Optimizing pet food processing equipment for sustainability

This article was published in the July 2024 issue of Pet Food Processing. Read it and other articles from this issue in our July digital edition.  

Sustainability initiatives are a top priority for companies in the pet food processing industry, from processors to the equipment suppliers that support them. Achieving these goals requires a unified effort across the entire operation. Equipment suppliers can support these initiatives by optimizing their products for maximum fuel and energy efficiency. Additionally, plant designers and builders can contribute by helping processors reach their sustainability goals through eco-friendly plant design and efficient processing systems.

Wenger Manufacturing, Inc., Sabetha, Kan., a designer and manufacturer of extrusion processing systems for pet food and animal feed, has taken significant strides in optimizing its equipment for sustainability including energy efficiency initiatives, sustainable material selection and designing durable, low-maintenance equipment.

“Sustainability is increasingly pivotal in our design and manufacturing processes,” said Daniel Tramp of Wenger Manufacturing.

“Sustainability is increasingly pivotal in our design and manufacturing processes,” explained Daniel Tramp, process director for Wenger Manufacturing. “At Wenger, we strive to exceed current industry standards by anticipating future sustainability requirements and aligning with global initiatives. Our approach includes using recyclable materials, minimizing waste, enhancing energy efficiency, and designing equipment for longevity, increased uptime and minimal maintenance. We also have innovations to accommodate different raw materials for enhanced sustainability without compromising quality or utility cost-efficiency.”

As sustainability becomes a critical focus across the pet food processing industry, companies are reassessing the environmental impact of each project more comprehensively. This broader evaluation is becoming a standard practice, reflecting a shift toward a deeper commitment to sustainability and readiness for future regulatory changes and market demands.

“The increased attention around sustainability has brought greater consideration around a project’s overall environmental impact including CapEx, OpEx, carbon, energy, water, waste, refrigerants and more,” said Jeff Wegner, fellow of energy and sustainability, CRB Group, Kansas City, Mo. “There is often more consideration given towards a project’s life-cycle impact, when you consider industry trends that may influence a retrofit to meet evolving sustainability targets, e.g. electrification or onsite water reclamation.”

 

Eco-friendly energy practices

Another crucial development is that while companies are adopting broader eco-friendly policies, they are also taking more focused steps to improve fuel and energy efficiency in their equipment. These efforts are key to reducing costs, minimizing environmental impact and meeting global sustainability goals.

“There is a strong push toward electrification to reduce carbon emissions,” said Jeff Wegner of CRB.

“There is a strong push toward electrification to reduce carbon emissions, but as with any change there are concerns, both legitimate and uninformed,” Wegner explained. “Once the decision is made to electrify it becomes increasingly important to ensure all energy efficiency measures are considered. Generally, to first reduce demands, second recover waste heat, and then apply reverse-cycle heat pumps where available, and lastly electrical resistance.”

Katie Ireland, senior packaging engineer at CRB Group, further emphasized the importance of comprehensive energy management in the industry. Companies are increasingly focused on monitoring and optimizing their energy use to align with ambitious sustainability targets. By implementing sophisticated tracking systems and leveraging real-time data, organizations can make informed decisions that drive efficiency and reduce environmental impact.

“The International Energy Agency (IEA) has a Net Zero Carbon Emissions by 2050 goal and meaningful progress is expected by 2030. This is driving the fuel and energy efficiency,” Ireland explained. “To optimize the industrial energy use we need to look at electricity and natural gas use in our industrial sector. Each company will measure their energy consumption on packaging equipment and look to reduce the electricity consumption annually.”

JBT Corporation, Chicago, offers its Energy Recovery System (ERS), which is designed to enhance the sustainability and efficiency of thermal processing. The ERS works by utilizing hot- and cold-water tanks to transfer energy between the come-up and cooling phases of a retort’s thermal process. During the cooling phase, the system extracts energy, which is then used to heat the water during the come-up phase. This method significantly reduces steam consumption and the demand on cooling towers, leading to lower utility costs and reduced CO2 emissions. 

“By implementing the ERS, processors can achieve up to 30% energy savings, making it an effective tool for advancing sustainability goals,” said Mike Fornes, product line director at JBT.

This system is compatible with all JBT Steam Water Spray (SWS™) retorts, offering both new and existing installations an opportunity to improve their environmental footprint. 

“JBT’s purpose is to help our customers succeed in the marketplace by giving them solutions to make better use of the world’s precious resources,” Fornes said. 

