Last Updated: 10/09/2026
How Dry Pet Food is Made
Ever wondered how kibble is made? Our vet explains the extrusion process, quality checks, and why kibble size and shape can vary between bags.
Author: Dr Teagan Lever BVSc (Hons)
Reading Time: 5 minutes - short read
The convenience of pouring a scoop of crunchy kibble into a bowl is a daily ritual for most Australian pet parents. However, the science behind how those ingredients are transformed into shelf-stable, nutritionally complete nuggets is quite a feat of engineering.
Most modern dry dog foods and cat foods are created through extrusion, a process that cooks a blended dough under heat and pressure, shapes it into kibble, dries it, and coats it with nutrients that may have otherwise been affected by cooking. Kibble size and shape can vary between batches or brands because of differences in the dies and recipes used, not because anything is wrong with the food.
Learn more in our guides to wet vs dry dog food, wet vs dry cat food, and the benefits of mixed feeding.
How is dry pet food made?
The process of dry food production is a precise blend of science and safety. Here is how dry pet food is made, step by step:
- Mixing the base: Primary ingredients are pulverised and blended thoroughly to create a consistent, nutrient-rich dough.
- Cooking and expanding: This dough enters a machine called an expander. Here, it is cooked quickly using pressurised steam or hot water at very high temperatures.
- Shaping the kibble: While under extreme pressure, the dough is forced through specially shaped holes called dies. As the dough emerges, a rotating knife cuts it into individual pieces.
- Drying: The fresh kibble passes through a hot air dryer to remove excess moisture, ensuring the texture is crunchy and the shelf life is stable.
- Nutrient coating: Once cooled, the kibble is sprayed with a specialised mist of oils, fats, vitamins, and minerals. This "top-dressing" replaces any nutrients that might have been sensitive to the initial cooking heat.
- Sealing for freshness: Finally, the finished product is sealed into airtight packaging, to prevent spoilage and lock in the nutritional value. The packaging usually has fat- and oil-resistant liners to maintain food quality, prevent spoilage, and preserve nutritional value. These liners are crucial for protecting the healthy fats and oils in the kibble from escaping or oxidising (going rancid) due to exposure to air, light, or the packaging material itself. It is for this reason we always recommend storing the dry kibble in its original bag, even after opening.
Why does my dog's kibble look different from bag to bag?
Slight variations in the size, shape or colour of your pet’s kibble are completely normal. Because kibble is a baked product made from natural ingredients, subtle differences between batches are expected and rarely affect the food's nutritional value or your pet's health.
Reasons for natural variations
- Size and shape: Minor size changes can occur if the food is made in a different manufacturing plant. Additionally, the machinery that cuts the kibble (die plates) can cause variations; worn plates produce slightly larger kibble, while brand-new plates produce smaller kibble. Machinery fluctuations (extruder surge) can also alter kibble thickness.
- Colour and texture: Because kibble uses natural ingredients (like meats, grains, and vegetables), seasonal harvest changes can cause subtle colour shifts. Minor temperature or humidity changes during the baking process can also slightly alter the kibble's crispness and density.
Planned manufacturer changes
Sometimes changes are intentional. Manufacturers may permanently update a formula to improve nutrition, adjust kibble size/shape to better suit a specific breed or life stage, or upgrade their ingredient sourcing.
For information about planned, permanent changes to specific products, you can check the product page or our Pet Circle Product Updates page.
When you should be concerned
While minor differences are normal, you should contact the manufacturer or our Customer Service team if:
- There is a drastic change, such as a vastly different colour, a foul smell, or signs of mould and spoilage.
- Your pet completely refuses to eat the new batch or shows signs of digestive upset (like vomiting or diarrhoea).
How is dry pet food kept safe?
High quality and premium pet food brands take the quality and safety of their products very seriously.
Good pet food producers will undertake a number of steps before, during and after the manufacturing process including:
- Testing and examination of primary ingredients for signs of harmful microorganisms, chemicals, foreign objects and other potential contaminants.
- Constant checks at various points in the manufacturing process to ensure quality and safety standards are being adhered to.
- Examination and testing of the finished product to ensure that it is safe, consistent and meets quality standards.
When we're asked how to judge food quality beyond the label, we tell clients to look for brands that publish their own quality testing, not just claim it - that's a genuine differentiator between manufacturers.
FAQs
While the manufacturing process is complex, the goal is simple: to provide a safe, convenient, and balanced diet for our furry companions. By understanding how kibble is made and the rigorous testing it undergoes, pet parents can feel confident that they are providing a high-quality foundation for their pet's health and longevity.
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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 9 Sep 2026
Edited by Dr Gillian Hill BVSc (Hons)Dr Teagan Lever BVSc (Hons)
Head Veterinarian, BVSc (Hons)
Pet Circle's Head Veterinarian, Dr Teagan graduated from the University of Queensland in 2010 and went on to work in small animal and mixed practice in various locations around QLD & ACT before joining Pet Circle in early 2016. Dr Teagan has special interests in dermatology, nutrition and preventative health care. She feels privileged to witness the special bond people share with their pets on a daily basis and enjoys forming lasting relationships with pet parents and their fur children.
