Technology challenges in the pet food pouch packaging production

Pet food pouch market insights 

Pouch packaging continues to be one of the fastest-growing formats in the packaging industry. The global liquid pouch packaging market was valued at approximately USD 8.46 billion in 2024 and is projected to grow at a compound annual growth rate (CAGR) of over 7.7% from 2025 to 2034, potentially reaching USD 17.83 billion by 2034. ​Global Market Insights 

​The pet food packaging market, in particular, is experiencing significant growth. In 2024, the global pet food packaging market size was valued at USD 11.38 billion and is projected to grow from USD 12.05 billion in 2025 to USD 18.48 billion by 2032, exhibiting a CAGR of 6.30% during the forecast period. marketsandmarkets.com / Fortune Business Insights 

Handling pet food pouches: critical issues 

While pouches offer numerous advantages, they present unique challenges during transportation and handling:​ 

• Stability Concerns: Unlike rigid packaging, pouches are less stable, especially when filled with liquid or semi-moist products. This instability can lead to difficulties during conveying and potential damage.​ 

• Surface Condensation: Post-filling, pouches containing hot liquids may develop condensation on their outer surfaces, increasing slipperiness and complicating handling processes.​ 

• Hygiene Requirements: Maintaining strict hygiene standards is crucial, as any damage leading to leaks can compromise product safety and quality.

Designing an effective pouch conveyor line 

To address these challenges, an effective pouch conveyor system should be incorporated: 

• Open Transport Systems: Minimizing or eliminating guide rails can prevent potential damage to pouches, especially when dealing with varying center of gravity due to liquid contents.​ 

• Inclined Conveyor Chains: Limiting the inclination to a maximum of 5 degrees (or up to 15 degrees with a friction top chain) helps accommodate the slipperiness caused by moist or greasy pouch surfaces.​ 

• Specialized Bridges: Implementing belt or roller bridges between conveyors ensures smooth transitions for unstable pouches, reducing the risk of tipping or jamming.​ 

• Automated Solutions: Integrating automation, such as collaborative robots (cobots) or case packers, can enhance efficiency in secondary packaging processes, reducing reliance on manual labor and minimizing contamination risks.

FlexLink’s solution: flexible, accurate, and hygienic 

FlexLink leverages extensive experience in designing automated conveyor systems tailored for pouch handling  

• Customized configurations: Systems are designed to meet specific client requirements, ensuring gentle handling and adherence to stringent hygiene standards throughout production.​ 

• Easy maintenance: Conveyor structures facilitate easy cleaning and quick resetting in case of spills, minimizing downtime and maintaining operational efficiency.​ 

• Stainless steel construction: Utilizing stainless steel materials ensures durability, washability, and compliance with food safety regulations. 

Secondary packaging requires scalable and replicable automation to keep pace with growing market demands for volume and variety.

The expertise of Coesia at your service 

Being part of Coesia enriches the company’s know-how, as the Company brings further expertise also thanks to partnerships among its member companies. This environment allows FlexLink to work in a predictive manner, taking advantage of the experience of its sister company. In this case, Volpak’s forty-year expertise in the pouch industry. For example, when designing a pouch packaging line dedicated to pet food. Volpak can carry out specific tests before the final installation by simulating production conditions and putting pouches into the same stress conditions that they may undergo during the actual process. More info in this blog. These tests are carried out at the “Pouch Lab”, a research and development center at Volpak’s headquarters. Here the company tests the mechanical resistance and behavior of pouches by using different materials and simulating different environmental conditions.

Hopefully, you gained some valuable information from our article. Contact us, if you would like to discuss your challenges in pet food production. Also, feel free to visit our website and follow us on LinkedIn for more regular updates on industrial automation and robotics.