Hill's Pet Nutrition built a 366,850-square-foot automated wet pet food plant in Tonganoxie, Kansas that uses advanced robotics and vision systems to enhance production flexibility while reducing manual labor and environmental impact.
- The facility spans 366,850 square feet on an 80-acre site and processes multiple varieties of canned wet pet food with advanced automation systems
- Automation includes AMRs for material movement, vision systems for quality inspection, and Boston Dynamics' robot dog Buddy for sample transport and maintenance checks
- Sustainability achievements include 74% construction waste diverted from landfill, water reclamation at 20 gallons per minute, and 65.98% water savings through gray water systems
- The plant uses gravity-fed material flow and over 1,000 variable-frequency drive motors to optimize energy use and reduce operational costs
- The facility employs approximately 100 workers on a 24-hour, five-day schedule and was designed with room for future expansion of production lines and utilities
Hill’s Pet Nutrition is among the best-known premium brands in the pet food industry, having pioneered science-led pet nutrition for cats and dogs since it was founded in 1948. The Kansas-based company’s success has followed the ongoing upward trajectory of the pet food industry over the past few years, and with that, a need for more manufacturing capacity.
“Our company as a whole has seen tremendous growth, and we utilized our existing assets as much as we could. However, we needed to increase our capacity to meet demands,” says Chad Sharp, director of manufacturing at Hill’s Pet Nutrition.
In response, Hill’s and design/build partner Gray built a 366,850-sq-ft greenfield wet pet food manufacturing plant on an 80-acre site in Tonganoxie, Kan. The newly constructed facility stands as a testament to strategic foresight and meticulous planning, and is designed to meet the demand for pet nutrition products while embracing the latest in automation, sustainability, and labor savings.
Sharp showed ProFood World around select parts the plant to highlight some of the innovative features that make the Hill’s Pet Nutrition facility in Tonganoxie our final Manufacturing Innovation Award feature for 2024.
Location
Sharp says the location of the Tonganoxie plant (see photo above) was chosen after careful consideration of various factors, including proximity to ingredient sources, the availability of skilled labor, and ease of distribution. The plant’s location in Kansas offers logistical advantages that minimize costs and ensure a robust supply chain. Its central position in the U.S. facilitates efficient distribution to various markets, reducing transit times and improving service levels. This strategic advantage is crucial in an industry where timely delivery is paramount to maintaining customer satisfaction and loyalty.
Efficient design and vertical space
Gray/Hill's Pet Nutrition
The single-level facility is dedicated to processing multiple varieties of canned, wet pet food, a complex operation that involves unique challenges compared to dry food processing. The process requires precise batching of ingredients, followed by sterilization to ensure product safety.
The plant’s design also emphasizes efficiency and flexibility. Redundancy is built into the systems to facilitate quick changeovers between different products, a necessity given the diverse and ever-growing range of Hill’s offerings. This flexibility is further enhanced utilizing ample vertical space and pneumatic conveyance, optimizing material flow, minimizing waste, and saving energy.
“We designed the process to be as efficient as we possibly could,” Sharp explains, “and then we put the building around that.”
Automation and labor
Gray/Hill's Pet Nutrition
Automation plays a pivotal role at the Tonganoxie plant, with advanced systems implemented to handle quality inspections and material movements both upstream and downstream on the line. For example, AMRs are used to move materials that human workers would have previously had to shuttle back and forth, while vision systems enhance quality inspection of products, and continuously verify key parameters Hill’s has set for its production.
The facility’s emphasis on automation and technology also addresses the broader industry trend of labor optimization. By automating repetitive and non-value-added tasks, the plant reduces the need for manual labor, allowing the workforce to concentrate on more complex and rewarding activities. This shift not only enhances productivity but also aligns with the evolving expectations of a modern workforce that values skill development and job satisfaction.
Sustainability
Gray/Hill's Pet Nutrition
One of the standout features of the plant is its commitment to sustainability. For example, the facility incorporates innovative methods to reclaim and reuse cooling water, a significant component in wet food processing. By supplementing this with rainwater, Hill’s not only reduces its environmental footprint but also sets a benchmark for sustainable practices in the pet food industry.
Also, as noted earlier, the ample vertical space at the facility allows the use of gravity to move raw materials through the processing stages, bypassing the need to use power to move those materials and saving on utilities as a result. Here are some additional sustainability achievements at the Tonganoxie plant:
- 74% of construction waste diverted from landfill for reuse or recycling
- More than 1,000 motors running at peak efficiency with variable- frequency drives (VFD)
- Water reclamation at 20 gallons per minute for reuse in non-potable processes
- Zero permanent irrigation for 100% elimination of outdoor water use
- Low-flow plumbing using gray water system in restrooms for 65.98% water savings
- Condensing 95% efficient hot water boilers for space heating
- High-efficiency wall materials and windows to minimize heat transfer
- High-efficiency LED lighting
Buddy
Gray/Hill's Pet Nutrition
The integration of advanced robotics, such as Boston Dynamics’ quadruped robot dog Spot (nicknamed Buddy by Hill’s staff), highlights the facility’s forward-thinking approach. Buddy is utilized for tasks ranging from transporting samples to conducting preventative maintenance checks, showcasing the potential of robotics in enhancing operational efficiency. This not only reduces the physical burden on employees but also ensures a higher level of precision in monitoring equipment health.
Cleaning and sanitation
Gray/Hill's Pet Nutrition
The facility was created with structural innovations aimed at enhancing sanitation and longevity. By avoiding rooftop installations, Hill’s Pet Nutrition protects critical power components from the range of weather conditions in Kansas, thereby extending their lifespan. The use of mezzanines, walkable ceilings, and stainless steel in high washdown areas minimizes potential contamination risks, ensuring the highest standards of cleanliness and safety.
“We also wanted to utilize clean-in-place systems throughout many of our processes to reduce the time our team spends directly cleaning, and let them focus more on monitoring the process versus the actual activity of cleaning,” Sharp says.
Employee welfare
Gray/Hill's Pet Nutrition
Employee welfare is another cornerstone of the facility’s design. Climate control ensures a comfortable working environment. Additionally, the plant offers amenities such as a break room and outdoor break spaces, a fitness center, and uniform services, reflecting a holistic approach to employee satisfaction.
The Hill’s Tonganoxie plant currently has approximately 100 employees, and operates on a 24-hour, five-day weekly schedule, while equipment is maintained on weekends, and as needed during the week.
Future Expansion
Gray/Hill's Pet Nutrition
The plant’s design incorporates strategic planning for future growth. With room for additional production lines and the capability to expand utilities, Hill’s Pet Nutrition is prepared to scale operations as demand increases, particularly in the segment of therapeutic pet food, where new formulas may be needed in the future. This foresight not only positions the company to swiftly adapt to market changes but also reflects a long-term vision for sustainable growth.
“We built this plant with the idea that this is a strategic facility that has room to grow,” Sharp says. “Inside the building, we have room to add production lines, and outside we have room to expand utilities and spaces as needed too. When we decide that we need to expand, we will be ready to do it.”
