasts, presented in their now familiar format of two hours, will once again be packed with a wealth of industry specific material delivered by carefully selected industry experts.

The two hours of teaching is then followed by a dedicated question and answer session, allowing participants to interact live with the program facilitators.

Developed by Progressus Agrischools and presented in partnership with Perendale Publishers Limited, these courses are formulated specifically to help attendees to build an understanding of the design, development, and operation of an aquafeed and livestock feed production plant, covering the entire range of products used in this industry.

This goal is achieved through twelve two hour long weekly sessions featuring industry experts who share their extensive knowledge relating to feed ingredients, the equipment used, as well as providing a general nutritional review.

These industry experts possess centuries of combined industry experience of includes Joe Kearns, whose experience in our industry includes decades in senior roles at Wenger manufacturing.

Wisdom & reliability

The Spring 2022 edition of Online Aquafeed Production School sees Mr Kearns take over the role of lead presenter,

a role that he will no doubt deliver with the same level of professionalism that has seen him earn a solid reputation throughout his career for wisdom and reliability.

Online Aquafeed Production School will enable interested individuals to understand the possibilities and developments over time with regards to what can be produced, as well as examining how all aspects of the process interact in order to achieve and maintain a successful standard of aquafeed production.

Basically, there are four areas of importance for aquafeed production; ingredients, equipment used, how it is operated, and the desired final product specifications. All aspects interact as each affects the other as the nutritionist makes the formula, sales or the customers define the desired end product while the production needs to perform efficiently.

Communication between these areas and the interactions between them will vastly increase the chances of producing positive results, including excellent aquafeed produced with acceptable margins.

It’s not too late to enrol

The Aquafeed Production School is running every Tuesday, from April 19 to July 12, 2pm Bangkok time and 9am CET. For those based in the US and Latin America, sessions begin on April 21 and conclude on July 15, 9am Chicago time.

The Livestock Feed Milling Management School is running every Wednesday, from April 20 to July 13, 2pm Bangkok time and 9am CET. For those based in the US and Latin America, sessions begin on April 21 and conclude on July 15, 9am Chicago time.

The course certification is very beneficial for the workplace, as it both signals an attendee’s interest in the industry and demonstrates an acquisition of the knowledge that they’ve gained whilst attending the program.

To enrol on the Aquafeed Production School course, be sure to visit https://aqfeed.info/e/1393 for more information.

To enrol on the Livestock Feed Milling Management School course, be sure to visit https://mymag.info/e/1392 for more information.

Why attend OMS | Livestock and Aqua Feed Production?

-

Update yourself with the latest technologies and machinery for feed plants Review key milling operations and gain ideas and knowledge that help further improve the feed production process Allows learning and development without having to leave your workplace

www.onlinemillingschool.com 30 | April 2022 - International Petfood

TROUBLESHOOTING

Petfood production troubleshooting Part 4:

T

Dryers

here are individuals who would argue that the most important part of an extrusion system is the dryer. If your extruder is under control and yielding the desired product, then I do not disagree. The dryer is without a doubt one of the machines in the system which greatly impacts the bottom line.

How? Water is the reason, as products are sold with a max water percentage on the labels, so it is the lowest cost ingredient and one that should be watched closely.

There are many different dryer styles with vertical and horizontal being the predominate designs. In either case the benchmark today is to have a variation in moisture out of the dryer at about 0.5%. An example is 10.5% to 11.5% M for all production across the dryer bed if your setpoint is under 12%.

Typically, on a horizontal dryer the samples are taken at the end of the dryer from points equidistant across the bed and about 25mm down from the top and 25 up from the bottom of the bed.

All moistures should be within the variance.

How does a dryer achieve this tough standard for moisture control?

Dryers are a time, temperature and air flow exchange device. If all are handled equally in relation to the product, then your moisture levels will be similar. The dryer assumes you are sending it a product that is not changing in moisture content, steady state extrusion. There are on-line control possibilities to assist in this.

Creating evenness in drying temperature

The time factor is based on product density, how much open area or bed area versus the product depth, thus speed control on the beds is important. Temperature is usually created with steam through exchange coils, direct fired gas or electrical inputs.

The point of heating and the method of moving the air through this heating chamber to the zones in the dryer, is what creates the evenness in drying temperature and air flow.

Exhaust air is also required to exhaust the moisture, as the overall design of the dryer itself is important to achieve these results.

