Automation Adds Flexibility at Hill's Pet Nutrition

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.”