This article was published in the January/February 2025 issue of Pet Food Processing. Read it and other articles from this issue in our January/February digital edition.
Fresh and frozen pet food formats continue to gain popularity among consumers, resulting in more options in the pet food aisle. In response, there’s been a surge of innovation in equipment and packaging materials available to pet food processors who are packaging these specialty pet food formats.
Compared to traditional packaging for dry kibble, which requires more barrier properties and has an inherent longer shelf life due to the nature of the product, fresh and frozen pet food must withstand lower temperatures during manufacturing, transport and storage. As such, the packaging must utilize specialty polymers for sealing to maintain seal integrity, as well as incorporate high-barrier polymers to maintain moisture and prevent oxygen transmission, enhancing shelf life and reducing spoilage.
Tim Kieny, vice president of sales and marketing for pet food at Montreal-based TC Transcontinental Packaging, notes packaging styles for fresh and frozen are quite different from the large quad-seal plastic bags that come in laminated plastic, woven polypropylene (WPP) and multiwall paper formats for dry kibble products.
Rollstock chub packaging used for ground meat products for human consumption is the same technology used to package many fresh pet food offerings.
|“The consumer for fresh and frozen pet food tends to purchase much more often than their kibble kin, one to three times per week versus several weeks to months for dry product,” Kieny said. “The package sizes are also quite different. Nearly half of all fresh and frozen pet food is consumed in 3-lb or smaller sizes with the largest at about 6 lbs of product. Compare this to the dry food consumer who, depending upon the size and number of their pets, purchase sizes from 3 to 5 lbs for small bags, 10 to 20 lbs for medium bags, and all the way up to 50 lbs for large bags.”
Fresh and frozen pet foods offer several advantages over conventional dry pet food. These formats are highly palatable, with improved appearance, aroma and texture that appeal to both pets and their parents. Due to gentler processing methods, they also retain more essential nutrients and generally have improved nutrient digestibility. In fact, many pet owners report noticeable improvements in their pets’ digestion, skin and coat health when feeding fresh or frozen diets, highlighting their potential for supporting overall pet wellbeing. These benefits play a significant role in processing decisions, emphasizing methods that preserve nutritional integrity while maintaining an appealing product appearance and texture.
Gerardo Perez-Camargo, Ph.D., senior vice president of R&D for Bedminster, NJ-based Freshpet, notes there are numerous advantages to making fresh products, including that the ingredients are visible and recognizable, maintaining their natural shape, color and texture.
“Scientific publications show higher digestibility and essential amino acid availability in fresh pet foods which make them superior choices for our pets,” he said.
Brittany White, Ph.D., vice president of research, development and commercial enablement at Ollie, a New York-based pet food brand, noted that maintaining product consistency and quality in fresh and frozen pet food manufacturing begins with sourcing high-quality ingredients.
“Beyond that, it is essential to establish and follow well-defined processing parameters, while keeping the process as gentle as possible,” White said. “This ensures that the food is safe while preserving its nutritional value and maintaining the integrity of the visible inclusions such as meat pieces, vegetables, fruits and grains. Balancing food safety with minimal nutrient degradation is key to delivering a high-quality, consistent product.”
Equipment innovation
Ryan Spencer, product marketing manager for Kansas City, Mo.-based Multivac Inc., noted the company’s thermoforming and traysealing packaging offerings are great solutions for fresh pet food products, as they help protect, preserve and showcase the food products inside.
“As fresh and frozen pet food has raised the bar for quality, the packaging has done the same so customers can more easily recognize the premium nature of these products,” said Ryan Spencer of Multivac.
“The packaging is continuing to look more and more like those you’d see in the refrigerated section of your local grocery store,” Spencer said. “People associate vacuum packaging with high-quality meats for their family to enjoy, and this is now extending to pet food products for the furry members of their family as well. As fresh and frozen pet food has raised the bar for quality, the packaging has done the same so customers can more easily recognize the premium nature of these products.”
TC Transcontinental Packaging offers a full line of high-barrier flexible packaging solutions including pre-made bags in both flat-bottomed and stand-up pouch format, along with flexible rollstock for chub packaging. All of the company’s packaging is created with sustainability top of mind.
“Sustainability has been and will continue to be the driving change for packaging over the coming decade,” Kieny said. “TC is working with the latest technologies in the sustainability space. We have a fully operational recycling lab along with a certified compost lab for testing all the newest developments. Perishable goods have particular challenges due to their historic multi-material makeup, which challenges the ability for the packaging to be recycled. We are developing elegant solutions for these challenging formats bolstered by our work in other market areas.”
