ANDRITZ ExMax - Extrusion for the production of high quality feed pellets

EXTRUSION SOLUTIONS - For healthy pets, healthy profit and a healthy planet.

Are pets getting pickier – or is it their owners? Either way, the demands on pet food producers are getting tougher, and pet food production technology is advancing to match.

Pet owners expect the very best for their furry (or finny) friends. And they have the backing of governments, many of which are pushing for higher standards by more strictly regulating cleanliness, hygiene, and safety on pet food production lines.

Working to meet higher expectations and stricter regulations pays off in the form of a higher quality product but can eat into the producer’s cost-effectiveness. As with most consumer goods products, the margins on pet food are precisely calculated. So, when external pressures change the maths, something needs to change on the production line as well, to bring everything back into balance.

The best solution is to improve efficiency. To put it simply: stop the production line less often, and for less time, so it can produce more per shift.

That’s easier said than done for pet food producers, who might have to keep stopping production to switch between different recipes and formats. The ingredients, the cooking conditions, and the size and shape of kibble bits might all need recalibrating at each changeover.

THE EXTRUSION PROCESS – HOW PET FOOD TAKES SHAPE

Most dry pet foods are made using a process known as extrusion. Extrusion is a continuous process that combines mixing, cooking, shaping, drying, and coating. Industrial extruders mix food ingredients to form a dough, cook the dough at high temperature and pressure, push the cooked dough through a die and a sharp knife that cuts it up like a cookie cutter, and finally dry it ready for bagging.

This process ensures consistent texture and nutritional quality, but it also introduces challenges. Switching between recipes – different ingredient mixes, cooking conditions, or kibble sizes – requires adjustments that often mean stopping the line. Each pause reduces overall productivity and can impact margins.

A PARTNERSHIP INTO THE FUTURE

Clearly, the efforts of ZMS and ANDRITZ in modernizing the Schwandorf waste-to-energy plant highlight the importance of innovative solutions in achieving sustainability and decarbonization goals.

“The modernization of the Schwandorf waste-to-energy plant not only ensures a secure energy supply for the future but also contributes to the region's environmental goals,” says Rieger. “As the Triphönix project progresses, the plant will continue to play a key role in providing sustainable energy solutions and reducing greenhouse gas emissions.”

Meyer concludes, “This partnership serves as a model for other regions and industries aiming to reduce their environmental impact and secure a sustainable future. This project proves that ANDRITZ is the perfect partner for tailored solutions, meeting both environmental and procedural requirements.”

ANDRITZ ExMax - Extrusion for the production of high quality feed pellets

RESTART FASTER AFTER DOWNTIME WITH DENSIFLEX™

When switching recipes, some downtime is inevitable - but its impact can be minimized. ANDRITZ’s DensiFlex system enables instant, safe pressure release inside the extruder, making changeovers faster, easier, and safer.

Instead of manual intervention, DensiFlex automatically adjusts die plate pressure to control starch cooking and dough expansion according to the recipe. This boosts safety, hygiene, and product consistency.

Real-time adjustments maintain quality from the start of each batch. If conditions fluctuate after a changeover, the system quickly stabilizes them, reducing waste and ensuring uniform results. Less manual handling further improves hygiene and operator safety.

ALL IN ONE: THE ExMax S1021

To maximize cost-effectiveness, every consequence of every change must be considered. Reducing downtime improves efficiency but longer runs can increase energy use and maintenance needs. The ANDRITZ ExMax S1021 addresses this balance with DensiFlex integrated as a standard feature. The ExMax is now complementing a comprehensive portfolio of single- and twin-screw extruders, covering everything from dry ingredient processing to high-meat formulations.

The ExMax S1021 uses a direct-drive IE4 motor for minimal energy loss and an automatic lubrication system to reduce wear and extend service life. This means lower energy consumption and longer operating cycles, helping control costs and support sustainability. Food-grade materials and stag bolts make cleaning and maintenance simple, while real-time monitoring streamlines upkeep and reduces downtime.

These features allow longer operating cycles with lower energy consumption, supporting both cost control and sustainability goals.

SUPPORT THE GREEN TRANSITION WITH EFFICIENT TECHNOLOGY

Improving efficiency is not just about eco-nomics. It is also about meeting rising standards while reducing environmental impact. As the global green transition accelerates, industries face pressure to use less energy, improve product quality and protect operators, all while running efficiently enough to be profitable.

Advanced technology is key to easing these pressures. By driving efficiency, companies can meet their responsibilities to people and planet without sacrificing profitability. With the right solutions, sustainability and business success go hand in hand – and that benefits everyone.