Many pet food facilities in operation today were not originally designed with modern sanitary standards in mind. However, legacy infrastructure does not preclude achieving high levels of food safety.
Alexandra Miller, global key account manager for Mérieux NutriSciences, guided a discussion of just that with Kris Newton, business development manager for Mérieux, during their Tech Talk session “Teaching an old plant new tricks: Retrofitting for pathogen control,” at Petfood Forum 2026.
Targeted upgrades can significantly reduce contamination risks without requiring full-scale reconstruction, Newton said.
Food safety control measures in older facilities
1. Traffic flow
A key starting point is evaluating traffic flow, both product and personnel. Older facilities often lack clear separation between raw and finished product zones, increasing the potential for cross-contamination, he said. Establishing controlled pathways can create meaningful improvements in hygienic zoning. Even relatively simple measures such as physical barriers, directional signage or procedural controls can have improve food safety.
2. Equipment design
Equipment design is another critical focus area. Many legacy systems include hard-to-clean surfaces, hollow structures or inaccessible niches where moisture and residues can accumulate. Retrofitting does not always mean replacing entire systems; in many cases, modifying or replacing high-risk components, such as conveyors, hoppers or transfer points, delivers substantial gains. Prioritizing hygienic design principles, including cleanability and drainage, is essential when making these updates.
3. Moisture control
Moisture control also plays a central role in pathogen mitigation. Water is often the primary vector for microbial growth in dry pet food environments. Addressing condensation, improving drainage and eliminating water accumulation points can significantly reduce risks. Air handling systems should also be reviewed to ensure they support proper airflow direction and filtration.
4. Discipline
Finally, Miller and Newton highlighted the importance of operational discipline. Even well-designed retrofits will fall short without consistent sanitation practices, employee training and verification protocols. Facilities should focus on building a culture of food safety alongside physical improvements.
Retrofitting a legacy plant requires risk-based decision-making. By focusing on zoning, equipment design, moisture control and operational practices, pet food manufacturers can modernize existing facilities and move closer to world-class pathogen control without the cost of a new building.
