Last Updated: 03/12/2025
Why Does my Pet's Kibble Look Different? Normal Variations Explained
Your pet's kibble colour, size, or shape has changed? Discover the normal manufacturing reasons behind kibble variations, how to tell the difference between natural changes and planned formula updates, and the signs that mean you should be concerned.
Author: Dr Gillian Hill BVSc (Hons)
Reading Time: 5 minutes - short read
You’ve opened a fresh bag of your pet’s favourite food and noticed something different - the kibble looks a little lighter, darker, bigger, or perhaps slightly smaller. It’s natural to feel a pang of worry when your pet's food looks different, but take a deep breath!
Rest assured that slight variations in kibble are completely normal and rarely impact the food’s nutritional value or your pet's health.
Kibble is a natural, baked product, and just like your home baking, there can be subtle differences between batches. These normal variations are due to the manufacturing process and fall into two main categories: natural processing variations and planned formula updates.
In this article
Natural variations in kibble size, texture, and colour
The process of turning raw ingredients into consistent, crunchy kibble involves complex machinery (extruders and die-plates) and natural ingredients. Because of this, small differences in the final product are to be expected.
These normal variations will have no impact on the nutritional value of the food and typically do not affect your pet consuming the food.
Here are the main reasons why your pet's kibble might look different from the last bag:
Changes in size and shape
Different manufacturing plants
It is possible that your previous bag of food came from a different manufacturing plant than your recent purchase. Even with strict quality controls, when this happens, you may see minor variations in kibble size.
Worn or new die plates
The die plate is the mechanism that cuts and shapes the kibble.
- Larger kibbles: After thousands of kilograms of product are produced, the die plate can wear down and begin to produce a slightly larger kibble.
- Smaller kibbles: When a new die plate is installed, the kibble may appear slightly smaller.
Extruder 'surge'
It is possible that kibble thickness may vary between batches due to natural variations related to the processing machinery (known as extruder "surge").
Variations in colour and texture
- Natural ingredients: Kibble is made from natural ingredients like meats, meat meals, grains and vegetables. The colour of these natural ingredients can change slightly depending on the season or harvest, just like a batch of apples or carrots might look slightly different year-to-year. This subtle colour shift is carried through to the final kibble.
- Processing: Minor fluctuations in temperature or humidity during the baking process can result in slight differences in the density or crispness of the kibble, leading to a minor change in texture.
Fond out more about How Dry Pet Food is Made.
For confirmation of any variations to your pet's kibble size, shape, colour or texture, it's ideal to contact the manufacturer directly, for timely, up to date information. You can also contact us for assistance.
Planned changes
Sometimes, a change in your pet's food is more significant because it's intentional and planned by the manufacturer. Brands make planned changes for various positive reasons, such as:
- Improving the formula to provide higher-quality nutrition and health benefits for your pet.
- A permanent shift in kibble size or shape to better suit a specific breed or lifestage.
- Changing ingredients due to new sourcing or improved quality.
For information about planned, permanent changes to specific products, you can check the product page or our Pet Circle Product Updates page.
When to be concerned
While minor variations are normal, there are a few signs that warrant attention:
- Significant, drastic change: If the kibble is a completely different colour, has a vastly altered, off-putting smell, or shows signs of mould or spoilage.
- Refusal to eat: If your pet completely refuses to eat the new bag of food, or if they show signs of digestive upset (like vomiting or diarrhoea) after transitioning to it.
In these cases, please contact us as soon as possible. It's always a good idea to keep the kibble in it's original packaging so that you have access to the batch details and expiry date of the food (which are generally required to investigate any issues). The original packaging is also designed in such a way to keep the food as fresh as possible, and reduce oxidative damage.
FAQs
Small variations in your pet’s kibble are a normal part of the manufacturing process. Whether it's a minor shift in colour from natural ingredients or a slight change in size from a new die plate, these differences won't affect the great nutrition you're providing.
Knowing the difference between a natural variation, a planned update, and a genuine cause for concern is key to being a confident pet parent. If you ever spot a drastic change, refusal to eat, or signs of spoilage, always reach out to the manufacturer or to us for peace of mind.
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History
Our experts continually monitor the health and wellness space and we update our articles when new information becomes available.
Wed 3 Dec 2025
Written by Dr Gillian Hill BVSc (Hons)Dr Gillian Hill BVSc (Hons)
Veterinarian
Dr. Gillian loves being able to provide depth and detail to pet parents questions, and give up to date, evidence based advice. She loves the variety of pets and inquiries she receives - she especially loves the 'curly' questions that require some research! Seeing the gorgeous photos that pet parents send through of their babies is a highlight of the day! Gillian enjoys to further her veterinary knowledge, and has completed further training in ultrasonography, behaviour and backyard poultry!
