Pet Food Processing - July 2024 - 26

PROCESSOR PROFILE
Left: After dog treats
are baked and cooled,
they can be conveyed
and sorted into
distribution bins for
packaging.
Right: Stand-up
pouches of baked
snacks are filled,
sealed and sorted into
boxes for shipping.
The Ogden two-in-one plant features separate processing
and cooking areas for kibble and treat products
and a shared 40,000-square-foot packaging area.
On the almost 35,000-square-foot treat side, the plant's
capabilities include making more than 20 different shapes
and sizes of treats, as well as the capability for custom treat
shapes and sizes upon customer request. Offerings also
include a wide range of styles and sizes of treat packages.
Recipe capabilities span meat inclusions, grain-free
and grain-inclusive varieties, which are mixed and
formed into treat shapes before being baked in one of
the plant's three, 300-foot-long ovens. After baking for
8 to 17 minutes, depending on the size and shape, the
biscuits are then dried for 28 to 58 minutes, again depending
on size, shape and recipe. Different ingredients
or inclusions, such as texturized vegetable protein, can
affect the baking and drying times.
Temperature and humidity in the facility can also affect
cooking and drying times. Each plant has its own
run profile to accommodate for conditions.
Biscuit packaging includes stand-up, resealable
pouches as well as larger bulk boxes. Pick-and-place robots
assist employees in some product loading processes
in order to increase efficiency and consistency. All products
pass through metal detection before packaging -
one of the many quality assurance processes in place.
The 192 million lbs of dry cat and dog food produced
annually at Alphia's Ogden plant is mixed, extruded, dried
and coated in the 21,425-square-foot extrusion side of the
facility. The kibble varieties, many with fruit, vegetable
and freeze-dried inclusions, are manufactured into various
shapes, sizes and colors to meet customer specifications.
Many are classified as super-premium diets, which
include meat-first formulas and specialty ingredients.
The bulk of the kibble is made from flour, chicken meal,
26 PET FOOD PROCESSING | July 2024 | www.petfoodprocessing.net
oats, barley and salmon meal which make up the premix.
These bulk ingredients are received at the plant and
stored in silos. Micro-dosed specialty ingredients including
dough inhibitors, vitamins and minerals are stored in
smaller quantities and are added per recipe specifications.
Ingredients are transferred from the silos to a mix bin
where they are blended according to the customer's recipe.
The mixed ingredients are then fed into one of three
extruders, where they are cooked and shaped into kibble.
The kibble then undergoes a drying process to remove
excess moisture.
Alphia is really born out of
several different manufacturing
companies that had similar
philosophy - food safety
first and super-premium
manufacturing. "
Dave McLain, Alphia
The dried kibble, after being coated with additional
nutrients and flavors to enhance its palatability and nutritional
value, is transferred to the finished product bins
for temporary storage.
Quality assurance (QA) testing is performed throughout
the production process - during the intake processing
of raw ingredients; during the kibble or treat production
process; before the kibble is transferred to the
finished product bins; before the packaging process; and
during the finished product packaging process.
After QA testing, the kibble is packaged into its appropriate
packaging container - in sizes up to 50-lb bags.
After which, the product is food safety and quality tested
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Pet Food Processing - July 2024

Table of Contents for the Digital Edition of Pet Food Processing - July 2024

Pet Food Processing - July 2024 - Intro
Pet Food Processing - July 2024 - 1
Pet Food Processing - July 2024 - 2
Pet Food Processing - July 2024 - 3
Pet Food Processing - July 2024 - 4
Pet Food Processing - July 2024 - 5
Pet Food Processing - July 2024 - 6
Pet Food Processing - July 2024 - 7
Pet Food Processing - July 2024 - 8
Pet Food Processing - July 2024 - 9
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Pet Food Processing - July 2024 - 11
Pet Food Processing - July 2024 - 12
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Pet Food Processing - July 2024 - 14
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Pet Food Processing - July 2024 - 17
Pet Food Processing - July 2024 - 18
Pet Food Processing - July 2024 - 19
Pet Food Processing - July 2024 - 20
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Pet Food Processing - July 2024 - 26
Pet Food Processing - July 2024 - 27
Pet Food Processing - July 2024 - 28
Pet Food Processing - July 2024 - 29
Pet Food Processing - July 2024 - 30
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Pet Food Processing - July 2024 - 34
Pet Food Processing - July 2024 - 35
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Pet Food Processing - July 2024 - 38
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https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-july-2024
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-may-2024
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-march-2024
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-january-2024
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-november-2023
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-september-2023
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-july-2023
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-may-2023
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-march-2023
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-december-2022
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-october-2022
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-september-2022
https://digital.petfoodprocessing.net/sosland/pfp/-pet-food-processing-june-2022
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-march-2022
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-december-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-october-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-september-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-june-2021
https://digital.petfoodprocessing.net/sosland/pfp/pet-food-processing-march-2021
https://digital.petfoodprocessing.net/sosland/pfp/2020_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_10_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2020_03_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_10_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2019_03_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_12_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_09_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_06_01
https://digital.petfoodprocessing.net/sosland/pfp/2018_03_01
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