Balancing Bulk and Sustainability: The Future of Large-Format Pet Food Packaging

Consumers purchase billions of dollars of pet food each year across all package sizes and formats. Of those billions of dollars in sales, 30- and 44-lb bags of dry dog food account for the lion’s share—almost $2 billion. Pet parents clearly like to buy in bulk, but why does this matter? 

What Drives Consumer Demand for Large Bags?   

Large bag purchase drivers include factors such as price (larger bags typically provide better value per pound), convenience (the desire for fewer trips to the grocery store), dog size, or the number of dogs in the household (both of which require more food).  

Retailers tend to push large bags because they increase ring and transaction size, require fewer units to be stocked, are harder to steal, and often have higher profit margins than smaller sizes. Consumer like buying in bulk because they believe that buying bulk cuts down on waste by utilizing less packaging. For example one 40-lb bag vs. four 10-lb bags.  

Pet food manufacturers offer large sizes to meet these consumer and retailer needs, but as sustainability becomes a greater priority and recyclable packaging requirements expand, these larger formats may need to be re-evaluated if they cannot meet performance demands. Simply put, large-format pet food bags require unique properties and stronger materials to support the package performance from manufacturing to the consumer, and it is these specialized structures that can make larger bags less recyclable. 

Package Design Considerations 

When it comes to designing packaging for heavier products, one important consideration is the ability for the package to withstand the demands of manufacturing (runability), transportation (shipping), handling (in store and at home), and storage (shelf life).  

Large bags require more robust materials to achieve these performance requirements and therefore rely on multi-layer or multi-material structures. Multilayer structures could include PET (polyethylene terephthalate), aluminum (foil), nylon, PE (polyethelene) or EVOH (ethylene vinal alcohol) used in combination. Multi-layer structures provide specific functional purposes like strength for puncture and tear resistance (nylon), and barrier from oxygen or moisture (aluminum and EVOH), which make them a great solution. However, the main challenge with multi-layer construction is that current recycling technologies cannot separate the layers, making these bags incompatible with standard recycling streams. 

Today’s Traditional Approach 

Mono-material polyethylene (PE) bags have emerged as a primary recyclable alternative to multi-layer PET (polyethylene terephthalate). Monolayer films may still have several layers, but those layers are each comprised of the same material. And yet, there are tradeoffs. These materials oftenrequire adjustments to existing package filling and sealing equipment, which can negatively impact manufacturing rates. In addition, manufacturers may need to invest in new packaging machinery designed to optimize performance and efficiency with emerging recycled materials. 

Mono-layer materials also may not offer equivalent barrier or strength properties as their multi-layer counterparts, which—especially in larger net weights—can impact pet food preservation or package durability. This why extensive package testing is required to first identify potential issues, then evaluate where compromises must be made to successfully launch the new material. In some cases, this may mean a reduction to the net weight offering to ensure product quality and package performance standards can be met.  

Finally, recyclable PE bags are more expensive, with an increased price point anywhere between 40% to 60%. When it comes to large format bags, the package costs are already higher, primarily based on the greater amount of material being utilized. The increased cost of materials would directly apply to the cost of the package and, ultimately, consumers could see these prices rise to offset costs. 

Could a Hybrid Approach Be Warranted? 

“That’s great,” you might be saying, “so what?” Consumers want recyclable, sustainable packaging when it comes to pet food, but they don’t always understand why it costs more. Is there an opportunity to shift the consumer mindset regarding large-format bags and their association with value? 

One benefit of large-format bags is there is a lot of billboard space to promote and educate consumers on the recycling process and options that could more easily and quickly meet the demand for sustainable packaging solutions.  

Alternatively, if we need to keep larger format bags in multi-layer structures in the interim, what is the opportunity to invest in third-party recycling or upcycling programs like TerraCycle? TerraCycle offers solutions from recycling to reuse of “unrecyclable” packaging not typically accepted through traditional recycling streams.  

Additionally, where can we work with retailers such as PetSmart and others to promote in-store recycling drop-off programs offered exclusively for large-format bags to ensure that they are repurposed at the end of their lifecycle? 

While the hybrid approach—combining different methods of recycling—holds promise, consumer behavior is a huge factor in its success. People may express a desire to recycle, but the convenience and simplicity of the process are key to whether they'll actually follow through. If the system feels complicated, is costly, time-consuming, or requires too much effort, it becomes less likely that consumers will engage consistently. 

How Can We Help?  

At BSM Partners, we know eco-friendly packaging isn't just about swapping materials—it’s about balancing sustainability with performance. Packaging needs to protect the product, withstand shipping and handling, and meet consumer expectations for convenience and durability. Sustainable solutions must check all these boxes while also aligning with evolving recycling capabilities. 

We remain committed to helping pet food brands design more sustainable packaging solutions that resonate with eco-conscious pet parents. Reach out to us today to learn how our expert team can help you craft packaging that stands up to both performance and sustainability standards. 

 

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About the Author

Oksana Lylak is the Director of Packaging Engineering at BSM Partners, offering over 20 years of experience across industries like automotive, consumer packaged goods, and pet food. Oksana specializes in developing innovative, cost-effective packaging solutions. Passionate about sustainability and pet food packaging, she combines technical expertise with a solution-driven approach to drive industry advancements.