As for operational points, these can vary greatly due to dryer designs. The heated air flow needs to move through the product to remove water, static pressure is needed to drive the air through the bed of product. Adjustable speed fans can assist in air flow volumes on different density and size particles as well as capacity at that moment. The bed level needs to be flat, if not then more air can go through the thinner areas, one of the biggest causes of moisture variance.

Once the above is controlled then the change of temperature in the dryer is the biggest control factor. Moisture too high then reduce temperature by five degrees or increase by five degrees if too wet. Check after the time, based on dryer retention time, and adjust accordingly zeroing in on the goal. Record data to use when this product is made again.

Previously on Troubleshooting…

1. Density An examination of product density and its relationship with moisture levels, heating, cooling feeder screw rate and automation.

2. Non-uniform and rough appearance A guide to understanding the science involved in improving the art of making products of all the same size.

3. Extrusion dies Die designs vary and are usually specific for the equipment manufacturer. This article takes a look at aspects of the process including high, medium and low shear as well the adjustments required when producing feed for small mammals.

International Petfood - April 2022 | 31

PRODUCTION FOCUS Innovations this month April 2022 This month’s Production Showcase section features equipment and ingredients that will help in the production of petfood, taking you right from the recipe book, right up until until your product is ready to leave your factory door.

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 High Shear Batch Mixers by Silverson Suitable for batches up to 300 US gallons, High Shear Batch Mixers

by Silverson can be used on mobile floor stands, making it easily moved from vessel to vessel.

The high-speed rotation of the rotor blades within the precisionmachined mixing workhead exerts a powerful suction, drawing liquid and solid materials upwards from the bottom of the vessel and into the center of the workhead.

Centrifugal force then drives materials towards the periphery of the workhead where they are subjected to a milling action in the precision-machined clearance between the ends of the rotor blades and the inner wall of the stator.

This is followed by intense hydraulic shear as the materials are forced, at high velocity, out through the perforations in the stator and circulated into the main body of the mix.

The materials expelled from the head are projected radially at high speed towards the sides of the mixing vessel. www.silverson.com

Qrill Pet by Aker Biomarine Qrill Pet is a 100 percent natural product, made only from whole Antarctic krill. A product of biotechnology company Aker BioMarine, who are developing and supplying krill-derived products for consumer health and animal nutrition.

Qrill Pet’s fully transparent value chain stretches from sustainable krill harvesting in pristine Antarctic waters through the company’s Montevideo logistics hub and all the way to customers around the world.

Produced woith the sole aim of keeping pets healthy and happy, Qrill Pet is rich in long-chain omega-3 fatty acids, marine proteins, choline, and the antioxidant astaxanthin.

Moreover, our ingredient is currently the only MSC (Marine Stewardship Council) certified krill meal in the world. Qrill Pet comes from one of the most sustainable fisheries in the world and can be traced back to the exact catch location of the krill to the delivery to pet food brands. www.qrillpet.com

Batch Dryer by Geelen Counterflow Designed specifically for high capacity and fast change-overs, the batch dryer from Geelen Counterflow operates by forcing hot air through 5 to 10 product beds. New product is continuously fed to the top bed deck which transforms the continuous flow into a series of batches.

Discharging from each bed deck is timer driven and powered by hydraulic cylinders. Discharging starts at the lowest deck and sequentially moves through the upper decks, avoiding product cross contamination.

Every product batch is treated individually in separated drying zones.

The amount of evaporation can be controlled on each deck by variations of the drying air volume and temperature.

A moisture sensor at the dryer outlet can serve as an input for the heater temperature setpoint to improve final product moisture control.

A controlled volume of drying air is exhausted with a high relative humidity while the remaining air is recycled back to the heaters. www.geelencounterflow.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 pet food 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

SEE YOUR PRODUCTS IN THIS MAGAZINE If you produce a product that you think we should feature in International Petfood magazine, please get in touch To be considered for inclusion in the magazine please; Email: editorial@perendale.co.uk Include 75 words about the product along with a high resolution image and a web link to more information about the product in your email

32 | April 2022 - International Petfood

The Sphere-izer by Extru-Tech The revolutionary Sphere-izer Agglomeration System™ (SAS™) is designed to produce starter fish feeds with nutritionally homogenous particles sized as small as 300 microns.

