This article was published in the January/February 2025 issue of Pet Food Processing. Read it and other articles from this issue in our January/February digital edition.
In 2023, the pet food and treat industry reached $64.4 billion in sales, a 10.8% increase from 2022, according to the American Pet Products Association. Additionally, consumer demand continues to propel the industry to new heights with predictions estimating the industry will reach around $112 billion in sales by 2030. It’s safe to say the pet food industry is booming.
To reach these lofty goals, as well as keep pace with evolving demand, processors are beginning to implement more innovative production technologies, especially automation and robotics equipment.
“In the evolving world of pet food processing, automation and robotics are game changers for the industry,” shared Keith Wilcox of APEC.
“Increase in demand for pet foods, diversification of product offerings, and growth in this market is pushing processors to add new production lines and more operators to satisfy demand,” said Krupa Ravichandraan, sales product manager at Bosch Rexroth, which operates a US headquarters in Charlotte, NC. “But that alone will not satiate consumer demand in a profitable and sustainable way. Automation and robotics could play a huge role in solving most of these challenges.”
Keith Wilcox, president of Lake Odessa, Mich.-based APEC (Automated Process Equipment Corporation) USA, added, “In the evolving world of pet food processing, automation and robotics are game changers for the industry. These types of technologies are not just about efficiency; they bring an advantage that can take the industry to the next level.”
Streamlining operations
Automation and robotics systems can be leveraged in nearly every aspect of pet food production, from raw material receiving, ingredient measuring and batching to product transfer and handling, packaging, palletizing and on — the capabilities are endless. For example, Hill’s Pet Nutrition uses a robotic dog, named Buddy, to transport formula samples to quality testing labs.
Automation and robotics can be used in a variety of processes. For example, this robotic dog transports product samples to be quality tested at Hill’s Pet Nutrition.
|Bosch Rexroth offers a variety of operational systems, ranging from hydraulics, control, motion and assembly technologies to automation services through its ctrlX AUTOMATION platform. ctrlX AUTOMATION includes control platforms, safety solutions, motion systems, robotics software, Internet of Things (IoT) solutions and much more. From controlling packaging equipment and optimizing handling systems to fully automating warehousing and distribution operations and much more, crtlX AUTOMATION aims to integrate operations.
As its name suggests, APEC homes in on automating specific equipment processes. The company provides a wide range of equipment complete with automation, including micro-ingredient scales, mistcoating and batch control systems, mixers and more. For example, APEC’s Automation Pro automatically controls the proper measurement of each ingredient in a pet food formula into a scale.
As an engineering, architecture and construction company that designs and builds various infrastructures, including pet food facilities, Burns & McDonnell, Kansas City, Mo., has had a hand in helping implement various automation and robotics systems. The company takes a comprehensive approach, providing recommendations as to where automation would best fit each unique operation.
The flexibility of these systems is just one of their various benefits. One of the main advantages of automation and robotics equipment is streamlining production, boosting efficiency and product quality.
“Robots can operate 24/7 without breaks, providing continuous production,” said Alfredo Valadez, automation consultant and project manager at Burns & McDonnell. “Their precision and consistency eliminate errors caused by fatigue or variability, maintaining a uniform output.
“Robots can operate 24/7 without breaks, providing continuous production,” said Alfredo Valadez of Burns & McDonnell.
“Tasks like palletizing heavy bags become faster and more efficient when automated, boosting overall throughput and reducing downtime,” he added. “Additionally, automated processing allows real-time monitoring and adjustments to optimize the product output, increasing efficiency, productivity and quality.”
Additionally, these types of equipment can help processors enhance their food safety and quality efforts. No matter how stringent a processor’s food safety standards are, human employees can easily make a mistake, leading to costly consequences.
“Automated scanning, product tracking, check weighing, etc. are some of the solutions that helps reduce expensive human errors which could lead to quality and food safety issues; this will prevent future food recall issues, for example, and damage to brand reputation, which once done is hard to rectify,” Ravichandraan explained.
Regarding labor, concerns are mounting about automation and robotics replacing the human workforce. But, according to Ravichandraan, automation isn’t about taking away jobs, it’s about enhancing employee safety.
“Robotic solutions in pet food processing will aid the human labor to focus on high-skilled, highly ergonomic floor operations and safe working conditions,” he explained. “Having robotic and automated solutions both in the processing side of the plant and primary to tertiary packaging side of the plant will quickly increase product throughput and line efficiency.”
APEC offers various automated-enhanced equipment, like this custom micro-ingredient scale with integrated automation controls.
|Alongside protecting employees from hazardous environments and reducing safety risks, these systems can also provide human workers with more valuable opportunities, according to Valadez.
