How the dry pet food is made? Virtual tour of Akvatera - dry pet food factory
Summary
TLDRIn this episode of Kika Pet Academy, host Roberta visits the Aquaterra dry pet food factory to explore the production process of premium pet food. She meets with factory owner Torres, who shares insights into the factory's history, commitment to quality, and use of advanced machinery. The tour covers the factory's raw material intake, lab testing, and the importance of maintaining product consistency. They discuss the factory's eco-friendly practices, including the use of solar energy and Tesla vehicles. The video offers viewers a behind-the-scenes look at how Aquaterra creates high-quality pet food while prioritizing sustainability.
Takeaways
- π Aquaterra is a dry pet food factory that produces economy, premium, and super premium pet food products.
- π The factory was established in 2004 and has been updated with the latest machinery to maintain its status as one of the most modern in Northern Europe.
- π Aquaterra has received numerous awards for their products, including gold and silver medals for product of the year.
- π¬ Quality control is paramount, with rigorous checks on raw materials for color consistency, protein, fiber, ash, moisture, oil, sugar, and more.
- πΎ The factory uses a variety of high-quality raw materials, including Australian lamb meal, white fish, shrimp meal from the North Seas, and ingredients from Lithuania.
- πΆπ± There are differences in nutritional needs and product formulations for cats and dogs, as well as variations in kibble size and shape for different pet sizes and preferences.
- π Aquaterra exports to 52 countries, with a significant portion going to Asia where strict regulations are in place.
- π οΈ The factory operates with high levels of automation, reducing the need for manual labor and increasing efficiency.
- πΏ Aquaterra is committed to sustainability, using green energy and producing a significant portion of its own energy needs through solar panels.
- π The company focuses on meeting the true nutritional needs of pets rather than following market trends, with an R&D team dedicated to innovation.
Q & A
What is the main focus of the Kika Pet Academy channel?
-The main focus of the Kika Pet Academy channel is to reveal the biggest secrets in the pet food industry and discuss topics such as dry pet food, nutritional values, and protein sources.
When was the Aquaterra dry pet food factory built?
-The Aquaterra dry pet food factory was built in 2004.
What types of pet food does Aquaterra produce?
-Aquaterra produces a range of pet food including economy, premium, and super premium products.
Why did Aquaterra rebuild their factory two years ago?
-Aquaterra rebuilt their factory two years ago to accommodate their capacity and to incorporate the latest and most modern machinery in the industry.
What is the significance of the awards displayed at the Aquaterra factory?
-The awards displayed at the Aquaterra factory represent the recognition they have received for their products of the year, with most of them being gold and silver medals.
How does Aquaterra ensure the quality of their raw materials?
-Aquaterra ensures the quality of their raw materials by checking the color, hemicon analysis, and using machines to analyze parameters such as protein, fiber, ash level, moisture, oil, and sugar.
What is the role of the extruder in the pet food production process at Aquaterra?
-The extruder is the main equipment in the pet food production process at Aquaterra, where the dry mix is preheated, steam is added to cook the product, and then it is cut and shaped into kibble.
Why does Aquaterra have different kibble shapes for their pet food?
-Aquaterra has different kibble shapes to cater to pets of different ages, sizes, and specific needs, such as cats with flat noses who require a triangle shape for easier eating.
How does Aquaterra manage to produce pet food with high-quality raw materials like Australian lamb meal and North Sea shrimp meal?
-Aquaterra sources high-quality raw materials from specific regions known for their quality, such as Australian lamb meal and North Sea shrimp meal, to create super premium pet food with added benefits.
What is the importance of the coating machine in the production process at Aquaterra?
-The coating machine at Aquaterra is important as it allows for the addition of a high level of fat into the product, which provides energy. It creates a vacuum to absorb the fat into the kibble, ensuring the energy content is locked inside.
How does Aquaterra's packaging process ensure the freshness of their products for export?
-Aquaterra's packaging process ensures freshness by minimizing the storage time and only keeping products in the warehouse until a full order is ready for shipment, especially important for export to countries with strict regulations like Asia.
What is Aquaterra's stance on environmental sustainability?
