Premixes for pet food: your development and manufacturing partner

In practice, where does a premix reach its limits?

Making a premix is straightforward. The real challenge lies in getting it to work on the production line in such a way that it consistently delivers the right result.

The challenges involved are complex: every production line operates according to its own parameters. No batch of meat is exactly the same as the previous one, and every end product has specific requirements in terms of texture, binding and appearance. If a batch does not meet these requirements, the line comes to a standstill. The resulting loss of production has a direct impact on profitability.

An overview of Stolpersteine

• Premixes that work in the laboratory but fail on the production line
• Separation of meat pieces and sauce in the one-shot or two-shot process
• A jelly-like deposit forming after sterilisation, which affects the product’s appearance
• Fluctuations in raw materials that jeopardise batch reproducibility
• Changes in the market price of raw materials that have a negative impact on cost calculations
• Deliveries of premixes to the production line without technical support
• Weeks of coordination for every new premix requirement

Pre-mixes for animal feed, custom-developed and supported on-site

NutraPet Systems develops premixes in close collaboration with its customers. The process always begins with an initial consultation, during which we discuss the machinery, meat preparation, filling methods and the desired end product.

On this basis, a formulation is developed that incorporates the collective expertise drawn from nutritional physiology, laboratory analysis and application technology. The benchmark here is not only the customer’s production realities, but also the nutritional quality that ensures the end product is viable on the market.

Custom-designed

Each recipe is specifically tailored to the machine, the meat and the end product, rather than being selected from a standard catalogue.

On-site technical support

Application engineers and developers come to the production line and oversee the start-up until the premix is running smoothly.

In-house laboratory

Incoming batches of raw materials and finished mixtures are tested in our in-house laboratory before they leave the premises.

Configurable functionality

Binding, viscosity, gel strength, consumer acceptance, colour and texture are adjusted to meet the requirements of the end product on the market.

IFS and organic certification

Our production is IFS-certified and also certified organic.

Formulation adjustment

In consultation with customers, existing formulations can be adapted as required and in line with changing requirements.

Premixes for every end product

The range extends from traditional products such as tinned food, sausages and aluminium trays to stand-up pouches, Tetra Packs and food in jars. NutraPet Systems supplies the right premix for all standard end products in the dog and cat food sector.

Wet food

It is in the field of sterilised wet food that we have the greatest wealth of experience, and the range of product types is directly reflected in the variety of premixes available.

The right premix ensures, for example, that pieces of meat do not sink during filling, that the jelly sets to the desired consistency, and that the texture delivers the desired sensory experience (smell, mouthfeel and taste).

• All Meat: A solid mass of meat with visible chunks, giving the impression of a tin filled with meat.
• Mousse and purée: soft and soufflé-like in texture, crumbly on the spoon.
• Chunks in sauce or jelly: Chunks that hold their shape in a homogeneous sauce or in a jelly, which can be adjusted to be either crumbly or elastic depending on requirements.
• Pâté: A light, smooth texture that retains a consistent consistency in the finished product.

Dry food

NutraPet Systems is also the right partner for premixes that are to be incorporated into dry pet food. Whether it’s functional premixes in the kibble or the appropriate palatability system on the outside: we develop a tailor-made solution to meet the customer’s specific needs.

In the case of dry feed premixes, the focus is on the functional components: namely vitamins, minerals, trace elements and palatability enhancers. The challenge lies in selecting and dosing these ingredients in such a way that they survive the extrusion process intact.

Snacks

NutraPet Systems develops premixes for semi-moist snacks that strike a balance between texture, palatability and shelf life. When it comes to functional snacks – such as those designed for dental care, joint health or digestion – it is essential to ensure that the active ingredients are reliably retained in the final product after processing. From concept to production: a partner for the entire process.

What goes into a premix?

A premix forms the functional core of a feed and contains all the components required for the final product. The exceptions are meat and liquid. Each component is specifically formulated for the target product and the relevant animal species.

Structural components

The binding properties, viscosity and gel strength are adjusted so that the end product achieves the desired consistency. Pieces of meat remain evenly distributed during filling. The jelly sets neatly after sterilisation. The pâté retains its smooth texture.

Vitamins & mineral supplements

All vitamin and mineral components are nutritionally balanced and formulated in such a way that the declared values are reliably present in the final product after processing.

Acceptance & Flavour

To ensure that dogs and cats actually enjoy their food, the taste and smell are specifically tailored to the preferences of each species.

Prebiotic and probiotic supplements

The premix can be supplemented with specialised components such as trace elements, prebiotics or probiotic cultures on request. The selection and dosage depend on the target formulation.

Scope of services: What does NutraPet Systems offer?

Formulation Development & Nutritional Physiology

The development process begins with a joint assessment of the machinery, meat quality, filling process and target product. On this basis, a recipe is created, which is developed and tested in accordance with FEDIAF guidelines and verified in practice before being approved.

Procurement and inspection of raw materials

We use only raw materials that are approved under German feed legislation. Before processing, every incoming batch is tested in our in-house laboratory to assess its functionality and relevant quality parameters.

Production & Batch Testing

The mixture is produced using high-precision batch mixers with a mixing accuracy of 1:100,000. Each finished batch is tested again in the laboratory before being released, and the mixing accuracy of the equipment is verified twice a year by external institutes.

On-site technical support

Application engineers and developers oversee trial runs and, if requested, also monitor series production directly on the customer’s production line. This includes providing advice on individual system components, such as steam nozzles or release stations. For international customers, this support is organised remotely by arrangement, provided that an on-site visit is not desired or is not feasible.

