Packaging for Pet Food — Dry and Wet Food

The pet food market is one of the fastest-growing segments of the food industry. In Poland, spending on dog and cat food grows 8–10% annually, and the premiumization trend drives demand for high-quality packaging — functional, visually attractive, and increasingly eco-friendly.

Flexible packaging (doypacks, sachets, side-gusset bags) dominates the pet food segment due to low cost, excellent product protection, and user convenience. In this guide, we discuss packaging specifics for dry and wet food — from barrier requirements to regulations and trends.

Dry food — packaging requirements

Dry food (kibble) is a product with relatively low water activity (aw <0.65), but with fat content susceptible to oxidation. Packaging must provide:

Key requirements

1. Oxygen barrier — fat oxidation (rancidity) is the main degradation mechanism for dry food. Required OTR <10 cc/m²/24h, for premium and high-fat foods (e.g., grain-free) <5 cc/m²/24h.

2. Moisture barrier — absorbed moisture leads to mold growth and texture degradation. MVTR <3 g/m²/24h.

3. Light protection — UV degrades vitamins (A, E) and colorants. Metallization or covering print.

4. Mechanical strength — 2–15 kg packages must withstand product weight, transport, and stacking. High tear and puncture resistance required.

5. Reclosure — after opening, customer uses food for days/weeks. Zipper closure or slider is standard.

6. Vent valve — freshly produced food "breathes" (emits gases). One-way valve prevents package ballooning without letting air in.

Formats for dry food

Format	Capacity	Application
Doypack with zipper	200 g – 2 kg	Premium food, samples, small breeds
Side-gusset bag	2–15 kg	Standard shelf packages
Doypack with flat bottom	1–5 kg	Premium segment, shelf stability
Portion sachet	30–100 g	Single portions, diet foods

Recommended material structures

• PET met/PE — market standard. Metallization provides light and oxygen barrier. Relatively low cost. Limited recyclability.

• PE/EVOH/PE (mono-material) — future-proof recyclable solution. EVOH layer provides oxygen barrier, PE metallization provides light protection. EU PPWR compliant.

• PET/AL/PE — highest barrier, used for premium and diet foods with extended shelf life. Non-recyclable.

• PA/PE — polyamide provides mechanical strength for large packages (>5 kg). Difficult to recycle.

Detailed material comparison in our article packaging materials.

Wet food — packaging requirements

Wet food (pâtés, chunks in sauce/jelly) is a high water activity product requiring thermal sterilization. Packaging must meet much higher requirements than for dry food.

Key requirements

1. Retort sterilization resistance — retort sachets must withstand autoclave sterilization: 121°C for 20–60 minutes at 2–3 bar pressure. This requires special laminates.

2. Hermeticity — any leaks after sterilization lead to product spoilage. Seals must be absolutely tight.

3. Oxygen and light barrier — after sterilization, product is sterile, but oxygen contact leads to oxidation. Aluminum or PET metallization is standard.

4. Puncture resistance — bone chunks, hard food elements cannot puncture packaging. PA (polyamide/nylon) layer provides strength.

5. Easy opening — tear-notch is standard. Consumer must open sachet with one hand.

Formats for wet food

Format	Capacity	Application
Flat retort sachet	80–100 g	Market standard (cat portion)
Stand-up retort sachet	100–300 g	Dog food, premium
Retort doypack	300–500 g	Large portions, family packs

Recommended material structures (retort)

• PET/AL/CPP — market standard for retort sachets. Aluminum provides full barrier, CPP (cast polypropylene) provides high-temperature sealability.

• PET/PA/CPP — without aluminum, but with polyamide layer for strength. Transparent — visible product. Lower oxygen barrier.

• PET/AL/PA/CPP — premium structure combining aluminum barrier with PA strength. For foods with chunks, bones.

Portion packaging — growing trend

The portion packaging segment for pets is growing dynamically, driven by premiumization and convenience trends:

Why portions?

• Freshness — each portion opened right before serving

• Hygiene — no need to store open food in refrigerator

• Precise dosing — facilitates weight control (diet)

• Travel convenience — lightweight, compact, don't require measuring bowl

• Premium perception — portion sachet communicates higher quality than can

Portion formats

• 80–100 g sachets — cat standard. One portion = one sachet.

• 30–50 g stick sachets — topper/treat. Squeeze and serve.

• 200–300 g sachets — dog portion for small and medium breeds.

• Multipack — 4–24 sachets in collective packaging (carton or film sleeve).

Pet food packaging regulations in the EU

Pet food packaging is subject to feed and food contact material regulations.

Mandatory packaging information

According to Regulation (EC) No 767/2009:

• Feed type — "complete feed" / "complementary feed" / "treat"

• Target species — "for adult dogs", "for kittens"

• Ingredient list — in descending order by weight

• Analytical constituents — crude protein, crude fat, crude ash, crude fiber, moisture

• Additives — vitamins, minerals, amino acids with quantities

• Net weight

• Batch number

• Minimum durability date — "best before..."

• Feeding guide — table with recommended daily portion by pet weight

• Manufacturer data — name, address, plant approval number

• Storage conditions — "after opening store in refrigerator, consume within 48h"

Packaging material

Although food is intended for animals, packaging material must meet requirements of Regulation (EC) No 1935/2004 on materials and articles intended for food contact (FCM). In practice, this means the same requirements as for human food packaging.

Trends in pet food packaging

1. Premiumization

Premium packaging (matte varnishes, soft-touch, metallic elements) gains share because owners treat pets as family members. Doypack with premium finish communicates "high-quality ingredients".

2. Ecology

Pet owners increasingly choose eco packaging. Mono-material PE with zipper closure is a compromise between functionality and recyclability.

3. Transparency

Windows in doypacks showing product build trust. "You see what you buy" — important in premium segment where consumers expect visible meat chunks.

4. Personalization

Digital printing enables short runs with personalization — e.g., different graphics for breeds, limited seasonal editions, packaging with pet name (trend in e-commerce).

5. Convenience

Easy-open packaging, precise dosing, and reusable closure. Slider zipper instead of standard ziplock — easier to operate.

More about general flexible packaging trends in our complete guide.

How to choose pet food packaging — checklist

When choosing packaging for pet food, answer a few key questions:

1. Food type — dry, wet, semi-moist, treat? Each requires different material structure.

2. Package weight — 80 g sachet vs. 15 kg bag are completely different mechanical and logistics requirements.

3. Shelf life — 12 months or 24? Longer shelf life = higher barrier requirements.

4. Sales channel — retail shelf requires standing packaging with attractive graphics. E-commerce focuses on functionality and transport durability.

5. Reclosure — ziplock, slider, zipper? For dry food, this is a standard expected by customers.

6. Budget and quantity — at small quantities (4,000–10,000 pcs) digital or flexographic printing. From 20,000 pcs, rotogravure pays off.

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Producing pet food?

We offer flexible packaging for dry and wet food — from 80 g portion sachets to 15 kg side-gusset bags. We'll advise on material, format, and closure matched to your product.

Contact us — we'll prepare a free quote and material recommendation.