-Aquaterra is committed to environmental sustainability, as evidenced by the owner's preference for Tesla vehicles, the use of green energy for the factory, and the production of a significant portion of their energy needs through their own solar park.
Outlines
πΎ Introduction to Aquaterra Dry Pet Food Factory
The video begins with the host expressing excitement about visiting Aquaterra, a dry pet food factory. The host meets with Torres, the factory owner, and discusses the factory's history, which started in 2004, and its evolution to produce economy, premium, and super-premium pet food products. Torres highlights the factory's modern machinery and the numerous awards it has won for its products. The host and Torres then proceed to explore the factory, starting with the intake of raw materials and the importance of the lab in ensuring quality and consistency.
π¬ Raw Material Quality and Production Process
The video continues with a focus on the raw materials used in dry pet food, which include various grains and meat meals. The host learns about the importance of checking the color and quality of raw materials to maintain a consistent final product. The factory uses advanced machinery to analyze the nutritional content of the raw materials, ensuring high-quality standards. The production process is described, starting from grinding raw materials to mixing and conditioning, leading up to the extrusion process where the pet food is cooked and shaped into kibble.
π Sourcing High-Quality Ingredients and Product Variety
The host explores the variety of high-quality ingredients used in Aquaterra's pet food, including lamb meal from Australia, white fish, shrimp meal, cranberries, and green tea. These ingredients are sourced from specific regions to ensure their quality and suitability for different pet food products. The video also discusses the differences in ingredients and nutritional values between dog and cat food, as well as the various kibble shapes designed for pets of different ages and sizes.
π¦ Advanced Packaging and Export Logistics
The video moves on to the packaging process, emphasizing the importance of efficient and careful packaging, especially for export to countries with different climate conditions. The factory uses advanced machinery that requires minimal human intervention, streamlining the process from filling to vacuum sealing. The host learns about the factory's reach, supplying to 52 countries, and the strict criteria for product freshness, particularly for exports to Asia. The video also touches on the factory's eco-friendly practices, including the use of solar energy and plans for a new, more efficient warehouse.
π± Commitment to Sustainability and Nutritional Needs
In the final part of the video, the host discusses Aquaterra's commitment to sustainability and the environment, noting the factory's use of green energy and Tesla vehicles. Torres, the factory owner, emphasizes the importance of meeting the true nutritional needs of pets over following market trends. The host concludes the video by expressing gratitude for the insights into the pet food manufacturing process and encourages viewers to ask questions and subscribe for more content.
Mindmap
Keywords
π‘Dry Pet Food
π‘Aquaterra
π‘Extruder
π‘Raw Materials
π‘Nutritional Values
π‘Quality Control
π‘Kibble
π‘Economy, Premium, and Super Premium
π‘Packaging
π‘Sustainability
Highlights
Introduction to the KiKa Pet Academy and the exploration of the Aquaterra dry pet food factory.
Meeting with Torres, the owner of Aquaterra, to discuss the factory's operations and pet food production.
The factory's history, starting from economy products to developing premium and super premium pet food lines.
Aquaterra's status as one of the most modern dry pet food factories in Northern Europe.
The factory's awards for product quality and innovation.
The importance of raw material quality and the lab's role in checking ingredients.
The use of computerized systems to track raw materials and ensure product quality.
The factory's production process, starting from raw materials to the final kibble.
The extruder's role as the main equipment in the production of dry pet food.
The factory's use of high-quality raw materials like Australian lamb meal and North Sea shrimp meal.
The differences in nutritional needs and product formulation for cats and dogs.
The variety of kibble shapes produced to cater to different pet sizes and preferences.
The advanced machinery used to add high levels of fat for energy into the kibble.
The importance of packaging for export markets and the factory's automation in this process.
The factory's reach to 52 countries and its focus on fresh production for export.
The factory's eco-friendly practices, including the use of Teslas and solar energy for production.
Torres' personal commitment to meeting the true nutritional needs of pets and creating new trends in pet food.
The appreciation for the factory's transparency and the educational value of the video for viewers.