Documentation & Traceability

The entire production process is barcode-controlled, meaning that every premix delivered can be traced back to the specific batches of raw materials used. If necessary, it is possible to identify which batches are affected within a short space of time. All relevant documents are available on request for audits, trading partners and regulatory authorities.

What specific changes will the partnership with NutraPet Systems bring?

The following three scenarios illustrate how working with NutraPet Systems affects different production set-ups.

The production manager: When the line mustn’t come to a standstill

Previously: Meat quality is subject to fluctuations; the system is sensitive to unfavourable recipes; and with every new batch of premix, concerns about a production line shutdown grow. The current supplier merely delivers the powder but does not have access to the production line. If the batch is then unsuitable, the only option is to make adjustments in-house, which costs time, materials and production capacity.

Thanks to the NutraPet approach: the premix is precisely tailored to the machine configuration and meat preparation. Every incoming and outgoing batch is laboratory-tested. Should any readjustments be required, the application engineer is on hand right at the production line. The result is a production process that runs reliably and predictably. Without the usual surprises.

The wet food entrepreneur: When the product range needs its own identity

Previously: The existing product range is solid, but largely interchangeable. Chunks in jelly, pâté and mousse are produced using standard recipes that can also be found in similar forms among competitors. More ambitious projects, such as an organic range or a premium wet food with larger pieces of meat, remain on the back burner because, although the current premix partner delivers the ingredients, it does not get involved in the development process.

Thanks to the NutraPet approach: Formulations are developed individually for each new product. For binding, texture, palatability and gelling, we have a partner who understands the technical aspects of what the market expects in terms of sensory and visual qualities. Certified organic ranges can be developed, premium variants become a reality, and the product range stands out from the competition on the shelf.

The snack manufacturer: When every tweak counts

Previously: The product pipeline is well-stocked, ranging from semi-moist snacks and extruded products to functional ranges. However, every new request for premixes triggers weeks of coordination. If raw material prices rise, the supplier simply passes on the cost increase. There is virtually no flexibility when it comes to smaller quantities.

Thanks to the NutraPet approach: samples are provided promptly and adjustments can be incorporated with minimal effort. Batch testing ensures that quality remains consistent across production runs. If market conditions for a raw material change, the formulation is adjusted jointly rather than passing on the cost increase to the customer. The result is planning certainty. Straightforward, fast, and without any friction.

From the initial enquiry to mass production.

1. Send an enquiry: To get started, simply send us a brief message via the contact form. If you already have documentation on the machine profile or the target product to hand, you are welcome to send it along with your message, but this is not essential.
2. Initial consultation: During the initial consultation, we will discuss the machinery, meat preparation, filling processes, sterilisation conditions and the desired end product.
3. Formulation development & sample dispatch: Drawing on NutraPet Systems’ experience with this type of product, a bespoke formulation is developed and then sent to the customer as a laboratory sample.
4. Line testing & adjustment: The premix is tested on the production line, with on-site technical support provided on request. Any adjustments are incorporated directly into the formulation until the premix is running consistently.
5. Mass production & delivery: Mass production begins once the customer has given their approval. Each batch is laboratory-tested, documented using a barcode system and delivered in accordance with the agreement.

Premixes for dog food, cat food and other pet foods

NutraPet Systems offers a comprehensive range of premixes for animal feed: for dog food, cat food and other applications. Production takes place at an IFS- and organic-certified facility. IFS stands for International Featured Standards, an internationally recognised quality standard for food and feed manufacturers. Each mixture incorporates the company’s expertise in the production of wet food, dry food and snacks.

Dog food premix: From tinned food to training treats

A dog food premix must cover a wide range of products, from traditional tinned food containing chunks in jelly, sausages and aluminium trays, to stand-up pouches, Tetra Paks and food in jars.

Each of these product types has its own specific requirements in terms of binding properties, viscosity, palatability and shelf life. The premix is formulated accordingly, drawing on 35 years of experience in feed development.

• All types of wet food: All-meat, mousse, chunks in sauce or jelly, pâté
• Dry feed premixes whose vitamins remain stable throughout the extrusion process and throughout the shelf life
• semi-moist and extruded snacks, as well as functional ranges
• Acceptance systems designed specifically for dogs

Cat food premix: Sensitive metabolism, clear requirements

A cat food premix must meet different requirements to a premix for dogs. Cats are strict carnivores, and their metabolism requires nutrient ratios that differ significantly from those of dogs.

This includes, amongst other things, taurine, arachidonic acid, vitamin A requirements and protein intake. These parameters are set out in the guidelines issued by FEDIAF (the European Federation of Pet Food Industries) for cat nutrition.

The premix for cat food must take into account the physiological characteristics of cats from the outset, whilst also catering to their specific sensory preferences. This is because a recipe that is readily accepted by dogs is often rejected by cats.

• FEDIAF-compliant vitamin and mineral ingredients
• Feeding systems designed specifically for cats
• Formulations for market segments such as skincare, urinary tract care and sensitive digestion
• Suitable for wet food products such as mousse, pâté or chunks, as well as dry food

Pet food premix: one base, many uses

Behind every pet food product lies a functional premix that balances nutritional requirements with production realities. The pet food premix is tailored specifically to the end product in question.

At NutraPet Systems, the focus is on premixes for dog and cat food. In addition, we also supply powdered mixtures for further processing in other applications. Whether complete or complementary feed, whether tinned, pouch or dry product: the framework is clearly defined. We use only laboratory-tested batches and ensure fully documented traceability.

FAQ section

Answers to the most frequently asked questions about premixes. If you still have any questions, simply get in touch via the contact form.