As the pet food industry continues to evolve, manufacturers are looking for ways to optimize energy usage, enhance product quality and improve sustainability.
Ed de Souza, extrusion systems process director at Wenger Manufacturing, will explore how advancements in extrusion technology are driving these improvements during his education session at Petfood Forum being held April 28-30 in Kansas City, Missouri, U.S.
During his session, Starch gelatinization in extrusion cooking of pet foods: Balancing quality and sustainability, de Souza will explore how to harness the power of science and technology in the extrusion process to optimize energy usage efficiently and precisely control the cooking levels of pet foods. This approach ensures both energy-smart practices and the perfect preparation of high-quality pet nutrition.
Carefully controlling starch gelatinization during extrusion cooking offers pet food manufacturers a pathway to improve product quality and nutritional profiles, reduce costs and energy usage and minimize waste, achieving a more sustainable production process.
The role of starch gelatinization in pet food nutrition
Controlling starch gelatinization during extrusion is critical for improving the digestibility, texture and nutrient retention of pet food. Over-processing can lead to nutrient degradation, while under-processing can result in lower digestibility.
Advanced extrusion and drying technologies allow manufacturers to fine-tune cooking energies — Specific Mechanical Energy (SME) and Specific Thermal Energy (STE) — to achieve optimal results.
“Wenger’s newest extruders deliver a sustainable thermal cook that reduces reliance on excessive mechanical energy,” said de Souza. “Under the right processing conditions, this approach can promote the generation of resistant starches, which help promote a healthy gut microbiome.”
Efficiency is the most important takeaway
When asked what the single most important takeaway attendees can leave his presentation with, de Souza said, “Efficiency!”
An efficient process leads to sustainability in extrusion cooking of pet foods. Efficiency can also enhance quality, he noted. This is especially critical as the industry faces increasing demands for eco-friendly practices and premium product standards.
“Pet foods produced in advanced kitchens, as well as on optimized legacy platforms, are scientifically proven to offer superior palatability, enhanced levels of resistant starches, and significantly reduced electrical energy usage/efficiency,” said de Souza. “These advancements not only extend the lifespan of equipment but also amplify efficiency and sustainability through unparalleled uptime, ensuring the consistent production of high-quality products, delivering better nutrition to pets while protecting and preserving our Earth.”
Balancing quality, sustainability for cost savings
By focusing on four core areas — hardware, ingredients, software and product specifications — pet food manufacturers can achieve greater efficiency while reducing waste and costs.
- Optimized hardware maintenance: Well-maintained extrusion equipment ensures consistent and reliable performance.
- Smart process control: Automated systems regulate energy consumption and prevent over-processing.
- Ingredient precision: Controlling ingredient ratios and moisture levels minimizes waste and enhances yield.
- Steam recovery: Reusing cooking steam further reduces energy waste.
“These advancements have led to improved product yields, enhanced efficiency, and a reduced environmental footprint, all while delivering superior quality pet food with smart use of resources,” said de Souza.
The future of extrusion technology in pet food
Looking ahead, extrusion technology will continue to evolve to meet the demands of the modern pet food industry, said de Souza. “Wenger is continuing to push the boundaries of extrusion technology, minimizing excessive heat from shear and mechanical energy while ensuring that high-quality pet foods remain free from harmful pathogens,” he said.
Process control will be further enhanced through advancements such as AI-driven optimization, which are pivotal in meeting the demands of today’s discerning pet parents.
“These parents seek clean labels, single-source ingredients, shorter ingredient lists, and solutions for processing challenging raw materials,” said de Souza. “This includes high inclusions of single-source raw meats as alternatives to traditional meat meals, the incorporation of highly reactive starch sources with minimal usage, and alternative proteins such as insect-based options.”
By leveraging emerging technologies, pet food manufacturers can enhance product quality, improve operational efficiency and contribute to a more sustainable industry. As de Souza emphasized, efficiency is the key to success — ensuring pet foods are produced with precision, sustainability and innovation at the forefront.
Ed de Souza is senior technology and applications specialist with Wenger Manufacturing and founder and former president of Wenger do Brazil. He will speak on the topic of Starch gelatinization in extrusion cooking of pet foods: Balancing quality and sustainability on Tuesday, April 29, at 3:10 p.m. during Petfood Forum 2025. To stay informed on the latest event developments, go to PetfoodForumEvents.com.