How freeze-dried pet food raises the bar

Globally, the numbers speak for themselves. In the U.S., for example, the American Pet Products Association reports that 66 percent of households now include at least one pet. Meanwhile, in Europe, the European Pet Food Industry Federation estimates there are over 340 million companion animals, including 113 million cats and 91 million dogs.

This shift is influencing how families think about pet nutrition. Owners are seeking food that mirrors their own priorities, such as high quality recognizable ingredients, minimal processing and production aligned with environmental values.

Freeze-dried pet food speaks directly to these expectations, and the category has grown steadily as families look for foods that preserve natural nutrients and flavor. Freeze drying – freezing the food and removing water through sublimation – protects the structure and sensory qualities of raw ingredients. The result is dried food that looks and feels fresh: visible pieces of meat, vegetables and grains that retain their color, aroma and nutritional integrity. Further, the removal of water provides stability, meaning these foods typically require fewer preservatives and producers can achieve shorter, more familiar ingredient lists – something pet owners consistently say they trust.

Sustainability across the supply chain

Beyond nutrition and transparency, families increasingly want their pet food choices to reflect their environmental values, and here the sustainability aspect of freeze dried pet foods is compelling – particularly as global agencies continue to draw attention to the environmental pressures of food production and logistics. The Food and Agriculture Organization highlights that one-third of all food produced globally is lost or wasted, contributing significantly to greenhouse gas emissions. Environmental agencies, including the U.S. Environmental Protection Agency, note that refrigeration and cold-chain logistics are among the most energy-intensive components of food distribution, accounting for a notable share of electricity use in commercial and industrial sectors.

Freeze-dried pet food avoids these challenges. Once packaged, it requires no refrigeration during storage or transport, lowering energy use throughout the supply chain. This matters both to manufacturers seeking to reduce operational emissions and to families who want their purchasing choices to reflect their environmental values.

Weight reduction further amplifies this effect. By removing moisture, freeze-dried foods become substantially lighter, meaning freeze-dried equivalents can weigh a fraction of the original product. Lighter shipment loads translate directly into lower transport emissions and more efficient distribution, which is a practical benefit for both brands and the planet.

The right partner is fundamental to success

Of course, delivering these benefits requires engineering precision, and this is where GEA’s expertise plays a foundational role. With decades of experience in freeze-drying technologies for food, nutrition and pharmaceutical applications, GEA supports pet food producers from concept to full-scale production.

Many manufacturers begin their journey with our GEA RAY Pilot Plant, a pilot-scale freeze dryer designed for experimentation and process refinement. Here, teams can evaluate new recipes, adjust cut sizes, assess rehydration performance and optimize drying curves. This early-stage work is essential for achieving the sensory and nutritional qualities pet families expect.

When the time comes for industrial production, we offer a portfolio of systems tailored to different needs. The GEA RAY batch freeze dryers are valued for their consistent, uniform drying - a critical factor for premium products where visual appearance and palatability matter – while GEA RAY Plus freeze dryers provide high throughput, hygienic design and energy efficiency, enabling manufacturers to meet growing demand while aligning with resource-efficiency commitments.

A full service partnership

GEA’s role extends far beyond simply supplying equipment. Freeze-dried pet food depends on fine process control, and GEA supports customers every step of the way through advanced test facilities.

GEA invests in research and development to continuously improve technology and processes. Global test centers are a valuable resource for customers looking to start up or scale up. Here, customers can conduct trials with their own products to evaluate performance under different freeze-drying conditions. They can also explore new formulations, ingredients and product formats to fuel innovation.

To ensure smooth transition to full-scale manufacturing, customers can run pilot production batches to test scalability and identify potential issues early. For those who prefer on-site development, GEA offers rental pilot equipment, with application engineers available to accompany the equipment for seamless startup and staff training.

This commitment matters because, as pet ownership grows, so does the expectation that food should support health, longevity and daily enjoyment. Families want to feed their pets with the same care they apply to their own diets – and, increasingly, they want those choices to contribute to a better world. Freeze-dried pet food delivers on both fronts, preserving nutrients and flavor while reducing reliance on the cold chain, lowering transport emissions and enabling more efficient use of raw materials. This is “Engineering for a better world” brought to life in a very personal way: by nourishing the family members who enrich the lives of their owners every single day.