PET Food Processing - December 2020 - 17

of the Brainerd facility, " Tom said. " One shortcoming being
the meat room that is 5,000 square feet at best with 8-foot
ceilings. For Little Falls, we designed the meat room we always wished we could have. "
The new meat room in Little Falls is 25,000 square feet
with 30-foot ceilings and much of the same top-quality meat
processing equipment, but with much larger capacities. One
example is they installed a much larger Wolfking frozenmeat grinder. The paddle blender they have in Brainerd has
a batch capacity of 600 lbs, while the new Mepaco steamjacketed paddle blender in Little Falls has a batch capacity
of 4,000 lbs.
The Little Falls meat processing room also includes a largesized Stephan emulsifier in addition to a larger meat feeder
pump. The blending and grinding capabilities in the new
plant allow BPI to incorporate different meats than what can
be processed in Brainerd. The Little Falls' meat room has the
potential capacity to process 200,000 lbs per day.

" We got a lot of
advice based on the
equipment we had. We
said no to nothing and
that taught us a lot. "
Sarah Barrett Reiner

" We do meat a little bit different than most other facilities, " Tom said. " We don't bring in a lot of slurries. We have
massive freezers. We buy the raw material from the producer, bring it in frozen, grind it frozen and process meat from
frozen to ready-for-the-extruder in 40 minutes. Just like the
mill, we are producing that meat in real time on schedule
with the plant, which gives us more flexibility. "
The system around which everything was built in Little
Falls, the Wenger TT3630 thermal twin-screw extrusion
system, is designed to handle ultra-high levels of fresh ingredients. The TT3630 feeds to a three-pass, three-section
CVR convection roaster/pre-dryer, which allows for higher levels of fresh ingredients in kibble plus the addition of
roasting and baking capabilities. The CVR removes moisture, increases the overall dryer capacity and prevents the
dryer from being a bottleneck. The CVR is in the same
room as the TT3630 extruder but sits in a pit to allow product to flow directly from the extruder on a very short conveyor into the convection roaster.
" With high meat, we can get some additional cook out of
the CVR because product is delivered to the CVR so quickly
after the extruder, " Sarah said. " The CVR provides us with

www.petfoodprocessing.net | December 2020 | PET FOOD PROCESSING

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PET Food Processing - December 2020

Table of Contents for the Digital Edition of PET Food Processing - December 2020

PET Food Processing - December 2020 - 1
PET Food Processing - December 2020 - 1
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http://digital.petfoodprocessing.net/sosland/pfp/2020_12_01
http://digital.petfoodprocessing.net/sosland/pfp/2020_10_01
http://digital.petfoodprocessing.net/sosland/pfp/2020_09_01
http://digital.petfoodprocessing.net/sosland/pfp/2020_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2020_03_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_12_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_10_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_09_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2019_03_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_12_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_09_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_06_01
http://digital.petfoodprocessing.net/sosland/pfp/2018_03_01
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