This article was published in the November 2024 issue of Pet Food Processing. Read it and other articles from this issue in our November digital edition.
Packaging large-format pet food presents unique challenges for manufacturers. Larger bags and containers require robust materials that can withstand the demands of transportation, storage and handling while maintaining product integrity. Sustainability has also become a key focus throughout the packaging industry, driving innovation toward eco-friendly materials that still offer durability and functionality. From recyclable solutions to advanced packaging technologies, the industry is constantly evolving to ensure that large-format packaging is both efficient and sustainable, without compromising on performance.
Scaling up from small to large formats introduces distinct obstacles. Larger packages must maintain structural integrity to handle increased weight, all while performing smoothly through production and distribution processes.
“Generally, the main difference between large and small pet food pouches comes down to the key requirements for packaging functionality,” Jacob Reinke of Amcor Flexibles North America.
“Generally, the main difference between large and small pet food pouches comes down to the key requirements for packaging functionality,” said Jacob Reinke, marketing manager, Amcor Flexibles North America, Deerfield, Ill. “The large pouches must meet the right Coefficient of Friction (COF) to avoid slipping on conveyors through the filling process and when filled bags are palletized. Additionally, the large bag structures must be robust enough to withstand drop-testing at customer specified heights to avoid packaging failures at retail. Amcor’s expertise in material science enables us to tailor our structures to very specific customer needs and requirements.”
As manufacturers work to ensure functionality, they also face the challenge of keeping heavier bags intact during transportation. This requires strong materials and designs to prevent issues like tearing. At the same time, there’s growing pressure to incorporate sustainable solutions without sacrificing performance.
“One of the main challenges in large-format pet food packaging is ensuring the structural integrity of heavier bags,” said Erin Larson, senior director of product development, TC Transcontinental Packaging, Montréal. “Larger packages must support more weight, so we utilize robust materials and reinforced designs to prevent tearing or bursting during transportation and handling. Sustainability is also a significant concern for us. We’re continually exploring eco-friendly materials that reduce material usage without compromising functionality or durability. By optimizing package dimensions based on the kibble’s density and shape, we can create efficient and durable packaging solutions.”
Effective equipment solutions
Selecting the appropriate packaging equipment is essential for handling the unique demands of large-format pet food products. The machinery must accommodate heavier weights and larger packaging sizes without compromising efficiency or product integrity. Innovative equipment solutions are enabling manufacturers to optimize their packaging processes, improve reliability and seamlessly integrate sustainable materials — all while maintaining high production standards.
“Pre-made bag fill-and-seal machines are ideal for large-format pet food packaging,” said Brent Bosman of TC Transcontinental.
“Pre-made bag fill-and-seal machines are ideal for large-format pet food packaging,” explained Brent Bosman, senior product development engineer, TC Transcontinental Packaging. “They offer flexibility in bag styles, high-quality sealing, and reduced changeover times, which are crucial for efficiency in production. When choosing equipment, factors like product characteristics, bag size, material compatibility and automation level are key. We collaborate closely with equipment manufacturers to ensure our packaging solutions integrate seamlessly with the latest machinery and technologies.”
A leader in sustainable packaging solutions, Thanh Phu Plastic Packaging Co., Ho Chi Minh, Vietnam, specializes in Design for Recycling (D4R) structures, particularly mono-material laminates. The company’s packaging solutions are compatible with rotary or standard pouch machines and include top-load and heat-sealing options.
“We see our D4R packaging run on rotary or standard pouch machines with top-load and heat-sealing,” said Alex Dam, executive vice president, Thanh Phu Plastic Packaging Co. “The biggest challenge with D4R packaging is to ensure an operational sealing window for the packing assets, as this mono-material structure tends to have a narrower window than conventional non-recyclable, multi-material laminates. Hence, it is Thanh Phu’s specialty to provide homogeneous mono-material laminated structures that our customers can fill and pack at a rate on par with their conventional non-recyclable films.”
Proven packaging materials
Selecting the right packaging materials for large-format pet food requires a careful balance of durability, functionality and sustainability. Traditionally, multi-layer laminated films have been favored for their strength and protective qualities, but newer, more eco-friendly alternatives are starting to emerge.
“Multi-layer laminated films have been highly effective due to their excellent barrier properties and resistance to punctures and tears,” Bosman said. “They also allow for high-quality printing and consumer-friendly features like resealable zippers, enhancing brand visibility and user convenience. Recently, mono-material polyethylene (PE) bags have emerged as a recyclable alternative. They address recyclability challenges but may require adjustments to existing filling equipment. Our collaborative approach ensures we recommend materials that enhance freshness, durability, sustainability and cost-effectiveness for each client.”
