Currently, the vast majority of pet food packaging is not recyclable. Major manufacturers and groups like the Pet Sustainability Alliance want to change that.
The pet food industry, known for its bulky, multi-material bags that are difficult to recycle, has become one of the latest sectors to rethink its flexible packaging. Single-material designs, lightweight design and recyclability are increasingly becoming a priority for brands.
Consumers spend billions of dollars on pet food each year, and the United States produces about 300 million pounds of plastic bags for pet food and treats, according to research conducted for the industry. Currently, the vast majority of these materials are not recyclable. But as younger, more sustainable generations begin to invest more in pet ownership, the need for change is growing.
“Consumers are looking for packaging that is recyclable, compostable, or reusable,” said Christine Mallier, sustainability manager at Petcurean. Petcurean is a Canadian company that makes the Go! Solutions, Now Fresh, and Gather brands. “For a long time, the costs were too high.”
Typical bags of dry pet food (called kibble) are made of a durable, seemingly unbreakable material covered with metallized paper or plastic to preserve the food and prevent fat from leaking. The outside of the bag usually has a shiny finish. Because these bags are made of paper and plastic, they are difficult to recycle.
Packaging companies have begun producing bags using polyethylene and ethylene vinyl alcohol (EVOH) and are looking for other ways to simplify their design.
The move comes in part from efforts by major pet food companies like Purina, Hill’s, and Mars, which have made sustainability commitments that include packaging. Purina says nearly 90% of its plastic packaging in North America is “designed to be recycled,” and the company aims to reach a 95% recycling rate by 2025.
The nonprofit Pet Sustainability Alliance launched its own sustainability pledge in 2022 to encourage pet food brands to switch to recyclable, reusable, and/or compostable packaging by 2025.
“We see the Packaging Pledge as a great opportunity to help the pet products industry move toward more recyclable solutions, and I think it’s a friendlier space overall,” said Ali Boden, senior packaging program manager at PSC.
Thirteen brands have signed on to the pledge, including Earth Animal, Instinct, and Petcurean, and it’s starting to gain traction among smaller pet food companies. The organization’s goal is to encourage change while holding brands accountable and uniting them around common goals.
The PSC provides signatory parties with access to a marketplace of pre-vetted packaging companies such as Ahlstrom and Printpack, enabling them to source packaging from recyclable, reusable and compostable solutions. The PSC also provides its members with tools such as assistance in developing recycling labels and packaging design advice.
Petcurean, which has been working with the PSC for several years, said its commitment was to be transparent about planned improvements.
Previously, the company’s bags were made from multiple layers of PET, which was difficult to recycle. Now they are made from low-density polyethylene (LDPE), a flexible, tear-resistant plastic, and their single-material design may make them easier to recycle in the future.
“You need to do your due diligence to make sure the packaging stays fresh and lasts as long as the last one,” Mallier said, noting that LDPE can provide that, but it will take time for brands to fully transition to the other packaging.
The use of EVOH, a flexible thermoplastic copolymer, is also gaining interest in this area. EVOH often poses recycling challenges, but some companies report finding solutions.
Roastar claims to have invented pet food packaging that includes a clear laminated barrier that prevents food from sticking to the bag and that could potentially use recyclable EVOH. Packaging machinery and equipment supplier Windmöller & Hölscher also said it produces recyclable pet food bags with a co-extruded EVOH barrier layer.
These trends also affect bag size. While the industry is known for large pellet bags weighing 10 to 20 pounds, many new designs weigh between 2.5 and 5 pounds.
Troy Snader, senior vice president of secondary packaging development at ProMach, explained that the change was made because the new design may not be as effective as the previous multi-layer design at keeping dry products dry due to barrier properties.
”There are still some restrictions and limitations in the packaging industry on the types of products that can be packaged, but things are constantly evolving,” Mallier said.
The trade-off between producing more and smaller bags and reducing waste is considered necessary to realise other potential sustainability benefits from the various materials. The move to more PE and EVOH also requires consideration of production factors.
ProMach has added new features, such as nip rollers, to handle these new materials. The cost of sealing polyethylene pet food packaging can also be higher because it has a much narrower temperature range than other materials.
”The challenge was to use a new heating technology rather than just heating the entire length of the rod as had been done before,” Snead said.
While the industry is moving in this direction, there is no clear end market for plastic pet food bags and their “sustainable” cousins. Pet food packaging of any type is easily contaminated with food residue, meaning that its recyclability is poor in many systems.
Many new pet food packaging solutions are only available for in-store return programs. Other brands, like Petcurean and Earthborn Holistic, have partnered with How2Recycle to use in-store return labels for HDPE and LDPE bags.
Recycling programs have come under increased scrutiny in recent years for a number of reasons, and the market for this material will likely only expand as more chemical or modern recycling facilities come online. Berry Global recently received recognition for producing flexible pet food bags for Hill’s using ingredients derived from this process, showing how this trend could impact the pet food market.
Meanwhile, while there is still no clear market for many of these packages, pet food transition groups say it is important to start raising awareness now.
”It’s hard to get people to stop littering,” Malil said. “From a consumer perspective, they can support companies that are taking these steps and being leaders.”
“While these materials are technically recyclable, most single-stream recycling facilities do not have the infrastructure to process them, or there is no curbside collection. As a result, most flexible plastic packaging ends up in landfill,” the company said, adding that “we will be ready once the infrastructure is in place.”
Growing regulatory and public pressure on single-use plastics is creating a market opportunity for fiber-based products. Companies like Pulpex, Paboco, DS Smith and others are helping customers develop innovative bottles, boxes and more.
The expected tariff structure is a major concern for some packaging and materials companies, who are also preparing for more mature negotiations on EPR and deposit refund policies this year.
Growing regulatory and public pressure on single-use plastics is creating a market opportunity for fiber-based products. Companies like Pulpex, Paboco, DS Smith and others are helping customers develop innovative bottles, boxes and more.
The expected tariff structure is a major concern for some packaging and materials companies, who are also preparing for more mature negotiations on EPR and deposit refund policies this year.
Post time: Mar-07-2025