The man — more than 8 thousand taste buds, dogs have about one and a half thousand, but the cat — 800. Taste of the same food we and our Pets perceive differently, moreover, is not the whole part of our daily diet suits the animal, and sometimes can harm them.
In 1968 French veterinarian Jean Katari in the process of monitoring the dogs found a direct link between the diet of the animal and the presence of various diseases. Katari brought a special nutritious diet and over time to mass-produce a balanced dry food for their formulas. Today, these rations for animals sell worldwide, and made in the factories of the company Royal Canin.
One of the largest production of the company is located near Krakow, in the Polish town of Niepołomice. Here, the dry protein, which is brought from nearby farms, goes through several stages of processing before turning into croquettes (pieces of food) a variety of shapes and sizes.
Factory in Niepołomice, which was opened in 2008 in the special economic zone near Krakow, is the third largest of all the factories of Royal Canin. The plant area is 10 hectares, it employs more than 250 employees and about 400 in the whole country in research and logistics centers.
In the first year of work at the factory was only one tower and one extrusion line (hardware system, where under pressure are made croquettes food), in 2009, opened a second extrusion line, and in 2012 added two new towers for storage of raw materials. In 2013, the company invested 15 million zlotys (about $4 million) in the installation of biofilters that eliminate bad odor, which is a result of feed production. Then Niepolomice plant became the first in Europe, where he set up such filters, but now it is a mandatory standard for all factories.
Today the production capacity of the factory is about 130 thousand tons of feed per year. Factory production is delivered in 23 countries, including Japan.
How to produce food
Every day the factory takes about 30 supply of raw materials. It is a dry animal protein (beef, pork, chicken, duck and fish), grains (wheat, corn) from local producers (local are those farms that are in a radius of 300 km from the factory in Poland, Ukraine, Germany, Czech Republic).
Each delivery of raw materials (van or tank) is analyzed in the laboratory for all parameters of security and for compliance with the desired nutrient profile. Only after receiving positive results on all the characteristics of the raw material is unloaded at the warehouse of raw materials.
The factory is divided into three zones. All zones are isolated from one another, navigate between them only in special isolated corridors.
In the red zone (pre-extrusion) that all the processes from raw material to heat treatment.
Here the raw materials are ground into pieces of different sizes — it also affects how the final product will be absorbed by animals.
Then the raw material is sent for mixing. Before that, he weighed, because different recipes need different proportions of raw materials.
In the yellow area is the actual extrusion, that is, the shaping of croquettes under the influence of the press and high temperatures. Here obtained in the “red zone” mix distributed on three extrusion lines.
In the blue zone croquettes dried, covered with a shell of fat and cooled.
After from special silos, a large vertical hollow columns for the finished product — croquettes go to the one of 6 packaging lines, 5 of which are fully automated.
Pack products in paper and plastic bags. The type of packaging determines the shelf life of the product: in a paper bag it is stored up to 12 months in plastic — for up to 18 months.
After packaging the products are moved to a distribution center where it is then distributed through the distribution channels. Each finished batch is assigned a unique number, through which you can trace the path of the product from consumer to production and raw material supplier for that specific party.
Royal Canin produces goods on order only — local distributors order a certain amount of product, and the company is obliged to produce and deliver. For Ukrainian distributors, the factory produces 8-10 thousand tons of products per year.
How to check
At all stages of production happen every half hour, intermediate quality control. Focusing on four critical control points that focus on security: Dosage of raw materials (control of the level of protein, fat, analysis of mycotoxins, allergic reactions, taste). The temperature of the extruder. The degree of cooling of croquet must be cooled in order not to pack her warm, otherwise it will deteriorate. Study on the detecting that the croquettes do not hit the metal.
The plant in Singapore is ISO certified (environmental safety, quality control) standards LRQA (manufacture and sale of rations for dogs and cats) and HACCP (hazard analysis and critical control points).
All raw material suppliers are subject to pre-audit a few years before their product gets to the factory. These checks are carried out according to several criteria: nutritional value of raw materials, validation of production facilities, quality systems and security, and sustainable development of the company. This allows not to buy raw materials on the exchanges, and to develop their suppliers.
All the formulas that are used in the manufacture of Royal Canin, a uniform for all factories of the company. Depending on the region may be different raw material, but the “recipe” is always the same.
Where else working Royal Canin
In 2001, Royal Canin became part of the international MARS.
Today the company has 16 factories and development centers worldwide, including one of its filling center in Japan. In total, the company employs 7,150 employees. 50% of world production is produced three European factories — in Cambrai and Aimargues (France) and Niepołomice (Poland). If there are problems with the supply of raw materials to a factory, they usually kompensiruet due to the volume with the other factory. In Ukraine deliver products from factories in Poland, France and Austria.
For feed production the company uses more than 116 types of raw materials and about 360 formulas. For developing formulas to feed attract pet owners, breeders, veterinarians, trainers and other professionals. About 500 scientists specializing in veterinary medicine and nutrition is constantly studying the behavior and diets of animals in order to develop the most balanced formulas.
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