How automation improves repeatability and cut quality in pet food treats
Pet food manufacturers with automated cutting machines can carry out high-speed cutting and handling of products without compromising quality. The pet food industry has significantly changed over the past decade because the demand for products has increased, and there is more variety.
Traditional methods have left pet food manufacturers dealing with challenges such as rising labour costs and product inconsistency. This results in low efficiency and leads to high volumes of waste. Pet food manufacturers have been turning to automation to improve consistency and efficiency across the production line.
This article explains how automated cutting machines help pet treat manufacturers achieve consistent product lengths and cleaner cut edges. It also highlights the positive impact on businesses that choose to invest in automation.
Why do cut quality issues happen in the first place?
Cut-quality issues cause major problems for manufacturers because they can lead to high levels of waste and damage customer perception. Various types of issues can occur as a result of an inaccurate cut.
Poor quality cuts can produce inaccurate lengths and weights. Even if the product is just a couple of millimetres out, it will probably fail quality checks, which leads to high levels of waste and increases inefficiency across the entire line. Introducing automated cutting machines will reduce waste.
Poor edges can cause the product to crumble over time. This often happens during transportation. Crumbs and dust can accumulate in the packet, causing problems for the customer. It can negatively affect the perceived product quality and damage brand reputation if the customer opens the packet to find lots of crumbs rather than a well-formed treat.
A high-quality cut can also make the pet treat sit comfortably within the packet. It may only be a subtle difference, but it can lead to a better presentation for the customer. Shelf appeal and how the pet food is presented can affect sales.
Frequent bad cuts can lead to jams or a build-up of waste around the blade system. This can clog the machine, which results in unplanned stoppages and significant downtime. Traditional systems lack real-time data collection, making mechanical issues harder to identify early.
Howautomated cutting machinesprovide a solution
AIR designsautomated cutting machineswith speed and accuracy at the forefront of the engineering process.
Inline product cutting with servo control
Our product cutting systems use servo control to regulate the speed of the cutting process. Servo control is a high-precision technology that can control the acceleration and velocity of a motor by using feedback mechanisms.
It allows for real-time adjustments and a level of precision that cannot be achieved manually. The controller can adjust the motor’s power to maintain the set speed. This ensures the system operates consistently regardless of load or resistance.
As a result of this automated cutting innovation, every single cut is delivered with the same level of precision because the fluctuations in speed are eliminated. Therefore, the system can achieve high levels of repeatability. There is no variation, and each product can meet strict specification requirements, so overall waste is reduced.
Stabilising product handling at the cut point
High-precision cutting must be combined with solid product handling to make sure that the pet food isn’t moving around whilst being cut. Any movement during the cutting process can reduce accuracy.Automated cutting machinesincorporate stabilised handling systems to ensure product movement does not become a limiting factor in quality.
Stable handling on theautomated cutting machinesreduces bouncing, recoil and stretching. This minimises misalignment, and everything is cut to the intended levels of precision.
Using the right cutting method
There’s a wide variety of pet food treats, so introducing a diverse automated cutting machine is crucial. To create a solution that works for your production line, we use varying techniques to give the result that you desire. For example, adog chew cutting machinewill require a different cutting blade compared to a dog biscuit cutting machine.
Rotary blade cutting
A rotary blade is most commonly used for cutting products on a high-speed, continuous line. It is often best suited to applications where a smooth and repeatable motion is required.
Guillotine cutting system
Our guillotine system provides a sudden vertical cut that will suit tougher textures. It works well for materials that may compress or deform when using alternative cutting methods. It delivers precise length control and produces clean edges. This adds consistency to the products.
Ultrasonic cutting
With ultrasonic cutting, our cutting machines can handle a range of different materials in varying thicknesses. These systems use ultrasonic energy to cut through the products. It can help maintain a sharp, consistent edge.
Howautomated cutting machinesmake a positive business impact
Automation can seem like a significant investment for a business, but the ROI is strong. It can elevate a manufacturing company and gives them a competitive advantage due to increased speed and precision.
Reduced waste
An improved cut quality means the pet treats are the correct length and weight every time. Overcuts and undercuts disappear, so more raw materials are used in products that will actually reach the customer, rather than being rejected. This makes the entire process more efficient from a cost perspective.
Less crumbs and fines
Cleaner cuts to the pet treats that are delicate and prone to breakage will result in less crumbling. This protects the quality of the product during the various steps that follow the manufacturing process. The customer will open the packet to receive a well-formed treat that remains consistent every time.
Better customer presentation
The appearance of pet treats makes a big difference in terms of customer satisfaction and retention. Uneven edges, fragmented portions or inconsistent sizing can reduce confidence in the brand.
The automateddog chew cutting machinescan produce the same product consistently with sharp edges and uniform portion sizes. The product looks and feels more professional. Consistency strengthens brand reputation and improves the overall consumer experience.
Higher throughput with increased consistency
Usingautomated cutting machinesincreases the production speed and accuracy of manufacturing pet food treats. The advantages also mean the process can run continuously, with minimal downtime. This helps support demanding production schedules and helps manufacturers meet deadlines.
Automated cutting machineswith AIR
AIR has extensive experience in inventing, designing, manufacturing, installing and supporting automated machines. Longevity is a priority to give added peace of mind. Over time, the cutting blade will naturally wear down. Our after-sales support team will supply the spare parts to replace the blade.
Speak with one of our specialists to discover the potential of automation for your business.Get in touchtoday.
Related news & insights
The conversation among manufacturers has moved on from, “should we automate?” to “how do we automate?” Darragh de Stonndún, CEO of Automated Industrial Robotics, says there’s a right and a wrong...
You might have heard of build-to-print manufacturing. Here’s a comprehensive guide on what it is, when to use it, and how it differs from build to spec.
An innovative single-line platform to significantly reduce time-to-market for new medicines