Automation and artificial intelligence (AI) technologies are becoming increasingly essential in the processing of all pet food including fresh and frozen formats. Automation can streamline production, improve efficiency and reduce human error, while AI can optimize processes by monitoring and adjusting parameters in real time.
“Advanced temperature monitoring systems are also critical to maintaining product safety and quality, ensuring that temperature abuse does not occur during processing, storage or transport,” White said. “These advancements collectively enable manufacturers to produce high-quality and safe fresh and frozen pet food products.”
Freshpet utilizes up to 20 times less packaging than other brands, but is still strong, light and efficient according to Perez-Camargo.
“We use transparent windows in our bag recipes, so consumers can see the exact product they are buying,” said Gerardo Perez-Camargo, Ph.D., of Freshpet.
“We use transparent windows in our bag recipes, so consumers can see the exact product they are buying,” he said. “Our packaging is multilayered and has oxygen barriers to help avoid oxidation of vitamins and polyunsaturated fatty acids.”
Safety considerations
Safety and compliance of fresh and frozen pet food products during the processing stage is vital for pet food processors. From a microbial perspective, ensuring the safety and compliance of fresh and frozen pet food products during processing involves two key steps: proper cooking and rapid cooling.
Freshpet utilizes transparent windows in its bagged products so consumers can see the fresh ingredients.
| Source: Freshpet“First, processing temperatures must be high enough to destroy both pathogenic and spoilage microorganisms,” White explained. “After cooking, the product must be cooled and frozen as quickly as possible to prevent microbial growth. In addition to microbial control, robust quality checks must be in place throughout manufacturing. These include foreign material prevention measures such as metal detection, visual inspections and equipment maintenance protocols to reduce contamination risks.”
Additionally, meeting pets’ nutritional requirements is a critical aspect of food safety. Verification procedures during processing ensure that essential nutrients are added accurately and in the correct amounts, supporting both product safety and nutritional compliance. These measures help maintain a safe, high-quality product from production to final packaging.
Overcoming challenges
When designing packaging for fresh and frozen pet food, issues related to moisture, oxygen transfer, and maintaining product integrity during storage and transport all come into play.
To combat moisture and oxygen transfer, manufacturers rely on advanced barrier materials such as ethylene vinyl alcohol (EVOH) and polyvinylidene chloride (PVDC), which provide exceptional protection. Active packaging technologies, including oxygen scavengers and moisture absorbers, are often incorporated to help regulate internal conditions and extend product longevity.
Maintaining product integrity during storage and transport requires robust packaging materials like multi-layer laminates that offer both durability and flexibility to withstand handling and transportation stresses. Proper temperature control across the cold supply chain is also vital, so the products remain safe and retain their intended quality.
Wellness Bowl Boosters Freshly products, which were introduced in June 2022, can be served as a meal topper, treat or complete-and-balanced meal.
| Source: Wellness Pet CompanyTC Transcontinental has extensive laboratories for development and testing so when packaging arrives at the manufacturer, they can be assured it will work for their needs and will serve the pet parents’ needs.
“We work closely with the customer, our engineers and our suppliers to design the right package for the exact product and size being packaged,” Kieny said. “Close collaboration is required to dial in the precise properties for the particular application. We apply our expert knowledge in barrier technologies incorporating a wide array of material choices and manufacturing techniques.”
White noted managing the logistics and supply chain for sourcing and processing fresh ingredients adds significant complexity to pet food manufacturing. Fresh ingredients, especially meats, have a shorter shelf life, making precise production planning essential to ensure they are used before expiration. For instance, fresh meats may have only a few days of usable shelf life upon arrival. Any delays in the supply chain, such as late ingredient deliveries, can disrupt production schedules. Similarly, if manufacturing issues arise and the production line cannot run, ingredients may expire and require disposal, leading to costly waste.
“To address these challenges, it is crucial to work closely with trusted suppliers, fostering strong partnerships to reduce supply disruptions,” White said. “Advanced planning and creating contingency plans are also vital to mitigate potential issues and ensure production continuity. By proactively managing these factors, manufacturers can minimize risks and maintain efficient operations while preserving the quality of fresh ingredients.”
Fresh pet food necessitates precise handling and quicker packaging to preserve freshness and prevent spoilage. Automated filling machines provide accurate portioning, followed immediately by sealing to lock in freshness and minimize exposure to contaminants.
Read more about packaging solutions and trends for pet food and treats.
