Project: Special Dog, Brazil

Loading, in-line drying & unloading of pet food pouches
special dog and cat food
Location Santa Cruz do Rio Pardo, Brazil
Pouch Hak Product Pouches 50g, 85g and 100 g
Interfaces with A-quality brands, like Toyo, Loma, Steriflow and Somic

The challenge

Special Dog Company, considered one of the Brazilian leaders in dry food for dogs and cats, decided to enter the wet pet food market in 2019.

 

The state-of-the-art 5,000 m2 factory of Special Dog in Santa Cruz do Rio Pardo (SP) has space for a production capacity of 600tons per month. Automation was necessary for the reliable production of six lines and a total of 30 different products.

The challenge was to finetune all parties involved, so handling costs per product could be reduced to a minimum. After contact with Stipare (a local integrator of various brands involved in the global wet pet food market), the trust was gained to step into an automated pouch handling system.

The solution

Our solution consists of a Loader and Unloader with a unique in-line drying system.

 

In short, when the products come out of the filler, they arrive at Lan’s loading area, a pouch pattern is formed and they are being loaded in to the retort tray.  These trays are designed that an optimum number of pouches will fit in, and thus the retort will be loaded most efficient. By doing so, the energy consumption per product is being kept to minimum. After the retort process, the pouches arrive at the unloader from Lan, where they will be picked out of the tray and dried in-line. This unique drying solution reduces the wet area in a factory and allows the pouches to directly go to the packaging machine.

Future proof 

Thanks to the different layout options, fillers, retorts, packaging and end-of-line equipment can be added. To complete a 100% automation, it is even possible to add a Lan shuttle system, so the loading and unloading of the retorts will be automated as well. This enables that the entire line can be operated by three persons only: one at the loader area, one at the shuttle area and one person at the unloader/ packaging area.

  • arrow-checkmarkLine capacity: 250 pouches per minute
  • arrow-checkmarkLabor saved: 2-5 persons pers shift
  • arrow-checkmarkOEE: 98%
  • arrow-checkmarkFuture proof: shuttle can be integrated
Special Dog pouch handling

A-quality brands

For this project, Special Dog Company selected A-quality technology brands.

 

Multipond (multihead weigher), Toyo & Jidoki (Pouch Filler Machine), Engilico (seal Inspection system), Loma (X-ray + Check-Weigher) Lan Handling (Loader, Shuttle, Unloader and as a second step Palletization), Steriflow (Autoclave to Sterilization) and Somic (Case Packer).

Balance

The difficulty in this is to balance the line speeds within all equipment, so working together like an orchestra. After more than a year of production, Special Dog benefits from total flexibility within the production line and the smooth interface is guaranteed.

Special Dog Lan Handling pouch

With the start of a new factory, pet food producers often have a certain output in mind.

Octavio Soberon, Production Manager at Special Dog “This is easily translated in to filler, retort and packaging capacity. Special Dog Company realized that the products also have to go from A to B, and that the interfaces between all machines play a crucial role. Lan Handling Technologies was called in to ensure an optimum overall OEE within the entire line.”

Good partnership

“Once the Special Dog Company project team identified and defined the project scope, Lan Handling has been a very reliable partner.  From concept to commissioning and after that, the ramp-up period, highly motivated and skilled professionals were involved. Lan’s installation team always do the best keeping in mind our needs. Distance has never been an issue; Lan colleagues have been deeply involved with the factory, through remote assistance for troubleshooting or process optimization. The line is performing according to the project goals and the partnership is very good.”

A very reliable partner
"Distance has never been an issue; Lan colleagues have been deeply involved with the factory. After one year of production, we achieve an OEE of 98%. Something to be proud of!"
Octavio Soberon, Production Manager
A very reliable partner
"Distance has never been an issue; Lan colleagues have been deeply involved with the factory. After one year of production, we achieve an OEE of 98%. Something to be proud of!"
Octavio Soberon, Production Manager
Special Dog Lan Handling pouch

With the start of a new factory, pet food producers often have a certain output in mind.

Octavio Soberon, Production Manager at Special Dog “This is easily translated in to filler, retort and packaging capacity. Special Dog Company realized that the products also have to go from A to B, and that the interfaces between all machines play a crucial role. Lan Handling Technologies was called in to ensure an optimum overall OEE within the entire line.”

Good partnership

“Once the Special Dog Company project team identified and defined the project scope, Lan Handling has been a very reliable partner.  From concept to commissioning and after that, the ramp-up period, highly motivated and skilled professionals were involved. Lan’s installation team always do the best keeping in mind our needs. Distance has never been an issue; Lan colleagues have been deeply involved with the factory, through remote assistance for troubleshooting or process optimization. The line is performing according to the project goals and the partnership is very good.”


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Thijs van Gerven - Lan Handling

Thijs van Gerven

Technical Sales Manager

Lan Tilburg

Our facility

Nieuwe Atelierstraat 9, Berkel-Enschot, The Netherlands