Repete, a provider of automation control systems for the process manufacturing industry, marks its 60th anniversary in 2025. To commemorate the milestone, Repete’s sales team, Jay Davis and Mike Nelson, offered Feed & Grain exclusive insights into the evolution of process and facility automation in the feed, pet food and processing industries.
Davis and Nelson described how increasing global complexity and regulatory oversight through the years has driven demand for more sophisticated automation systems.
They trace automation’s progression from hardware-based, fixed-function control systems to today's intelligent, software-driven platforms that emphasize documentation, precision and safety, while also addressing challenges like rising manufacturing costs and labor shortages.
Looking forward, they identify artificial intelligence (AI) as the next transformative force that will enable predictive, self-optimizing "smart mills" with minimal human intervention, adding that real-time data visibility and regulatory compliance will continue to drive innovation in process automation solutions.
Feed & Grain: How has rising global complexity and regulatory oversight in the feed industry shaped Repete’s approach to automation and system design?
Jay Davis and Mike Nelson: Over the past several decades, globalization has reshaped the dynamics of the feed industry. From sourcing ingredients internationally to navigating cross-border regulations, today's feed producers operate in a more complex commercial environment. Increased global competition and influence from adjacent markets like pet and human food have raised expectations around safety, efficiency and automation. Even for domestic producers, these pressures have driven the need for smarter, more responsive systems.
Oversight has also intensified, especially with increased regulatory involvement. New rules around ingredient sourcing, medication and quality assurance have made traceability a top priority — particularly in the pet food sector. Repete addresses these challenges by building systems that emphasize documentation, precision and safety at every stage.
Rising manufacturing costs, especially in premix operations, have challenged producers to find new efficiencies. At the same time, industry consolidation has changed the landscape. Larger mills are acquiring smaller ones and increasing production complexity, which in turn raises the bar for process control and automation capabilities.
Other forces — such as the growing complexity of feed formulations, evolving nutrition science and a tightening labor market — have accelerated the need for intelligent automation. Over the last 60 years, Repete innovation offers solutions that reduce labor demands while improving plant consistency and throughput.
Feed & Grain: How has facility automation evolved over the last 60 years, and what role will artificial intelligence (AI) play in the next phase of that evolution?
Davis and Nelson: Automation has transformed dramatically since Repete began. What started as hardware-based, fixed-function systems have become highly dynamic, software-driven control technology. Today’s platforms are built to adapt — delivering intelligence, integration and usability across every part of the plant.
Repete has evolved through major system generations — from relay logic supported DOS-based solutions to our modern software-based platform. Each generation brought greater intelligence, reliability and efficiency. These changes also align with broader industry shifts.
Looking ahead, artificial intelligence is poised to alter the landscape once again. The industry can expect predictive, self-optimizing control — systems that operate with minimal human input. The concept of a "smart mill" is no longer theoretical; it's becoming a reality.
What’s equally important is accessibility. Advanced automation is no longer limited to the largest companies. Repete solutions come with built-in functionality and industry best practices, making it easier for smaller and mid-sized operations to adopt modern, compliant and scalable systems.
Feed & Grain: What trends are driving the development of new process automation solutions?
Davis and Nelson: Real-time data visibility has become critical to making informed, timely decisions about your manufacturing process. Feed and pet food manufacturers should expect contextual dashboards, downtime tracking and detailed material flow insights to be built into their systems.
Smart control systems are becoming more common, with features like predictive modeling and automated adjustments. These capabilities reduce the risk of error, increase efficiency, and improve consistency across shifts and plants.
Regulatory and commercial risk demands are also key drivers. Detailed ingredient tracking and process traceability are now essential, especially in pet food, where safety and compliance are closely tied to brand reputation. Automation plays a critical role in meeting these expectations.
There’s also growing demand for scalable, modular systems and toolsets that help manufacturers automate specific workflows, even when plants and process areas aren’t fully automated from end to end.
Feed & Grain: Where do you see the most promising opportunities for innovation in feed production over the next decade?
Davis and Nelson: The feed industry’s resilience comes from its foundation — built on longstanding companies and people deeply committed to feeding the world. That consistency creates strength, even as markets shift and challenges emerge.
It’s also a massive, stable market. With a global value over $500 billion and steady year-over-year growth, the feed industry isn’t just essential — it’s enduring. The high cost of starting a new mill creates a natural barrier to low-quality competition, reinforcing long-term viability.
Looking ahead, the greatest opportunities for innovation lie in building agile manufacturing environments driven by accurate, easily accessible data, faster cycle times, and relevant input — all supporting optimal nutritional outcomes.
As Repete enters its sixth decade, the company stands at the intersection of time-tested expertise and cutting-edge innovation. Automation’s evolution from relay logic to AI-driven smart mills signifies not only technological progress, but also the industry's commitment to feeding the world more effectively, safely and sustainably.
With the feed industry's $500-billion-global-market steadily growing and the increasing demands for safety, efficiency and compliance, opportunities for intelligent automation solutions will extend well into the future.
