Dogs are not easy consumers. They hate boredom in their bowls and expect perfect crunchiness, aroma, and taste. And they can sense immediately if something is wrong. That's why producing dry food is much more than just mixing ingredients and heating air. The key moment? Drying. This determines the texture, shelf life, and whether the dog will eat enthusiastically or walk away from the bowl. To meet these challenges, FESSMANN, in collaboration with JUMO, has designed an automation system based on the variTRON 500 controller and precise temperature sensors. The result is a repeatable, fully controlled drying process, tailored to each recipe and ready to meet the demands of even the most discerning... four-legged customers.
Dog food production is not a process that can simply be “set and forget.” Each recipe differs in protein, fat, and moisture content, which means that it requires different drying parameters. The biggest challenge, however, is that the product must be dried not only on the outside, but above all on the inside. Insufficient evaporation of moisture from the inside poses a risk of microorganism growth, while excessive drying can destroy the structure and taste.
In addition, production lines must be flexible. Three different types of snacks can be processed in a single shift, each requiring precise control of temperature and drying time. In the North American market, which was the customer's target, not only shelf life but also aesthetics and repeatability are important. Consumers expect a product with identical appearance and crunchiness in every batch.
To ensure the highest drying quality under a wide range of production conditions, FESSMANN opted for the JUMO variTRON 500 automation system as the control center for the process. Together with JUMO engineers, a control architecture was designed that enables complete control of the pet food drying cycle, from starting the fans and regulating the temperature to dynamically adjusting the drying time to the current load.
Temperature sensors also play an important role: RTD resistance sensors and thermocouples are responsible for the precise measurement of both the chamber temperature and the product temperature. Thanks to the use of redundant measuring systems and configurable control algorithms, it was possible to achieve excellent production process stability, even with constant changes in the load and external conditions.
The implementation of an automation system based on JUMO variTRON 500 enabled FESSMANN to offer its customers a significantly more efficient and predictable drying process. First and foremost, full control over critical parameters such as temperature, time, and humidity was achieved, allowing the drying process to be precisely tailored to the specific recipe and type of treat. As a result, each batch of feed has a consistent structure, the right crispness, and microbiological stability, without compromising on quality or efficiency.
Process automation has also enabled faster production line changeovers, which is particularly important when recipes change frequently. As a result, the flexibility of the production process has been increased without the risk of errors resulting from manual operator intervention. The manufacturer has gained the ability to respond quickly to changing market requirements, including export standards applicable in markets such as the US and Canada.
Thanks to the JUMO control system, it is now also possible to collect and analyze process data in real time, which translates into better operational decisions and continuous optimization of drying parameters. The end result? High quality of the final product with lower energy costs, fewer defects, and greater predictability of each production cycle.
If you are looking for proven technologies for automating dog food production or want to improve temperature control in the animal feed drying process, please contact us. We will help you implement a solution that combines efficiency, quality, and reliability in every production cycle.
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