PET Food Processing - September 2021 - 20

PROCESSOR PROFILE
" Smaller batches give us
better control. When creating
products that are required to
be nutritionally balanced, it's
important to mix the product
right and deliver the right
amount of ingredients to
every single package. "
Pawel Marciniak, NaturPak
and dogs enjoy more of a firm texture in meats. The
company's process can be adjusted to accommodate a
range of end-product goals.
The NaturPak-Tetra Pak process
When NaturPak moved from Beloit to its new facility in
Janesville, the company increased its overall production
capacity by 300%. At its current pace, the company anticipates
needing to add more carton capacity by mid2022.
Current capacity equates to 50 million cartons
annually with plans to add capacity for an additional 25
million packages.
Carton sizes range from 500 ml or approximately 17
oz to 200 ml or 5.5 oz. A 100 ml or 3.5 oz. package will
be available from Tetra Pak in 2022 and NaturPak will be
adding this new size intended primarily for cat products.
The company's current Tetra Pak systems can accommodate
two different carton footprints and varying heights
to offer a range of per-package capacities.
NaturPak's small batch production is divided between
two automated Tetra Pak R2 recart filling systems.
" Smaller batches give us better control, " Pawel said.
" When creating products that are required to be nutritionally
balanced, it's important to mix the product right
and deliver the right amount of ingredients to every
single package. We use a batching process to control the
proper delivery of the product to each package. "
The batch process typically starts with processing the
meat, usually in frozen form. The meat is ground on a
Wolfking grinder or diced on a Treif system while other
ingredients are weighed and portioned. Then the ingredients
are combined in an FPEC mixer and pumped to
the batch-mixing kettles. One mixer and three kettles
feed each processing line. Each eight-hour shift typically
completes eight batches per line and the maximum individual
kettle capacity is about 3200 lbs.
" The kettle process is very unique, " said Tommy Vang,
research and development supervisor. " The kettles mix
batches on an angle, which delivers a more uniform
mix from the bottom of the kettle all the way to the top.
Therefore, when we're filling our product, we know it's going
to be the same from the first package all the way to
that last package. "
The first step of processing happens when formulas are
gently cooked between 160 F and 175 F in the kettles. This
begins the slow-cook process and ensures product uniforTop:
Batch-mixing kettles begin NaturPak's slow-cook process and
help to ensure the correct texture and consistent distribution of
ingredients throughout the production process.
Bottom: By combining purchasing power with IPM Foods,
NaturPak stives to source premium ingredients at price savings it
can pass on to its customers.
20 PET FOOD PROCESSING | September 2021 | www.petfoodprocessing.net
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PET Food Processing - September 2021

Table of Contents for the Digital Edition of PET Food Processing - September 2021

PET Food Processing - September 2021 - Intro
PET Food Processing - September 2021 - 1
PET Food Processing - September 2021 - 2
PET Food Processing - September 2021 - 3
PET Food Processing - September 2021 - 4
PET Food Processing - September 2021 - 5
PET Food Processing - September 2021 - 6
PET Food Processing - September 2021 - 7
PET Food Processing - September 2021 - 8
PET Food Processing - September 2021 - 9
PET Food Processing - September 2021 - 10
PET Food Processing - September 2021 - 11
PET Food Processing - September 2021 - 12
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PET Food Processing - September 2021 - 14
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PET Food Processing - September 2021 - 16
PET Food Processing - September 2021 - 17
PET Food Processing - September 2021 - 18
PET Food Processing - September 2021 - 19
PET Food Processing - September 2021 - 20
PET Food Processing - September 2021 - 21
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