The short answer is yes, it is absolutely possible—and increasingly common—to produce different types of pet food on a single production line. Driven by the need for operational efficiency and the rising demand for product variety, modern pet food manufacturers are moving away from dedicated lines for single products toward highly flexible, multi-purpose systems .it’s possible with modular systems and proper planning, but each type of pet food has unique requirements that cannot be ignored.
1. The Drive for Flexibility: Why One Line Makes Sense
Traditionally, manufacturers operated separate production lines for different product formats—one for dry kibble, another for wet food, and perhaps a third for semi-moist treats. This approach is costly and inefficient .
Operating multiple dedicated lines requires significant capital expenditure (CAPEX), floor space, and labor, regardless of actual production demand. A wet food line might run at partial capacity yet still require full staffing and maintenance . A single, flexible line solves these problems by consolidating capabilities, allowing manufacturers to:
- Reduce CAPEX by investing in one versatile system instead of several single-purpose ones.
- Optimize floor space, freeing up valuable real estate in the factory .
- Cut labor costs by streamlining operations .
- Respond quickly to market trends and produce a wider range of products based on demand.
A prime example of this philosophy in action is GA Pet Food Partners in the UK. Their facility uses advanced automation, including automated storage and retrieval systems, to keep their central extruder running 24/7. This setup allows them to manufacture an astounding 930 different products for their global customer base while achieving a 15% improvement in extrusion uptime . Their motto, “If it ain‘t turning, it ain’t earning,” perfectly captures the economic imperative of maximizing a single line’s utilization .
2. Technological Enablers of Flexible Production
The feasibility of a multi-product line hinges on modern processing equipment designed for quick changeovers and a wide processing window.
The Extruder: The Heart of Flexibility
For dry and semi-moist pet food, the twin-screw extruder is the cornerstone of flexibility. Unlike single-screw extruders, twin-screw models offer a high degree of control over shearing, temperature, and residence time, allowing them to process a vast range of recipes .
- From Basic to Super-Premium: Systems like the Dinnissen Magi-N.ext are explicitly designed to allow producers to use a single line for manufacturing economic, premium, and super-premium pet foods. Features like large inspection hatches and easy-to-clean components enable fast and efficient changeovers between different product types and recipes .
- Multiple Formats, One Machine: Bühler’s PolyOne single-screw extrusion system can produce direct-expanded kibbles, semi-moist pet foods, and even diets for smaller companion animals on the same platform. Its control system stores formulations and automates start-up and shutdown sequences, which reduces errors and saves time during product changeovers .
- Fresh Meat Inclusion: Advanced systems from companies like FAMSUN allow for the direct injection of fresh meat slurry into the preconditioner, enabling the production of high-meat, nutritionally dense formulas on the same line used for more traditional recipes .
Beyond Extrusion: Adapting Wet and Semi-Moist Production
Flexibility isn’t limited to dry kibble. Innovations in processing allow for the integration of wet and semi-moist product lines.
The DANA Wet-Semi Moist FlexLine™ demonstrates that wet chunks and semi-moist products can be processed on the same equipment. Both product types undergo similar initial steps like protein structuring and thermal treatment. The key difference is the final moisture content. A flexible system can route products through an extended cooking zone to achieve the higher moisture levels (50-60%) required for semi-moist products, or directly to sterilization (autoclaving) for wet products in gravy .
The Role of Precision in Changeovers
The ability to switch between products quickly and hygienically is critical. This is where precise, flexible components make a difference.
- Cutting Systems: Machines like the Fam Stumabo Yuran Hytec 300 EC feature removable splined shafts on the cutting spindles, allowing for fast adjustments between different cut sizes and shapes, which minimizes production downtime .
- Automated Control: Modern lines rely on sophisticated PLC control systems that store recipes for countless products. These systems automatically adjust parameters like temperature, pressure, and screw speed to ensure consistency from batch to batch, whether producing a crunchy kibble or a soft, chewy treat .
3. Operational Considerations for Running a Flexible Line
While the technology exists, successfully running a multi-product line requires careful planning.
| Consideration | Description |
|---|---|
| Hygienic Design & Cleaning | Quick changeovers are only possible if the equipment is easy to clean. Features like easy-to-clean facilities and designs that limit “product fouling” are essential to prevent cross-contamination between runs of different recipes, especially those with different protein sources . |
| Process Control & Recipe Management | Storing and precisely executing formulations is key. Automated systems that remember settings for each product reduce the risk of human error and ensure that a “super-premium” formula is treated with the exact parameters it requires, even if the line was making a “basic” food an hour ago . |
| Material Handling & Logistics | A flexible line requires a flexible supply chain. As the GA Pet Food Partners case study shows, having an automated system to manage thousands of different ingredients and finished goods is crucial for keeping the main production line running without interruption . |
| Process Validation | When switching between product types, especially between products with different safety requirements, the process must be validated. For example, while semi-moist products may not require sterilization, chunks in gravy must pass through an autoclave, a step that adds significant cost and time to the production cycle . A truly flexible line must accommodate these differing process steps. |
Modern pet food manufacturing has evolved to embrace flexibility. A single, well-designed production line can indeed produce a wide variety of pet foods, ranging from basic dry kibble to premium semi-moist treats and even different cuts of wet food.
Breaking Down the Core Differences
So every pet food category need different process and equipment. Attempting to run them all on the same line without preparation can lead to inefficiencies, quality issues, and even safety concerns. Here is a simplified breakdown:
| Pet Food Type | Moisture Content (%) | Core Equipment | Hygiene Level |
| Dry Kibble | 6.5–11% | Extruder, Dryer, Coater | Moderate |
| Wet Food (Canned/Pouch) | 72–82% | Cooker, Retort Sterilizer, Filler | High |
| Treats & Snacks | 8–25% | Baking Oven, Molding Machine | Moderate |
| Freeze-Dried/Dehydrated | <6% | Freeze-Dryer, Dehydrator | High |
This is made possible by advanced technologies like versatile twin-screw extruders, modular system designs, and sophisticated automation that ensures fast, hygienic changeovers . While it requires a higher level of operational sophistication in terms of process control and logistics, the ability to produce a diverse product portfolio from one line is a significant competitive advantage in today’s dynamic pet food market.
At Chunm, we specialize in building customized Pet Food Extruder systems with modular designs, CIP cleaning, and automation features that help you scale efficiently. Whether you want to produce wet food, dog food , or other different types of pet food machine , we can give you good advice and Complete solution .
Comprehensive FAQ: Expert Answers
Can one line make dog food or cat food?
Yes, double screw extruders allow recipe adjustments for different animals. Dies and molds can be swapped to match size and texture requirements.
If we can avoid cross-contamination?
Install CIP cleaning systems and separate storage for meat vs grain ingredients. Following HACCP standards ensures safety.
Is a multi-product line worth the cost?
For medium exporters, yes. Modular Pet Food Processing Equipment offers flexibility without building multiple facilities. Large manufacturers often mix modular and dedicated lines.
How do you think freeze-dried or raw diets?
These require specialized systems (freeze-dryers, cold storage), but modular setups can integrate them alongside traditional extrusion lines.
Can we visit your factory ?
Yes , wlecome to our factory at any time , you can contact me .