“Automation allows employees to focus on high-value tasks rather than repetitive manual labor, improving employee retention by eliminating tasks prone to high turnover and allowing businesses to operate despite labor shortages,” he explained.
Wilcox echoed this sentiment, adding, “With automation implemented, it allows skilled workers to focus on more complex and creative tasks by taking over routine operations… understanding how automation can alleviate labor issues is more critical than ever to evolve.”
Top considerations
With all these benefits, it’s easy to see why automation has become a hot topic in the pet food industry, however, these systems come with their own challenges. Because of the highly advanced nature of this equipment, they often carry significant price tags, posing a barrier to processors looking to implement automation systems and receive a quick return on investment (ROI).
“It is easy to be carried away with an all-in-one over designed solution with all the bells and whistles, especially if you are relatively new to the automation and robotics equipment world,” Ravichandraan shared. “Sometimes, people choose the least expensive equipment or solution, which barely meets their current needs or fails prematurely or is not suited for even minor changes to production requirements. So, it is very critical to work with experienced professionals in the OEM (original equipment manufacturer) and vendor world to help you walk through the process.”
Because of their significant costs, companies looking to add automation into their operations should first target more labor-intensive processes.
Implementing automation into more labor-intensive processors, like palletizing, can easily boost output and provide quicker ROI.
|“Automation is most effective in processes with high volumes, consistent batch production and uniform packaging,” Valadez detailed. “… Automating entire production lines may require significant investment, but targeting labor-intensive processes like case packing or palletizing can provide quicker ROI. Automation is best implemented in processes where throughput justifies the capital expense.”
In addition to ROI and costs, Wilcox recommends that processors make the following considerations:
- How well the new technology will integrate with existing processes and infrastructure, as well as if the current facility has additional capacity.
- If the solutions are able to grow and scale with future needs and production demands.
- The impact on existing workforce, what additional training is required to operate such systems, if the current workforce can handle such training, and how much cross-training is needed.
- A vendor’s reputation with past customers and the level of support they provide during and after installation.
“Knowing the current workflow and identifying bottlenecks or inefficiencies can guide you in selecting the right technologies,” he added. “Researching industry trends and best practices can provide insights into how automation is being successfully implemented by others in your field and where it might benefit your company the most. Once you have identified those areas, the next step is to assess return on investment. Consider both the short-term and long-term benefits, such as increased productivity, cost savings, improved accuracy and safety.”
Considering future needs and demands is also paramount.
“Think about your current production needs and what your needs would be two to four years into the future,” Ravichandraan said. “Work with your marketing and product development teams to understand your company’s goals going into the future and how that might affect your production in the medium and long-term. It is okay to focus on immediate returns through continuous improvements, but your largest impact will come from long range planning.”
With all this in mind, Ravichandraan recommends processors prioritize automating food quality and inspection equipment, like scanners, X-ray machines, check weighing solutions and more, as high food safety and quality is imperative amongst pet owners. Following this, companies then can look to automate palletizing, packing and conveying processes, as well as storage and retrieval systems in warehousing before moving onto other production areas.
An automated future
As processors continue to produce more innovative products, automation and robotics equipment has also advanced. Artificial intelligence (AI) has infiltrated the manufacturing space and the equipment side as well.
“Robotic solutions will aid the human labor to focus on high-skilled, highly ergonomic floor operations and safe working conditions,” said Krupa Ravichandraan of Bosch Rexroth.
“Automation is on the brink of transformative advancements, driven by AI and machine learning,” Valadez explained. “Future developments may include humanoid robots and advanced AI systems. For example, humanoid robots could handle tasks like packing variable-sized bags without requiring expensive reconfiguration of existing lines, making automation accessible for more processes.”
AI and machine learning will only enhance these systems, Ravichandraan shared, linking them together to communicate, allowing them to identify bottlenecks in the line and solve problems by adjusting settings or quickly notifying operators, and more.
“Systems will be more modular where a click of a button will optimize all the machines and sub-systems in the production line to adjust to a different product run or a group of products on the fly,” he added. “Minimal human intervention would be required, and cost of such systems would also come down with increased usage of such solutions.”
Wilcox concluded, “Honestly, automation and robotics are good for all as they help cut cost to the end consumers. Technology is an ever-changing thing that we all must eventually get used to; it cuts out human errors, streamlines processes and cuts costs, which is every business owner’s dream. Automation is the way of the future, and we all need to embrace it.”
Find more articles about the latest pet food processing technologies on our Equipment page.
