During his presentation at Foro Mascotas in Guadalajara, Mexico, Antonio Huerta of Manzoni Industrial said that companies planning new pet food facilities should begin with a clear understanding of market trends while designing plants around food safety, process efficiency and long-term flexibility.
For companies considering a new manufacturing project, current market dynamics highlight the importance of designing facilities that can produce a range of products rather than focusing exclusively on premium formulations, he said.
Start with project management
Huerta said successful projects begin long before equipment is installed. One of the first decisions is selecting engineering and equipment partners with demonstrated experience in pet food manufacturing.
When evaluating suppliers, companies should examine their project portfolio, technical infrastructure and experience delivering similar facilities. Equipment selection should also consider critical support systems, including liquid and fat application, dust collection and cyclone systems, rather than focusing only on major processing equipment.
Food safety should remain a primary design consideration throughout the project. Huerta emphasized that preconditioning plays an important role in reducing bacterial and pathogen loads while protecting the nutritional quality of ingredients through controlled processing temperatures.
Build the process around extrusion
Extrusion remains the core technology in dry pet food production and should drive much of the overall plant design, Huerta said. He described extrusion as a thermomechanical process that subjects ingredients to heat, pressure and mechanical energy. Properly managed, the process improves digestibility, eliminates pathogens, ensures product safety and allows manufacturers to produce a variety of kibble shapes, textures and densities. Process control also influences water activity and other quality characteristics.
Because extrusion involves numerous process variables, automation becomes essential for maintaining consistent product quality and maximizing production efficiency. Automated control systems improve productivity while supporting palatability and stable operating conditions throughout the production line.
Design downstream systems carefully
Huerta stressed that drying, coating and cooling should be viewed as integral parts of the production process rather than secondary operations.
Following extrusion, drying removes moisture to create a stable product suitable for storage. Huerta noted that kibble typically leaves the extruder at approximately 22% to 23% moisture before being dried to about 10% to 11% for safe storage and shelf life. Proper drying also helps maintain texture and preserve nutritional components such as antioxidants.
The coating stage provides additional energy through fats and oils while improving palatability. It also allows manufacturers to add heat-sensitive nutrients that would not survive extrusion. Proper coating contributes to product texture and helps meet nutritional targets for different formulations.
Cooling represents another critical control point, Huerta said. Besides stabilizing product structure, cooling reduces the risk of condensation, helps preserve coated ingredients and minimizes oxidation that could lead to rancidity. Huerta recommended cooling finished product to approximately 5 to 15 degrees Celsius above ambient temperature, with a target product temperature of roughly 25 to 35 degrees Celsius before packaging.
Do not overlook supporting systems
Beyond the primary production equipment, Huerta highlighted the importance of auxiliary systems that support plant performance.
Dust collection systems, cyclones and aspiration equipment help control airborne dust generated during drying and cooling, contributing to both environmental management and operational cleanliness. Chilled water or air-conditioning systems may also be required to maintain appropriate operating temperatures depending on plant location and climate.
These supporting systems, while often receiving less attention during project planning, can significantly influence plant efficiency, product quality and food safety.
Planning for long-term success
As the pet food market enters a period of more moderate growth, Huerta suggested manufacturers should prioritize disciplined project planning over rapid expansion. Selecting experienced partners, integrating food safety into facility design and ensuring every processing step, from preconditioning through cooling, is part of a complete system can help position new plants for reliable, efficient, profitable operation.
Rather than viewing a new pet food facility simply as a collection of equipment, project developers should approach it as an integrated manufacturing system designed to consistently deliver safe, high-quality products while remaining flexible enough to respond to evolving market demands.