A mixed and pulverized formulation passes through a low shear, low temperature extrusion process where it is conditioned and compressed to form agglomerated strands. The strands enter the Sphere-izer, a sizing and shaping device that breaks the strands into small individual agglomerations and shapes them into spherical particles.

The spheres pass through a dryer/cooler unit where excess moisture is removed and the particles are cooled. The spheres pass through a screener for size classification.

Because very little heat is introduced into the raw materials during the SAS process, raw material nutrients are undamaged. Heat sensitive major and micro ingredients, along with medications need not be over formulated to offset heat-related losses. http://extru-techinc.com

We can help you improve your feed pellet durability testing...

Holmen NHP100 Portable, manual pellet tester.

Holmen NHP200 Series 2 Laboratory based, automatic pellet tester.

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.

Don’t miss out on seeing the finalists of the feed innovation award, coming soon in International Petfood magazine.

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

Holmen NHP300 Inline, process based system.

N HOLM

®

Made in Britain, Trusted Worldwide.

We are

Industry Events 2022

May

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.

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

Deadline for submissions: February 25, 2022.

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

Build my Feedmill conference to take place at VIV Europe 2022 The Build my Feedmill conference is based on a flow chart of a typical feedmill and will cover many aspects of feedmill operations.

It provides an excellent opportunity for companies that supply feed manufacturers with advanced equipment and other services, to explain their most technically-advanced innovations and why they offer advantages in the feed production line.

2022

During the Build my Feed Mill Conference which is set to take place in June 2nd , 2022, companies are given the chance to present 10-minute presentations about how their solutions assist feed mills in their everyday processes and practices.

June 2 Build my Feed Mill Utrecht, The Netherlands https://vivhealthandnutrition.nl/visit/conference-program/

2022

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

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

Taking attendees through every process within a feed mill, Build my Feed Mill enables attendees to discover the latest innovations that help make your feed mill truly innovative, efficient and profitable.

Topics being discussed include grinding, feed formulation, extrusion, pelleting, dosing and more.

Find out more: https://mymag.info/e/1326

Two-hour event

13:00-15:00

June 2nd , 2022 Part of VIV Europe

Organised by

34 | April 2022 - International Aquafeed

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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. https://magstand.com/petfood The App can be downloaded from your favourite app store.

We invite you to use the code below for a free edition of our March magazine either mailed to you or via our App Use coupon code:

IPF2204

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

International Petfood - April 2022 | 37

Industry PROFILE

PLP Systems Continuous coating test plant

Specialising in machinery and systems for food, pet food, aquafeed, animal feed and chemical industries, PLP Systems is a company with over 40 years’ experience in dosing, mixing, spraying, coating and handling of liquids and micro powder additives.

The primary focus of the company is to create customised dosing units suitable for the client’s needs, projecting on each occasion a tailored solution on request. For this reason, PLP Systems invests substantially in research and development (R&D) each year, developing new and exciting concepts whist always trying to improve and push forward existing technology.

An important area for PLP is the coating process that is used in different sectors including: post pellet coating for feed and aquafeed, pet food coating, seeds coating and fertiliser, as well as crisps, chips and snacks in the food sector.

Developing a continuous coating system

Initially, testing for new coating

applications were done using internal small-scale laboratory equipment, simulating what could possibly be a true production, but this procedure was limited in many aspects compared to real production conditions.

Key changes occurred once PLP developed a continuous coating test plant system in its workshop which was able to reproduce the full capacity of the demands of the industry and minimise the difference in results between a lab test trial compared to a real production.

After having faced various challenges brought on by following a great variation of projects, we have managed to gain an extensive knowledge, understanding and competence in this field.

This in-house continuous coating test plant is used for: Innovating PLP technology and know-how in order to compete in the market with an advanced post pellet coating application.

The focus is not only on the coating machine but also on the development of new types of sprayers, dosing equipment and software managing systems.

Customers that are looking for creative applications are able to test and develop new products for their feed (aqua feed, poultry, pigs, dairy) by coating with powders such as aromas, vitamins,

38 | April 2022 - International Petfood

whey and milk powder, flour meat, probiotics, antibiotics and medicines in general.

Another service that the company provides for new customers, is to let them fully test the PLP coating application before purchasing the system, in order to make them comfortable on deciding to choose PLP technology.

