The problem with making crunchy dry kibble homemade is that the things that make food get crunchy in the oven (Grains, Flours, Meals) are not the best food for cats. If I were to try it myself, I would make a cooked ground beef based cat food (brown the ground beef, drain thoroughly, and press out excess moisture between two thick towels - THEN add the rest of the food ingredients after the beef is already nice and dry), dehydrate it for 12 hours (think jerky - get out the ronco food dehydrator, LOL)), and then spread it out on a big cookie sheet, and bake it until it was browning on top, take it out of the oven, spread it over a thick absorbent towel, and toss it until cool. I know ground beef does dehydrate and become crunchy with time, as I use it a lot, and find pieces and chunks in the weekly cleanup that can ONLY be described as "crunchy".
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