Wet pet food manufacturers are increasingly looking for ways to innovate, not just to meet consumer demand for premium-quality products, but also to improve sustainability and cost efficiency. High-moisture extrusion (HME), when combined with aeration technology and breaker plates, offers a novel approach to wet pet food production that expands formulation possibilities while delivering improved texture, appearance and palatability.
HME is a food processing technique used to create plant-based meat analogs with a fibrous texture and appearance similar to animal meat that uses a high moisture content (40%-80%) during the extrusion process.
During her education session at Petfood Forum 2025 in Kansas City next month, Jenni Harrington, director of sales and technology at Bühler Group, will present test results on HME methods, demonstrating how they can be used to create tailored wet pet food formulations for both dogs and cats. According to Harrington, HME has the potential to transform the wet pet food market by enabling new textures, optimizing ingredient use, and offering greater flexibility in raw material selection.
Enhancing product quality and nutrition
Traditional wet pet food production relies heavily on meat-based ingredients and standard processing methods that may limit texture and formulation options. HME, when paired with aeration technology, introduces nitrogen into the extrusion process, creating a microporous structure that enhances product brightness, softness and thickness without requiring additional additives.
This microporous structure also improves the absorption and retention of fats and flavors, increasing palatability and nutritional value. “The product quality can be improved, and a variety of textures, densities and thicknesses can be achieved,” Harrington explained. “This has a direct impact on the biting properties and mouthfeel for the cat or dog.”
In addition to its textural benefits, HME technology is highly adaptable to different ingredients, including animal, insect and plant-based proteins, as well as starches, fibers, and flavors. This flexibility allows manufacturers to create hybrid (meat and vegetable) or fully plant-based formulations, offering opportunities to diversify product lines while managing ingredient costs and nutritional profiles.
Creating unique textures, colors to drive consumer appeal
Pet owners are becoming more discerning about their purchasing decisions, often selecting products that resemble human food in both texture and appearance. Breaker plates and aeration technology play a crucial role in achieving this, allowing manufacturers to replicate the fibrous, flaky consistency of meat and fish, for example.
“Aeration technology changes the color and creates unique textures by injecting different volumes of nitrogen gas,” Harrington said. “This provides a great degree of versatility, ranging from a simple color change to generating softer textures. Meanwhile, breaker plates can modify texture and appearance, making them especially useful for creating fish-like structures.”
By combining both technologies, manufacturers can produce innovative wet pet food products that align with evolving consumer expectations. “Consumers are always looking for new and unique products, and these innovations can significantly influence their purchasing decisions,” Harrington added.
Expanding raw material use for sustainability, cost efficiency
Sustainability remains a key concern in pet food manufacturing, and HME technology offers new solutions for reducing environmental impact while maintaining high product quality. Currently, most wet pet food products rely on fresh meat or meat meals, but HME enables partial or complete replacement of these ingredients with plant-based proteins, which have a significantly lower carbon footprint.
Additionally, aeration technology allows manufacturers to use fewer raw materials while maintaining or even increasing product volume and weight. Given that raw materials are among the biggest cost and CO2 contributors in pet food production, this approach supports both cost efficiency and environmental sustainability.
“HME technology allows for high production capacities — up to 4 tons per hour — which further contributes to cost savings,” Harrington noted. “Reducing reliance on meat-based ingredients and optimizing production processes are critical steps toward a more sustainable and economically viable wet pet food industry.”
The future of high-moisture extrusion in pet food
As the pet food industry continues to evolve, Bühler Group is focusing its research and development efforts on refining HME technology to further improve wet pet food textures and structures, said Harrington. Future developments may include enhanced palatability solutions for both dogs and cats, as well as continued exploration of new raw materials with improved nutritional and sustainability benefits.
“One area of interest is working with fermented plant-based proteins, which offer better nutritional value and a reduced carbon footprint,” Harrington said. “We’re also developing new methods to further improve the textures and structures of Wet Tex pet food to ensure optimal palatability.”
Key takeaways
For pet food manufacturers looking to stay ahead in a competitive market, high-moisture extrusion presents an opportunity to create innovative, cost-effective, and sustainable wet pet food products. Bühler’s flexible and patented Wet Tex/HME technology enables manufacturers to produce unique formulations that align with consumer demand for premium quality and environmental responsibility.
“Innovation, sustainability and cost efficiency are key in the lucrative wet pet food market,” Harrington emphasized. “Our goal is to provide manufacturers with the tools they need to develop the next generation of wet pet food products that meet both pet and consumer expectations.”
With its ability to improve texture, optimize ingredient use, and expand raw material options, high-moisture extrusion is set to play a crucial role in shaping the future of wet pet food manufacturing.
Jenni Harrington, director of sales and technology, Bühler Group, will present her educational session, New methods in high-moisture extrusion for creating innovative, diverse and nutritious wet pet food, on Tuesday, April 29, at 3:10 p.m. during Petfood Forum 2025. To stay informed on the latest event developments, go to PetfoodForumEvents.com.