The test plant can be adapted for different products with a production capacity ranging from 300 kg/h up to 40 tons/h, managing different densities. It is equipped with an accurate gravimetric continuous dosing of the main product (pellets or mash) done by either a weighing belt or weighing screw.

Dosing of liquids by pumps and flow meters and dosing of the powders by loss in weight feeders. All are controlled by the automation and proportional dosing adjusted by frequency control drives.

The test plant can be integrated with three different PLP continuous coating technologies including drum coaters, twin paddle continuous coater and mass spin coater.

Specifically recommended for small pellets

The state of the art of the more traditional drum coater is specifically recommended for small pellets extruded or granulated and for a lower capacity of production.

The special corrugated shape of the drum increases the rotation of the product, at the same time it protects it from damage and reduces the residue dirt inside the machine, making it a perfect machine to be used in the most delicate of applications.

The same Drum Coater, applied with different construction standards is widely used in the food process and seeds coating, where the handling of the product is very important.

It’s PLP's most utilised machine for standard coating applications. This machine has received the most improvements during the last few years of R&D. There are different models that can cover all production ranges required with high inclusion rates of liquids or fats.

The focus of the machine is the retention time, and this is achieved by independent speed regulations of the shafts, internal damps and automatic hatch valve on the outlet that retains the product. Retention time in standard production can reach up to 200 seconds.

This coater is used in the feed and aquafeed industry for adding a high inclusion of oils, molasses on cattle feed, whey powder on the pellets for piglet feed. Cross contamination is prevented in the feed plant as antibiotics and medicines are added at the end of the production directly on the outside of the pellets. It’s also able to add small inclusion rates such as vitamins, enzymes and probiotics, guaranteeing a perfect homogeneity of distribution.

The machine can be used as a continuous mixer, for mixing pellets with grains and flakes, different types of mash feed or for the preparation of minerals in the premix industry.

Mass Spin Coater

A compact continuous coater is used for adding micro liquids from 0.005 up to one percent, which includes enzymes, probiotics, vitamins, acidifiers, aromas, sweeteners etc and powder additions from 0.005 up to 0.25 percent for items including aromas, medicines, nutritional additives, vitamins, probiotics.

The MSC integrates a continuous and precise weigher technology, based on Coriolis forces, able to detect the flow of the main product (pellets, mash, grains) from a minimum of four ton/h up to 100 tons/h.

Thanks to a special 360° nozzle and the configuration of the

spraying chamber, it is able to obtain a perfect homogeneity even when the inclusion rates are very low.

The same technology is also used to add medicines and other additives on the mash feed just before entering the conditioner and pelleting machine, in order to bypass the batch mixer and transportations, avoiding the cross-contamination through all the lines, by dedicating one pelleting machine for the addition of these products.

Powder coating additives

Powders are often used to coat the products, if you look at the food sectors a wide range of powders (salts, pepper, garlic, paprika and many other spices) are added on the surface of the crisps and snacks. In pet food a lot of appetising powders are used to coat the kibbles.

PLP applies this science to the feed and aqua feed industry for the use of coating powder additives and medicines. The powders can be injected in a dry form, in a suspension or a solution of powder and liquid more or less concentrated, creating a slurry that is then sprayed on the pellets.

The company has developed different types of sprayers, motorised or statics, that are able to distribute and inject the liquid solution or the dry powder in a even way, avoiding the risk of blocking of the nozzles.

International Petfood - April 2022 | 39

the interview Ariovaldo Zani

For over 30 years Ariovaldo Zani has dedicated his work to the science of animal nutrition and for fifteen years he has represented the interests of the members of the Brazilian Association of Animal Food Manufacturers/Sindirações.

For many years he has also been part of the Board of the Brazilian College of Animal Nutrition (CBNA) and in 2020 he was elected president of this entity. He is very pleased to meet the desire of the community of associates and to have the unanimity of fellow directors and coordinators of the thematic committees, whilst he feels that his obligation is to give back, since his dedication focused on animal nutrition for more than three decades provides a feeling of full professional fulfillment.

In addition to the satisfaction of enjoying the company of so many friends, the expertise absorbed by professors, researchers, specialists and nutritionists from the private sector and public segment, as well, the many consultants, undergraduate and graduate students, are all key elements that keep Mr Zani focused.

Above all, he emphasises how pleasant it is to exercise the continuous learning required of those who voluntarily dedicate themselves to the CBNA.

