PET Food Processing - March 2020 - 54

EQUIPMENT

which read air temperatures and moisture rates that are tied to modern automation systems allow for the maximization of moisture retention per
volume of air by controlling exhaust
air flow rates."
Inline sampling is also tied to improved cost efficiency. "Recent advancements in real-time, inline sampling
allow for optimizing the timeframe
for making appropriate drying adjustments," Martinez-Kawas adds.
Maximizing energy efficiency is
another key concern for pet food and
treat processors. This can be achieved
by taking steps to continually improve the drying process. "During site
evaluations, field engineers inspect
the product and review control parameters and operation reports. They
apply decades of industry experience
to improve the process and maximize
energy conservation," McKeithan says.
"But now that a processor can be constantly connected to a solution provider's expertise, access to a collection
of real-time data means improvements
can be made automatically."
ALKAR, a division of the Middleby
Food Processing Group, has placed
particular emphasis on improving
energy efficiency. The company just
introduced a new continuous linear oven, the TurboChef by ALKAR
which utilizes a combination of microwave energy, convection heating (dry
bulb) and humidity control (wet bulb)
concurrently. Microwave energy heats
the product from the inside out, convection air flow cooks the product on
the outside. Steam is used as a kill step
for biogens and to fine tune coloring of
the product. The oven's cook zone is 11
ft. within the compact unit length of 20
ft. "The size of the oven provides another competitive edge because it takes
up less space and requires less energy
than comparable lines," Zopf explains.
"Product cook times are reduced
Ensuring kibble reaches a uniform target moisture content without over-drying preserves
value in a product that is sold by weight.
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anywhere between 35% and 80%, significantly reducing energy and space
consumption in plants."

Impact of the drying stage
The drying stage of pet food and treats
has a significant impact on overall
process efficiency. "The way the dryer
is operated and managed can impact
product safety and profits. Any variation, from shift-to-shift, day-to-day or
week-to-week, can have a major impact," Carney says.
Some aspects of the drying stage
that relate to overall process efficiency
are often overlooked. "Proper dryer
sizing is an underrated aspect of overall process efficiency. If a dryer is too
small, maximized profitability may not
be realized due to limitations on output. Whereas if the dryer is oversized,
the duration of adjustments to drying
attributes may be lengthened which
may adversely affect overall efficiencies," Tramp says.
Another consideration for processors is the number of drying passes
that are needed. This can be determined by several factors, including
target moisture content and specific
product attributes. "Some of the criteria include moisture of incoming
product, target moisture of outgoing
product, and specific recipe needs or
attributes," Tramp explains. "Another
consideration may include product
integrity and durability concerns. In
some cases, it is highly desirable to
'flip' the product multiple times on a
multi-pass dryer. But in some cases,
it may be important not to disturb or
move the product, which bodes well
for the single pass dryer system."
There are several considerations for
processors looking to optimize drying processes. Thanks to equipment
innovations, automation technology
and the development of modern best
practices, there are also several ways
pet food and treat manufacturers can
ensure consistency and efficiency, including by asking suppliers for their
expert advice.
PFP

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PET Food Processing - March 2020

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