Transcripts
[Music]
[Music]
chipset
oh my god how cool is this place they
even have scooters
awesome hey guys
welcome back to the kika pet academy you
might notice i'm super excited today
you remember on the first episode of
kikkaped academy
i promise you that on our channel
we're gonna reveal the most the biggest
secrets
in the pet food industry and today we
have a huge opportunity to see
how the dry pet food is made from the
inside the factory
let's go guys
so today i'm going to meet torres the
owner of
aquatera dry pet food factory hi torres
hi roberta how are you
i'm good how are you good did you enjoy
the electrical i did does everybody
ride the electric bikes here okay taurus
thank you so much again for
inviting us to your factory i'm super
excited
because on our kika pet academy in our
videos we always talk about
dry pet food about nutritional values
protein sources and etc and
that's why i'm so excited today that we
can see from the
inside the factory how the dry pet food
is made
so can you tell me a little bit more
about aquaterra tripod food factory
yes our factory was built in 2004 and
the reason why we built the factory
it was our customers which were pushing
us
to deliver a good products into the
market so we started for
from economy products from their product
to supermarkets
and later we developed premium and super
premium products as well
okay so here in this factory you produce
economy premium and super premium range
all of them
is correct okay that's pretty cool okay
so i'm not gonna lie before coming in
here
to the factory i read a little bit more
about
aquaterra and i noticed you say it's one
of the most modern
dry pet food factories in northern
europe is that true
yeah it's true it's true as we built our
factory in 2004
and we were close to our capacity so
than two years ago we started to rebuild
our factory
and we have now the latest and most
modern
machinery in this industry what we can
buy for money
okay taurus i can see so many awards
here
what are they for the awards of the
products of the year where we are
participating
each year and you see the most of the
gold and silver medals we got for our
product
okay that's so cool okay i'm so excited
should we go in
should we start seeing the factory let's
do it let's go guys
[Music]
okay i can see we're all set very
fashionable closes i could say
so taurus so from where everything
starts
everything starts from intake of raw
materials and from the lab
because the lab is very important place
where we're checking all raw materials
which are mostly of them they're human
great
let's go inside to look okay so then
the main ingredient for the dry pet food
is a different
kind of grains but also meat
meal dried meat meal so what's important
for us
to check did the color of raw materials
various or not because it's for us
it's very important to keep the constant
color of the final product
okay so using these raw materials
you can maintain the same color for each
cable
yes yeah okay yes uh we're checking the
color but also we're checking the
hemicon analysis you see here
for example the salmon
meal krill which is very important for
human as well
[Music]
so tell us how can you make sure that
you know the raw materials are the the
highest quality
how you do that so then we have machine
we're putting
the samples in and then we're getting
the all results of
of all materials stored we checking the
protein
the fiber the ash level the moisture oil
starts sugar and so on so and that's
most important parameters which is
making the
composition on our food and we should
guarantee the level
in the final product okay so everything
is computerized and you can see
all the information in the computer yes
and it's a very important thing then we
can track
back the raw materials and the quality
of the product if
if somehow appears the questions okay
perfect
that's so interesting so let's go inside
the factory to look
how the production looks like okay let's
do that
[Music]
this part of the factory is where
everything begins so that we have
the silo for the green meat meals and we
have
the liquid additives we have vitamins
minerals where we will be lifted
up to the second floor okay
and here the process begins
and here we see our history so then we
built that factory
in eight months and three weeks which
was
super super fast oh my gosh that is fast
it's very loud in here yeah it is
because we're grinding raw materials and
we will start production soon
so we have the raw materials we have
process
and the last silo is the final product
so factory is really
very small and we have three
layers and uh we're using kinetic energy
to hold it down okay so it's like a
dragon yeah we will see the chart
okay inside awesome let's go
so this machine is our main equipment
it's an extruder
okay which extruder product
from upstairs we're getting the dry mix
which is preheated
and it has a little humidity and then
inside the extruder we have the screw
which is pushing the furnace forward
we're adding steam we're cooking product
and then going out and expanding
out of the extruder okay so then we're
cutting with the knives and then we're
making the nice kibble but
but not the sausage okay so this is the
main
equipment the most important one in the
factory yeah
the most important algorithm let's go
inside to look