Knowing the Brazilian market has grown exponentially the last few decades with regards to all kinds of petfoods and pet treats. What would you attribute this growth to and how has it affected CBNA? How about the future use of Meats and meat by products in petfood knowing Brasil does have a sizable rendering industry?

In the last decades, my colleagues at CBNA and I, have been encouraging the continuous and growing admission of a new generation of researchers and professionals engaged in favour of the animal protein production chain and, above all, encouraging the responsible guardianship of everyday companions/ pets.

We have been successful because these new professionals noticed the numerous opportunities to build a stable and successful career and are convinced that the sector is not so conservative and reduced to cattle and plows, or even table scraps, in the case of pets.

Unlikely, the segment is multidisciplinary and incredibly diverse. This movement converges with the interest of the industry, which has been anticipating and seeking in this new generation, candidates who are well prepared, creative and sufficiently willing to complement the team of notables, made up of experienced and wise human resources employed who have already stamped their legacy in the history of the Brazilian animal nutrition.

On the other hand, the electronic commerce of products for pets has advanced exponentially in Brazil, favouring and speeding up the introduction of petfood and pet treats, in addition to clinical nutrition aimed at "pets", which has already become fundamental in the prevention of diseases and adjunct to treatment of the mascots that have become true members of the contemporary family.

Do you foresee a continuing growth pattern and what kind of new developments do you in-vision?

Technology and science undoubtedly go hand in hand and the Brazilian national production chain has to drive value aggregation with more automation and remote sensing, artificial intelligence and blockchain, and above all, strengthening the interrelationship of genetics and microbiology with nutrition and its benefits for gut health and immune modulation.

Furthermore, the sector cannot ignore the growing interest of investors who have directed assets or

funds to those companies aligned with the “ESG/ Environment, Social, Governance” principles, with priority given to sustainability, social and governance aspects, even surpassing those traditional economic and financial indicators.

By preserving almost 70 percent of its forests and already feeding 25 percent of the global population, Brazilian agriculture has occupied the spotlight on the world environmental agenda, and due to different interests, it suffers the escalation of unfair accusations by radical activists who insist on disdain of science and data.

The antidote to this war of narratives must not be based on conflict but must diligently communicate the true reasons for our enviable productivity, in addition to revealing to global society how those who disobeyed the rules in force were punished (deforestation and illegal burning, degrading conditions work, violation of fundamental rights, corruption, etc.).

Are there any movements towards green production methods?

As the population grows and income improves, the demand for animal protein increases and, despite the projections pointing to an increase in methane/ H4 emissions, the perception is that the provision of more ambitious agricultural climate policies ends up colliding with the protectionism and heavy subsidies offered to producers in developed countries, and even for diverging from the key function for achieving nutrition, rural development and poverty reduction goals in developing countries.

In addition, methane/H4 may even seem to be a supporting target for mitigation, given the role of carbon dioxide/CO2 for persisting in the atmosphere for many centuries and even millennia, accumulating over time, and warming prevailing until net emissions to zero for temperature stabilization. On the contrary, methane/H4 has an atmospheric life of approximately twelve years, that is, its emissions will not result in additional warming when compared to the present moment, and even modest reductions will be able to promote neutrality.

The intensity of methane/H4 emission from rumen fermentation can vary quantitatively and qualitatively, depending on the length of the production cycle (reduction in slaughter age, calving interval, extensive diet or confinement) and the type and digestibility of the feed consumed (pastures, silages, concentrates), respectively.

40 | April 2022 - International Petfood

In addition to the traditional nutritional strategies with a direct influence on fermentation and based on ionophores, probiotics, yeasts, essential oils, unsaturated fats, etc., the manipulation of the rumen microbiota, through a certain chemical compound capable of inhibiting methanogenic microorganisms and reducing up to 30 percent of the relative emission of methane/H4, has proved to be a very promising innovation.

It is opportune, however, to carefully assess how much methane/H4 has to be reduced by livestock in order to meet the target established in the Paris Agreement and which enhancement technologies offered are best suited to contemporary livestock systems and to the absorption capacity on the part of demand, under penalty of suffering undesirable effects, as has been the case with the rapid energy transition (fossil to alternative fuels) and its inflationary impulse, more associated with the negative supply shock than the positive demand shock.

What future events are planned for CBNA and is there any special focus for these events?

