With growing consumer demand – and increasingly stringent quality standards – modern pet food production faces mounting challenges. A recent large-scale facility expansion demonstrates how capacity and process efficiency can be significantly increased within an existing plant infrastructure, without interrupting live operations.

An established international pet food manufacturer invested over €10 million to upgrade its production facility, partnering with Austrian bulk handling specialist Daxner to lead the integration. The project required precise planning and execution to incorporate new systems into the existing structure, while maintaining continuous production.

Daxner installed five fully integrated systems for storage, conveying, and dosing -ensuring reliable handling of bulk, major, minor, and micro components with strict hygiene compliance. Pneumatic conveying systems were designed to handle throughputs of up to 50 tonnes per hour, with specific attention to wear protection and sensitive material handling.

One of the project’s central challenges involved adapting the design to existing structural constraints. Using a modular approach, Daxner modified the original layout to minimise foundation work and seamlessly integrate new systems. The upgrade included 11 large-capacity silos (three newly installed), 18 major component silos, five super sack dosing stations, and over 40 minor and micro component feeders.

Automation throughout the dosing process ensures high precision and traceability, while supporting rapid recipe changeovers.

Efficient coordination between the project stakeholders enabled quick resolution of planning adjustments and technical requirements. Daxner’s in-house fabrication ensured consistent equipment quality and hygienic design, essential for maintaining batch purity and reducing cleaning time.

This expansion positions the pet food manufacturer to respond quickly to market fluctuations, while maintaining high product standards. By leveraging smart system architecture and scalable technology, the plant can adapt to new production demands with minimal disruption.

The project exemplifies how targeted investment and technical expertise can deliver a sustainable boost in capacity and operational agility – offering a future-ready solution in an increasingly competitive industry.

Outdoor Major Ingredient Silos

Feeding Raw Materials into the Major Silos

Pneumatic Conveying Systems Fed by Sending Hoppers

Cyclonic Separators with Rotary Valves