how the flowchart looks like okay
okay so i understand this is the the
main equipment how does
everything work sure then if we can see
that extruder is
the hurt of our factory so when i hear
the brain because
all existing machines they are connected
into the system oh that's
nicely nicely put a brain and a heart
okay
so then you was asking me about the
dragon so then
we can we can see the way that the
product moves it moves like this
we have the part of raw materials we
have the grinding system
after product is grinded then we're
mixing
we have a lot of ingredients which
should be put it after the grinding
because we can destroy vitamins and
minerals if we
will go through the hammer mill okay
knowing that we are putting them
after the grinding we're mixing here
for it and then the blending bringing
the dry mix
into the conditioner where we're putting
the moisture
the water and the steam to have the the
whole mass
like uh prepared like a 90 degrees
and enough humidity to go to the cable
or to extruder to extrude and what's
happening in the extruder
in the extruder we have the screws which
are the pushing
the four product the forward
we have the high pressure and high
temperature there soren
in just a few minutes being inside the
extruder
the whole night they're cooking and then
when it's going out through the dye
it's expanding and then we are cutting
with the knives and we're getting
then the nice cable if we will if we
would not use the
the knife it would be not the kibble
but such at the meter the sausage
okay so you mentioned all of these
tables you mentioned there you have so
many raw materials ingredients that you
use can you show me some of them
yeah so then we're using the raw
materials which are used usually in the
dry pet food factories
but some of them they are used only for
very specific foods
and they are very high quality grade for
example
we have the lamp meal from australia
it's from australia because of the bsc3
yes correct okay
nice also the other very important raw
materials like a
white fish because of our hypoallergenic
product
which is very important in our portfolio
shrimp meal
from north seas and
cranberries green tea marigold which is
uh delivered from lithuania so then this
it's a big set
of very specific raw materials which
allows us to
create super premium food with a lot of
benefits
i can see you have so many ingredients
as all the factories have so many
ingredients
uh actually not because it's very
depending on
what kind of product and what level of
the product you're producing
and also how deep you are digging
finding
the benefits of each raw material and
what is your target
you are working on the list on the
packaging or your
problem solver okay which one are you
wear problem solvers that's a good one
okay i have one more question so i see
you have many ingredients
uh like dehydrated meat poultry meat
fish meat and etc uh is there a
difference whenever you
you're producing the food is there a
difference in the ingredients for cats
and dogs
in general the group of ingredients they
are the same but the cat has a bit
different
nutritional needs so then the
decomposition the formulation they are
different okay and second the cats do
you like
more dry food if the dogs enjoyed it
like our targets around nine percent of
humidity
the cats should go like five and a half
up to six okay so basically we can say
we you use the same ingredients but with
different
nutritional values for dogs and cats
correct okay
awesome okay i noticed that you have so
many
different kibble shapes why is that why
you need so many
sure then we have um our customers
dogs and cats soren they are in
different ages and different sizes
the puppy will use the smaller cables
when
he is growing and while he's
the big large dog he needs a large
cables
also there are some specific cables for
the cats for example the cats which are
with a flat nose
they need to have a triangle shape to
more easy to pick their cables
okay nice okay so this everything
looks very impressive i could say so i
can see you seek for a very high quality
from the starting from the raw materials
to the equipment and the process
this is very very impressive
this machine is also very very important
for us because it allows
us to add a high level of the fat
into the product which gives a lot of
energy
okay so that it's vacuum inside
and it's only one inlet and outlet and
it's turning around
so it's very very advanced machine
which is produced by french company so
this is basically
how this equipment this machine helps
to absorb the fat into the kibble yes
we're after we're filling the product
inside the coating
we're making the vacuum inside and then
we're spraying the pad
the bed goes inside the cable yeah we're
releasing the vacuum
and then we're applying the digest so
then we have a high content of that of
energy
but it's locked inside the cable
let's go downstairs
what is this place behind that wall
we're producing the cable
and here we're packaging okay so the
packaging is
not less important than the production
itself
especially if you're working with the
export countries with a human with a hot
areas
like eastern asia and so on here we have
machine which
needs only one person to be served okay
so the operator
is putting the empty bags here and the