The Covid-19 pandemic led to compulsory social distancing and the closure of venues. This unpredictable phenomenon accelerated the introduction of virtual platforms capable of reaching the most inaccessible places and enabling distance learning at the speed of broadband.

The CBNA's commitment to continuous learning and the dissemination of innovation took advantage of this alternative tool that will be maintained, simultaneously with the face-toface modality to be resumed on the agenda of future events, an action that converges with the expectations of the community of enthusiasts, employees and partners who highly value the relationship of social proximity.

The mature process of anthropomorphisation, on the other hand, was recently contextualised during compulsory social isolation, demonstrating the importance of the company of pets in the psychological balance of tutors who exercise responsible guardianship.

There are reasons, therefore, for the CBNA to continue to be one of the main forums for scientific discussion and encouragement for the continuous improvement of nutritionists for dogs, cats and other pets.

THE INDUSTRY FACES “I and love and you" names new CEO Manufacturers of ‘the next generation brand of premium, holistic petfood and treats’, “I and love and you”, announces the appointment of Michael Meyer, a veteran leader in the pet category and current member of the “I and love and you” Board of Directors, as its Chief Executive Officer.

This move comes as the company continues to accelerate its growth, which has repeatedly landed the company on the Inc. 5000 list of fastest growing companies. “I and love and you” wins with consumers who share millennial and Gen Z values of offering human focused, pet specialty quality to an omni-channel digitally native consumer.

The company, known for both function and fun, is expanding its product line in 2022. In the face of a nationwide shortage, it is launching ‘hugs and kisses’ wet cat food, including ‘XOXO’s & XOXO Mix,’ ‘Feed Meow,’ and 'Treat Meow.'

Mars Petcare-India unveils new Managing Director, Mars Petcare-India Mars Petcare India has appointed Salil Murthy as Managing Director, India. He will be taking the place of Ganesh Ramani, who is moving as President, Mars Petcare China. He joins the company from General Mills, where he was the Managing Director for India and South-East Asia.

Mr Murthy has 20 years of FMCG experience across General Management, Marketing and Sales with a proven ability to lead businesses and organisations to growth across diverse geographies and categories. He has experience across the Asia-Pacific in both regional/global and country roles spanning India, China, South East Asia, Australia/New Zealand and South Africa markets too.

“We welcome Salil as Managing Director, Mars Petcare India. In this role, Salil will be leading one of our fastest growing Pet Nutrition businesses globally. Given India’s potential, he will work towards identifying future opportunities for growth and value creation,” says PVV. Srinivasa Rao, Regional President Petcare Asia & Asia Pacific, speaking on the appointment.

Anpario appoints new senior technical and account manager Manufacturers of natural feed additives used in livestock and aquaculture production Anpario, is pleased to announce the appointment of Dr Lawrence Brown BVM&S MBA MRCVS as senior technical and account manager for aquaculture.

Dr Brown is an experienced animal health professional who, since qualifying as a veterinary surgeon graduating from the University of Edinburgh’s veterinary college, has worked in mixed practice and industry across the UK, Middle East and Australia.

Motivated by the need for antimicrobial alternatives in the fight against AMR, Dr Brown returned to Edinburgh, where he is currently based, to offer consultancy services to innovative companies and organisations interested in sustainable food security.

Over the last five and a half years, Dr Brown has worked with several private and public sector organisations including the Department for International Trade as the ‘Animal Sciences and Aquaculture Specialist’, supporting major aquaculture producers expand their operations in the UK, and helping local aquaculture businesses to export their goods worldwide.

American Pet Products Association announces new board member The American Pet Products Association (APPA) has announced that Savina Singh, CEO and founder of JoJo Modern Pets, has been appointed to its board of directors.

Established in 2012, JoJo Modern Pets supplies some of the largest retailers in the US, as well as 2000 independent shops that sell pet products. It is an independent pet manufacturer, importer and distributor, helping solve the bulk of supply chain issues many pet brands and retailers face.

“Savina brings extensive leadership experience to her new role as a member of the APPA board of directors after serving as the CEO of JoJo Modern Pets for almost a decade,” says Chuck Latham, chairman of the APPA board and founder of H&C Animal Health.

“On behalf of the entire APPA board, I am pleased to congratulate Savina on her new role, and we look forward to the expertise and insights she will bring to the association.”

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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.

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