PET Food Processing - December 2018 - 63

can run all the way through the process, compounding
waste. Connecting a data stream to a decision maker on
the floor is critical. With top management buy-in and
fierce collaboration among operations teams, companies can turn process automation into a positive culture
change that empowers employees. An empowered employee, making process decisions based on live data, is a
company's most valuable asset."

Batches of benefits
Although all areas of a pet food processing facility can be
improved with process controls and automation, Peter
Ensch, president and CEO, WEM Automation, New
Berlin, Wisconsin, believes batching is one area that can
benefit the most. "This is especially true in the past several
years where the proliferation of formulas a typical plant
produces has expanded exponentially. Batching is the
heart of any pet food facility and has a large impact
on operational efficiencies such as quality, production
capacity, inventory cost and product safety."
Ensch adds that people often think of the obvious
impact of increased production, but possibly more important is the impact seen in product quality. Today's
automation systems have built-in intelligence that enables greater accuracy with weighing and measuring
ingredients, uses feedback to control tolerances, and
alerts operators of any deviations. Modern control systems also offer formula-based logic to prevent mixing
the wrong ingredients or following the wrong material
through the stream of equipment.
The ability to accurately measure utility inputs such as
water, steam and electricity improves product quality as
well. Practical benefits of automation and process control are important to mention, Tramp says. "Knowing
that your critical control points are being met, that your

temperatures for your kill step are correct and that your
processes are repeatable regardless of operator creates a
process that is sustainable."
While producing more with the same equipment is
always a plus, Chris Dubbers, KSE Process Technology,
The Netherlands, believes flexibility and transparency
are the main goals of automation. "The need to keep up
with a highly evolving market while keeping production
capacity high is a big challenge. Good automation can
help eliminate waste in the process and reduce the amount
of people needed. At the same time, it offers the flexibility
needed to reduce time to market for new products with
new additions and ingredients. This flexibility can be even
more valuable than the cost reductions itself."

Smart systems
can recognize
when a facility is
not running at
its best and in
context identify
opportunities to
improve the
overall efficiency.
Shick Esteve

Technology for the win
Integrating various systems across all levels of a business
helps maximize a return on that investment. "Processors
have spent a considerable amount of money on all their
systems - why shouldn't they talk." Ensch says. "The technology exists to automatically download your formulas,

"An empowered
employee, making
process decisions
based on live data,
is a company's most
valuable asset."
Susan Newman, Ph.D., METER Group

www.petfoodprocessing.net | December 2018 | PET FOOD PROCESSING

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PET Food Processing - December 2018

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