machine keeps the bag
filling shaping
then making the vacuum after ceiling
yeah then we have the checklist and then
we have
publicizing okay so each step is very
important
i can see there is no people yeah where
are all the workers
now is at the break and they are having
the lunch okay i'm joking
this machine is only one person to put
the empty bag
uh to be prepared with the empty
pallets and cardboard and all other
process will be done by machines so how
many countries do you support today
we have 52 countries foreign
and this machine can contact into the
bank from 7 kilograms up to
20 kilograms okay so and then i
mentioned before that
we need only one person uh to keep this
machine running this is actually like
i'm really shocked about this bag
because it looks like such a huge
machine and you need only one person to
control
[Music]
everything
[Music]
so here you can see we're putting the
top layer
to keep the product safe during the long
journey
because it can be some drops from the
roof of container on
in the truck so then we hear about our
product and deliver it to the last point
of this nation so torres this is the
place
where all the products from the factory
comes to you
yeah to this place they can products
only which we will be delivering to the
export
okay okay so uh for how long
you keep them in here well all products
deliver it from here to export they are
quite fresh
so then the products will kept here only
till we will collect the full
order uh the full list of the items
which
was ordered okay so basically you try
not to keep the stock of the products
you you produce them and then you just
ship them
well around 60
of our export items goes to asia where
their regulations are very strict
including and best before date so we
cannot
send them the product which is staying
here for three or four months
because then we will not match that
criteria okay
so all the products that are in here
they're very freshly made yes it is
okay i see there's so many different
brands so many products how you keep
track of them
well we're tracking with our system but
also you can see the
the letters and numbers here it means
i eel it means israel but it's only the
four visual check
because each place they are uh linked
to the system okay and the people they
are picking
with the scanners the pallets and items
there
they know where to go next and where
they need to
deliver and if you will look you will
see the consolidated item sort of
each block it goes to one container for
delivery okay and
as you saw in our warehouse we have
plenty of pallets standing in the isos
so it means that our efficiency cannot
be as high as we want to
and the reason why we made the projects
for new warehouse
and it will be built and we will
starting to build in a few months from
now
okay and it will be three times bigger
than we have at the moment
so while i was driving with the electric
scooter
to the aquaterra factory i noticed
there's so many teslas in here
yeah uh does that mean your factory
and you as the owner have like a
eco-friendly mindset
yes it's true i am a fan of tesla from
the very beginning
me and my family were with driving
teslas and we will add more
cars within next few years when the
european factories will be in in
progress and
also about the the uh solar energy
and energy in general what we're using
for our factory
so the the whole energy we're using is
green the part of energy
we produce by ourselves by our solar
park
in the sunny days starting from the end
of may we can produce up to eighty
percent of actually we need
to produce production of 80 percent yeah
oh my god
that's our plan to have so many solar
panels
to cover all our energy within the year
okay
i'm always so excited and so happy to
hear whenever you know factories really
do care about environment and
try their best you know to be more
sustainable
and more eco-friendly so
uh torres i want to ask you a question
uh
for you personally as a human being
as a owner of aquaterra factory
what is the biggest value for you well
the most important for me to me the true
nutritional needs for the dogs and the
for cats
and our r d teams working not to follow
the trends of the market
but to create the new trends to find the
answers and to find their solutions
okay so i could say that from this
experience
thank you for the visit by the way i can
see that aquaterra really do care about
cats and dogs as mentioned i'm very
impressed about you know the quality the
raw materials that you use
in the in the dry pet food i didn't
expect that
you know when you buy a product you can
see only a kibble but you don't really
understand you know
how how the process is going so thank
you for explaining thank you for showing
and guys thank you so much for watching
i hope this video helped you to
understand
how the dry pet food is made so if you
have any questions
about the factory about the dry pet food
don't forget to comment
and subscribe
Browse More Related Video
Willy Wonka Tour Scene | CHARLIE AND THE CHOCOLATE FACTORY (2005) Johnny Depp, Movie CLIP HD
ALLES ZEIGEN - Redstone Factory | π Pt. 31
Amul Food Factory - Milk Beverages
We Visited A High-tech Chinese Car Factory
BU HATALARI YAPMAYIN! (Kedi Sahiplerinin YaptΔ±ΔΔ± 11 Hata)
Kegiatan Ekonomi Pelaku Produsen - EDURAYA MENGAJAR EKONOMI KELAS X
5.0 / 5 (0 votes)