As companies continue to innovate, the integration of advanced technologies plays a pivotal role in enhancing energy efficiency. These innovations not only help in real-time monitoring and predictive maintenance but also ensure that equipment operates at optimal efficiency, reducing energy consumption and minimizing environmental impact.

“Most systems are now being designed with smart drives/power monitoring capabilities that allow the end-user to detect inefficiencies on any motorized device,” said Katie Hunt, marketing director, Gray Solutions, Lexington, Ky. “By integrating with Maintenance Management System, PMs are automatically scheduled when certain thresholds are surpassed. The intelligence in the smart-drives also allows for the most efficient ramp-up to reach the required speeds for the application, rather than a simple on/off state found in traditional motor controls.”

In addition to these technological advancements, companies are also enhancing the design and functionality of their equipment to improve energy efficiency. These efforts are not only about adopting new technologies but also about rethinking and refining existing processes. Packaging machinery producer Wexxar Bel, Richmond, British Columbia, has been working toward this goal.

“Energy efficiency was really the starting point at Wexxar Bel as we looked at sustainability,” explained Sander Smith, product manager, Wexxar Bel. “This is well within our sphere of control from an equipment design standpoint. Initially we introduced simple things like ‘ready mode,’ which allowed our WF line of case erectors to form cases as needed, without having devices like the conveyors running while not in actual running mode.”

 

Efficient plant design

In the pursuit of sustainability, plant designers and builders play a vital role in shaping eco-efficient pet food processing facilities. By integrating advanced technologies and innovative design principles, they ensure that new plants are not only environmentally friendly but also highly efficient in their operations. These experts focus on optimizing resource use, reducing waste and enhancing overall productivity, significantly contributing to the industry’s sustainability goals.

“Expert plant designers are essential for building eco-efficient facilities,” Tramp said. “They utilize modular designs to adapt production processes, minimizing waste and optimizing resource use. Smart technologies like IoT and AI are integral to improving operational efficiency and reducing environmental impacts. The Wenger Corporate Project Services team — which works with pet food producers on new plant designs — use cutting-edge techniques to deliver sustainability-oriented layouts with advanced waste recovery systems, odor abatement and energy efficiency, in addition to proper food safety and process optimization aspects.”

Another aspect of sustainable plant design involves ensuring equipment can handle sustainable materials and maintain high efficiency under various operational conditions. This comprehensive approach allows for a balance between energy-efficient equipment and informed decision-making.

“Packaging equipment is being retrofitted to handle sustainable materials that have lighter weights or different compositions than their current or non-sustainable packaging counterparts,” Ireland said. “New packaging equipment is being designed with more control over the parts of the packaging equipment that are critical to making a consistent and high integrity seal. The designers and builders will need to look at the systems holistically to strike the right balance of energy efficient equipment, run those facilities with data driven information that allows for efficient and informed decision-making to run with top OEEs (Overall Equipment Effectiveness). 

“LCAs (life cycle assessments) of materials and understanding of shelf life is also going to drive the turns of inventory and volumes, so achieving the right balance is key to making sure the operations are built to serve the company volumes in the most sustainable way,” she added. “Knowing your KPIs (Key Performance Indicators) and keeping all your systems in check is vital to overall consistent performance.”

 

Navigating sustainability challenges

Optimizing equipment for sustainability presents several challenges including balancing costs, maintaining high throughput while reducing energy consumption, and integrating new technologies. However, equipment suppliers and plant designers are evolving to meet these demands. Through investment in R&D, modular designs, and a focus on renewable energy and sustainable materials, the industry is working toward long-term sustainability goals.

“Balancing cost with sustainable innovation can be a challenge. Our response involves a robust investment in R&D to develop cost-effective, sustainable solutions without sacrificing performance,” Tramp said. “A sustainability analysis with scorecard is performed on all innovation projects to ensure sustainability is at the forefront of all equipment developments. Modular design and hardware standardization allow for easy integration of new technologies as they become available, which is crucial for staying current with technological advancements. The integration of AI and neural networks presents new opportunities and challenges, particularly in sensor technology and data processing speeds.”

Looking ahead, the industry must continue to innovate and adapt to meet future sustainability demands. 

“As sustainability demands increase, we anticipate that our sector will increasingly invest in renewable energy sources and sustainable materials,” Tramp said. “The main challenge lies in integrating these new technologies while managing costs. Wenger is committed to leveraging our research and development capabilities to devise scalable, adaptable solutions that offer long-term sustainability benefits at a reasonable cost.”

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