Pet Food Contract Manufacturing: Finding the Right Co-Packer
The US pet food contract manufacturing sector serves as the backbone for thousands of brands that lack in-house production. With approximately 400 pet food manufacturing establishments in the US generating over $23 billion in combined annual revenue, the private-label and contract manufacturing segment continues to grow as new DTC brands enter the market.
Market Landscape
The pet care contract manufacturing market is projected to reach $155.93 billion globally by 2033, growing at a CAGR of 8.5%. In the US alone, the top eight companies account for roughly 75% of total pet food sales, but the contract manufacturing tier is far more fragmented — offering opportunities for emerging brands to find production partners at every scale.
Key Production Formats
- Dry Kibble & Extruded
- The largest segment. Contract manufacturers like Alphia operate six facilities with capacity exceeding 1 billion pounds annually. Extrusion lines accommodate various formulations including grain-free, high-protein, and specialty diets.
- Wet Food & Canned
- Simmons Pet Food is the largest private-label wet pet food manufacturer in North America, operating plants in Arkansas, Kansas, Iowa, and Ontario. Newer entrants like NaturPak Pet specialize in Tetra Pak carton formats at their 162,000 sq ft BRC AA-rated facility.
- Treats & Chews
- Specialists such as Phelps Pet Products maintain libraries of 550+ recipes and offer SQF Level II certified production of jerky, sticks, and training treats from their Rockford, IL facility.
- Freeze-Dried & Raw
- A fast-growing premium segment. Companies like North Freeze Dry operate dedicated freeze-drying facilities to serve brands targeting the raw and minimally processed market.
What to Evaluate in a Co-Packer
| Factor | Why It Matters |
|---|---|
| Certifications (SQF, BRC, USDA Organic) | Retailer requirements — major chains mandate specific food safety certifications |
| Minimum Order Quantity | Startup-friendly co-packers accept runs as low as 5,000 lbs; larger facilities require 40,000+ lbs |
| Formulation & R&D | Full-service partners develop recipes in-house, reducing time-to-market by months |
| Export Capability | EU, AAFCO, and international compliance opens global distribution channels |