Part
01
of one
Part
01
Who are the top 5 highest quality dry dog food (extrusion-based) co-packers in the United States with current capacity?
Hello! Thanks for asking Wonder for the top 5 highest quality dry dog food (extrusion-based) co-packers in the United States with current capacity
In short, based on your specific criteria and high quality standards, I determined that the top dry dog food (extrusion-based) co-packers in the United States include CJ Foods, Tuffy's, and American Pet Nutrition. Below, please find the results of my research, along with my methodology.
METHODOLOGY
I reviewed the previous response and your feedback to ensure I understood the information you are seeking. I then reviewed the Barrett Pet Food website to understand their services since you presented them as an example of what you are looking for. I perused a variety of pet food manufacturer/supplier databases, including the Pet Food Industry Directory of Suppliers, to identify companies that might meet your needs. I then visited each of their websites to ensure they offer the services you seek, specifically co-packing services for extrusion-based dry dog food. I also culled industry sources for information on the quality ratings and recall histories for these companies.
The pet food industry is a bit veiled and opaque in regard to the publicly available data it provides regarding manufacturing. Multiple companies are often involved with the production of pet foods, making it challenging to ascertain which companies are responsible for certain brands.
At your request, I have excluded Barrett Pet Food Innovations, BrightPet Nutrition, Diamond, and Simmons.
OVERVIEW
Over 70% of the pet food in the US is manufactured by five companies with some of these companies acting as contract manufacturers for other brands. Del Monte, for instance, is the contract manufacturer for Walmart's pet foods. In a report by the Packaging Machinery Manufacturers Institute, a third of survey respondents named Simmons, American Nutrition, and CJ Foods as some of the largest contract manufacturers.
THE COMPANIES
To find the top extrusion-based dry dog food co-packers, I defined "top" based on your request for high-quality companies, reviewing data on recalls and safety protocols to select companies that meet your criteria. Therefore, each of the companies listed were identified as offering co-packing services, as well as recipe formulation, for the pet food industry in the US. I confirmed that each company offers extrusion-based methods and has a limited number of recalls and strict quality standards and protocols. Ultimately, I identified three companies that meet all of your exacting criteria.
While I found other companies in my research that came close to meeting your criteria, they did not meet each of your criteria. The Scoular Company, for instance, is listed as offer co-packing at the Pet Food Industry Directory of Suppliers, and its capabilities include pet food manufacturing, including "blending, custom packaging/repackaging, risk management, and logistics services," but I was unable to determine if they off extrusion-based processes.
CJ Foods was identified in several sources as an example of a pet food co-packing company. According to their website, CJ Foods specializes in "co-manufacturing brand specific recipes to private label pet food programs with a full offering of services and support."
- Brands: Their website states that they maintain the confidentiality of their clients. However, a 2012 article at Truth About Pet Food suggests their brands include:
Castor Pollux dry* (recently purchased by Merrick Pet Food – it is not known when or if they will move manufacturing to the Merrick facilties)
Drs Foster & Smith
Nature’s Variety dry
Rotations
Timberwolf"
I also found this list that includes Back to Basics, Burns Pet Health, Dick Van Patten's Natural Balance, and Wellpet.
- Location: CJ Foods is based in Bern, KS with facilities in Pawnee City, NE, Bern, KS, and Baxter Springs, KS.
- Safety protocols/recall record: CJ Foods "has a rigorous Quality System to manage food safety risks and provide safe products, audited and certified by SQF (Safe Quality Foods), recognized by GFSI (Global Food Safety Initiatives)." The only reference I found to a recall was a 2007 FDA investigation of a contaminated shipment of rice protein concentrate. This recall was part of the Great Pet Food Recall of 2007.
- Minimum production run, availability, and cost: They do not provide this information publicly. Instead, interested companies can contact them via their website.
- Do they help with recipe formulation?: Yes, they have nutritionists on staff to help clients with product formulation.
- Where do they get their meat sources/novel meat sources? No publicly available data.
TUFFY'S
Tuffy's, owned by parent company KLN Family Brands, offers co-packing services for extrusion-based dry dog food and has opened a new "13,000 square-foot state-of-the-art manufacturing facility" in Perham, MN, that will initially have three extrusion lines that can produce 180,000 tons of pet food.
- Brands: NutriSource, Pure Vita, Natural Planet Pet Foods, Tuffy's Gold, Supreme Quality Pet Foods, and Premium Tuffy's
- Location: Perham, MN
- Safety protocols/recall record: "Each facility has their own dedicated team of quality control technicians who sample and test the products to make sure each batch meets our specifications. The quality control managers are experts in their field, with over 100 years of combined experience." They also conform to the "Association of American Feed Control Officials (AAFCO) protocols" to ensure their pet foods are nutritionally balanced. They had a voluntary recall in 2015 when salmonella was detected in one of their products.
- Minimum production run (in pounds), availability, and cost: No publicly available data. The only reference I found says, "Products made to order; thus, providing the freshest product available."
- Do they help with recipe formulation: No publicly available data.
- Where do they get their meat sources/novel meat sources: Their website does not specify their source. It simply states that the company is "committed to using only quality ingredients. Testing begins with ingredients. All goods are purchased only from approved suppliers who have agreed to supply ingredients that meet predetermined specifications. As each lot arrives at the plant, samples are taken before acceptance of the lot. Materials are tested by Tuffy’s Pet Foods internal Ingredient Testing Frequency protocol to confirm ingredients meet the specifications for key nutrients, free from foreign material, and do not contain known toxins. After testing confirms the ingredient meets the established criteria, it is accepted."
AMERICAN NUTRITION
With facilities in Woodland, WA, Ogden, UT, and Hazleton, PA, American Nutrition (also known as American Pet Nutrition) offers an array of services including "formulation, production, packaging design, and distribution" for a variety of pet food option, including extruded dry dog food.
- Brands: American Pet Nutrition's own brands include VitaBone®, Supreme Source®, Beggar Dog®, Atta Boy!®, Atta Cat!®, and Maintain Chunks®. The names of brands it offers co-packing services for were not widely available. I found mentions that it used to produce Blue Buffalo and Wellpet.
- Safety protocols/recall record: American Nutrition states that they "exceed FDA, AAFCO, and USDA industry-wide standards" and are Safe Quality Food (SQF) Level III Certified by the Global Food Safety Initiative. The have a Food Safety Plan in place to monitor their facilities and processes. American Pet Nutrition was also caught up in the Great Pet Food Recall of 2007.
- Minimum production run, availability, and cost: No publicly available data. Their contact page provides a contact form and lists Steve Mills, SVP of Customer Brands, as the primary contact. He can be reached at 801-625-6221.
- Where do they get their meat sources/novel meat sources: No publicly available data.
SUMMARY
To sum up, CJ Foods, Tully's, and American Pet Nutrition are top, high-quality dry dog food (extrusion-based) co-packers in the United States.
Thanks for using Wonder for your research needs! Please let us know if we can be of further assistance.