The pet food industry is transforming fast. Manufacturers face mounting pressure to produce different products, from wet pet food to semi-moist treats and delicious snacks. Normally, the solution would be to add more production lines. But that is not always the case or the answer.
The solution: build flexibility into a single, integrated system that can switch between wet and semi-moist production without the overhead of multiple dedicated lines.
Running separate lines is costly
Most pet food manufacturers face the same challenge: running separate production lines for different product types. The wet food line operates on one side of the plant, while treat or snack manufacturing runs on the other—two independent operations that both demand full resources, regardless of actual output.
At the same time, your wet food line—often designed with larger capacity—might be running at only medium capacity when operating both products simultaneously, yet still requires full staffing and ongoing maintenance. In today’s competitive market, this kind of inefficiency has a direct impact on profitability.
There is a smarter solution – a multi purpose line
Many processors don’t realize they can process both wet chunks and semi-moist products on the same equipment with an extended steam cooking zone. Both undergo protein structuring and thermal treatment—the main difference is final moisture content.
A flexible system leverages this overlap, processing wet chunks through steam cooking or routing them through extended cooking to achieve 50-60% moisture for the semi-moist drying line. One line, two outputs, based on demand.
This reimagines semi-moist production. Instead of traditional batch processing with its tray handling and manual transfers, products flow continuously from forming through cooking to packaging. However, semi-moist products processed continuously from the DANA steam cooker can still transfer into batch drying equipment if needed.
The FlexLine™ advantage
DANA’s Wet-Semi Moist FlexLine™ (dual targets) shows this integrated approach in action. The same line seamlessly switches between producing wet products and semi-moist formats—all through the same line, before moving into the final drying stage where the desired moisture level is set according to customer specification.
The technical configuration optimizes both processes: a steam tunnel ensures precise thermal treatment, while the dedicated drying system features controlled airflow and temperature zones. Semi-moist products don’t require sterilization, unlike chunks in gravy, which pass through an autoclave—a step that adds significant cost.
By consolidating two production capabilities into one flexible system, manufacturers reduce CAPEX, optimize floor space, and cut labor costs. It’s a win-win.
The future of pet food manufacturing isn’t about having more equipment—it’s about having smarter solutions that adapt to your business needs.