Mono-material solutions, like those provided by Thanh Phu Plastic Packaging Co., are also gaining traction in the industry for their recyclability.
“Thanh Phu only manufactures mono-material, recycle-ready packaging materials used in the pet food industry,” Dam explained. “Our Veloflex™ packaging films perform favorably compared to other mixed plastic structures. This is true of our High Barrier Veloflex™ structures as well.”
However, despite the progress toward sustainable options, many manufacturers still depend on multi-material combinations to achieve the optimal balance of strength and flexibility. This remains a key challenge when trying to enhance the recyclability of packaging solutions.
“Oriented Polyester (OPET) proves to be the most successful print layer with large-format pet food packaging. However, the combination of the print layer with the sealant is what creates a functional pairing,” Reinke noted. “Pouches need to be carefully designed to provide enough stiffness, which OPET naturally offers, but paired with the right balance of High-Density PE and Low Density gives the bag additional stiffness and flexibility to be able to pass drop-testing. The downside to the current standard offering is that it contains mixed materials and there is no avenue for recycling currently.”
Balancing sustainability and functionality
Sustainability has become a key focus in pet food packaging, but balancing eco-friendly materials with the performance needed for large formats remains a challenge.
One area seeing significant attention is the move toward recyclable materials, such as Oriented Polyethylene (OPE), as an alternative to traditional multi-layer options like OPET. This shift addresses recyclability concerns while maintaining the functionality needed for large-format packaging.
“OPE is proving to be a suitable replacement for OPET which would create a recycle-ready structure where the existing PE recycling stream is made available,” Reinke said. “Those currently utilizing OPET will find the path of least resistance to achieve recycle-ready structures through this development.”
For some manufacturers, achieving both performance and sustainability involves using a combination of recycled and recyclable materials. This is particularly important in large-format pet food packaging, where the demands on material strength and durability are higher.
“Sustainability significantly influences our material choices,” Larson said. “Using recycled materials reduces resource consumption but can present challenges in performance and quality consistency. We strive to balance performance with sustainability. Our goal is to meet functional requirements while advancing environmental objectives, considering economic implications, and embracing innovative materials and technologies.”
While incorporating recycled materials is key to reducing environmental impact, it also introduces challenges, particularly in maintaining packaging performance and ensuring food safety. Issues such as reduced material strength and potential contamination can arise, making it essential for manufacturers to carefully manage recycled content in food-contact applications.
“Recycled materials with an FDA non-objection letter (NOL) are High-Density PE, which poses a threat to drop strength if included at a high percentage,” Reinke said. “Recycled materials without the FDA NOL do not have the full traceability or testing to demonstrate that they should be used for food applications. All the recycled PE materials may have the potential for some off odors, which could bring organoleptic concerns with the packaged product, especially in the case of pet food since pets have a keen sense of smell.”
Innovations and future directions
As the pet food packaging industry continues to evolve, innovations in materials and equipment are driving changes that address the increasing demands for both sustainability and performance. Manufacturers are focusing on recyclable solutions, reducing environmental impact, and enhancing operational efficiency to meet future challenges.
Included in these solutions are recycle-ready offerings, which are designed to provide sustainable options for large-format pet food packaging.
“The latest developments are around recycle-ready PE offerings,” Reinke said. “Amcor has developed offerings for small treat pouches and large-format pet food pouches within our AmPrima® portfolio. The focus of innovation has been around sustainability. The market has recognized that there needs to be environmentally friendly packaging solutions for these formats. This is really being driven by consumers of pet food and the want for not only the products to be more sustainable but also the packaging that protects the product.”
As sustainability drives the industry, packaging equipment is also undergoing significant advancements to improve efficiency and adapt to changing materials. TC Transcontinental has been investing in new technology to align its packaging solutions with both sustainability goals and consumer demands.
“We’ve recently invested in Biaxially Oriented Polyethylene (BOPE) technology, which we believe is a game-changer for large-format pet food packaging,” said Alex Hayden, senior vice president of R&D, sustainability and ESG at TC Transcontinental Packaging. “BOPE films offer enhanced recyclability as a mono-material structure, superior strength allowing for thinner films, improved mechanical properties and excellent printability.”
Read more about packaging solutions and trends for pet food and treats.