1. Standard Full Production Process of Filled Dog Food
Raw material receiving → Crushing treatment → Accurate batching → High-speed mixing and stirring → Screw feeding → Twin-screw extrusion and curing → Online core filling injection → Die cutting and shaping → Mesh belt conveying → Multi-layer drying → Cooling treatment → Oil spraying and flavor coating → Screening and debris removal → Finished product conveying → Automatic weighing and packaging → Warehouse storage
Process Details
- Raw Material Pre-treatmentGrains, meat meal, fish meal, mineral materials and other powder raw materials are crushed to uniform fineness by professional grinders. Fresh meat, liver and frozen raw materials are processed through meat grinders and bone mud mills to form fine meat paste. This step removes fascia and hard blocks, effectively preventing pipeline blockage and ensuring fine and uniform filling texture.
- Automatic Batching & MixingAll raw materials are weighed and batched in strict accordance with fixed formulas. Powder materials, meat paste, grease, water and nutritional additives are fully stirred in a horizontal mixer. Stable mixing parameters ensure consistent density, humidity and basic taste of the outer layer base material in every production batch.
- Quantitative Feeding SystemMixed base materials are evenly transported to the extruder hopper by screw conveyors. Stable and continuous feeding avoids material interruption and uneven feeding speed, which prevents irregular dog food particle size and unbalanced hardness.
- High-temperature and High-pressure Extrusion CuringThe twin-screw extruder adopts zoned temperature and pressure control. Raw materials are fully cured under high temperature and high pressure inside the barrel, completing starch gelatinization and protein denaturation. This process makes the outer shell crisp, easy to digest and keeps stable hardness for long-term storage.
- Core Online Filling Injection SystemEquipped with constant temperature filling storage tank, high-speed emulsifying delivery pump and precision metering injection device. While the outer extruded material is extruded and shaped, the fluid paste filling is quantitatively injected into the center at constant pressure. The integrated forming process realizes the stable wrapping structure of outer shell and inner filling.
- Cutting & ShapingHigh-speed rotary cutters cut materials at fixed lengths, matched with vibrating distributing equipment to prevent particle adhesion. Standardized shaping ensures regular appearance and unified single particle weight of filled dog food.
- Gradual Low-temperature DryingMulti-layer continuous drying equipment adopts gradient temperature rise drying technology. Slow moisture precipitation avoids cracking, oil precipitation and hardening of inner filling caused by rapid water loss, and maintains stable taste of both outer shell and inner core.
- Constant Temperature CoolingCirculating cold air is used for overall cooling after drying. Balancing the internal and external temperature and moisture difference prevents moisture return, filling fermentation and internal mildew, and stabilizes the overall structural strength of finished particles.
- Oil Spraying & Flavor CoatingRotary drum equipment completes grease spraying, palatability enhancer coating and meat powder surface treatment. The surface sealing effect can reduce the oxidation of internal filling grease and significantly improve food palatability.
- Screening & Sealed PackagingVibrating screens remove broken particles and defective products. Fully automatic weighing and sealing packaging isolates moisture and air, effectively preventing moisture absorption and deterioration of sandwich filling during shelf life.
2. Core Measures to Stabilize Filled Filling Texture & Quality
2.1 Raw Material Standardized Control
Unify fixed suppliers for key raw materials and test moisture content, crude fat, viscosity and microbial indicators for each batch. Store meat paste, animal fat and dairy raw materials in sealed and low-temperature environments to avoid grease rancidity and raw material deterioration. All powder materials are crushed to unified fineness to prevent filling precipitation, delamination and hard particles.
2.2 Scientific and Stable Formula System
Compound colloids, modified starch and food-grade emulsifiers are added in a fixed proportion to solve oil-water separation, stratification and caking of filling. Compound humectants such as glycerin and sorbitol lock internal moisture, keeping the filling soft and chewy without drying and hardening.
Adopt two sets of adjustable formulas for summer and winter: anti-fermentation and anti-thinning in high temperature seasons, and anti-coagulation and anti-thickening in low temperature seasons. Fix the proportion of meat flavor paste, liver extract and fish oil to ensure consistent flavor and taste of each batch.
2.3 Professional Filling Production Technology
All filled fillings are processed by high-speed shear emulsification and constant temperature cooking to form delicate paste without granular impurities. Vacuum stirring and degassing reduce internal bubbles, avoid hollow filling and loose taste, and slow down raw material oxidation.
2.4 Constant Temperature Equipment & Conveying Control
The filling storage tank, conveying pipeline and metering injection pump support overall heat preservation and constant temperature control, maintaining a stable working temperature range all year round. Sanitary grade screw pumps realize quantitative and fixed-pressure filling injection to avoid insufficient filling, core breaking and material cracking.
A circulating reflux system is installed in the conveying pipeline to prevent condensation and blockage of residual filling during equipment shutdown. Precision filters are set at the front end of the injection port to intercept fine agglomerates and ensure continuous and stable filling operation.
2.5 Hygiene Management & Anti-corrosion Protection
Carry out CIP cleaning and high-temperature disinfection for filling tanks, conveying pipelines and injection structures before and after production to eliminate residual materials, peculiar smell and cross contamination. All filling materials are stored in a fully sealed environment to isolate air contact.
Compound food-grade preservatives and antioxidants are reasonably added to inhibit mold, yeast reproduction and grease oxidation rancidity. Cooperate with the temperature and humidity control of the production workshop to fundamentally avoid filling deterioration.
2.6 Whole-process Quality Inspection Standard
Inspect filling viscosity, moisture, consistency, color and odor in real time during production, and file all test data for traceability. Reserve standard sample products for each batch to compare softness, toughness and flavor, and unify sensory evaluation standards. Regular microbial testing is implemented to strictly control total bacterial count and mold indicators.
3. Linkage Key Points of Production Line and Filling Preparation
- Fix the operating parameters of extruder speed, barrel temperature and feeding volume. Stable hardness of the outer shell is the premise to match the soft taste of inner filling.
- Synchronously link the injection pressure, filling speed and cutting frequency to prevent particle cracking caused by excessive filling or poor taste caused by insufficient core content.
- Avoid ultra-high temperature drying. Excessive temperature will lead to internal grease precipitation and dry and hard filling, and gradient drying is the key to stable quality.
- Control workshop humidity and ventilation throughout the whole process. Finished products should be sealed and packaged in time after cooling to prevent moisture return and quality decline in subsequent storage.