What ‘Fresh’ Really Means in Pet Food Manufacturing

New pet food product formats and marketing terms are emerging at a rapid pace as the market continues to grow. Among these, “fresh” or “gently cooked” pet food has become one of the fastest-growing categories.  

The term appears frequently in the media, on packaging, and in consumer conversations; however, "fresh" is not currently defined by AAFCO or the FDA. Because of this, products marketed as fresh can vary significantly in formulation, processing methods, packaging technologies, storage requirements, and shelf life. For pet parents and professionals alike, this can make it difficult to compare products. 

Fresh pet food is often marketed as “less processed,” “gently cooked,” or “minimally processed.” However, as with other pet food formats, processing still plays a critical role for several reasons: 

• Food safety: Applying validated controls such as thermal treatments or other pathogen-reduction measures to minimize microbial risks for both pets and the people handling their food 
• Nutritional reliability: Helping ensure nutrients are digestible and bioavailable through steps such as grinding, cooking, and by neutralizing antinutrients 

• Palatability: Influencing texture, aroma, and flavor characteristics that encourage consistent consumption 

• Consumer convenience: Allowing products to be packaged, portioned, stored, and served in ways that make feeding more practical for pet owners 

What Is Meant By ‘Fresh’ Pet Food? 

While definitions vary by company, fresh pet food is often characterized by:  

• High moisture content 

• Cold-chain distribution, including refrigerated or frozen storage depending on the brand’s delivery model 
• Shorter shelf life compared to canned or dry foods due to less intensive processing and fewer shelf-stabilizing technologies 

Fresh pet food may be sold as rolls, trays, pouches, or bulk refrigerated products, and may be formulated for complete-and-balanced nutrition or supplemental feeding. Because the term is not formally defined, two products labeled “fresh” may be manufactured very differently. This makes it especially important to understand the underlying manufacturing processes rather than relying solely on label language. 

To meaningfully evaluate any pet food format, it is essential to understand how it is made. This provides critical context on food safety, nutrition, and overall product quality. Let’s look at a few “fresh” processes currently utilized in pet food manufacturing. 

Sous-Vide Pet Food Manufacturing: Step-by-Step 

1. Fresh and/or frozen ingredients are ground or cut in pieces and combined with other ingredients, such as oils, vitamins, minerals, etc., into a mixer. 
2. Product is filled directly into pouches to the desired weight, then vacuum- and heat-sealed. 
3. Sealed pouches are placed in a temperature-controlled water bath and cooked for a validated time to kill harmful pathogens. 
4. If necessary, products are blast-frozen in final packaging.  
5. Finished product is stored either refrigerated or frozen.  

Kettle-Cooked Pet Food Manufacturing: Step-by-Step 

1. Fresh and/or frozen ingredients are ground or cut to pieces and combined with other ingredients, such as oils, vitamins, minerals, etc., into a mixer. 
2. The product is loaded into a large kettle to undergo cooking. 
3. Cooked product is filled directly into pouches according to desired weight, then vacuum- and heat-sealed. 
4. If necessary, products are blast-frozen in final packaging. 
5. The finished product is stored either refrigerated or frozen. 

Steamed Pet Food Manufacturing: Step-by-Step 

1. Fresh and/or frozen ingredients are ground or cut to pieces and combined with other ingredients, such as oils, vitamins, minerals, etc., into a mixer. 
2. The product is cooked inside the mixer by steam injection. 
3. Cooked product is filled directly into pouches according to target weight, then vacuum- and heat-sealed. 
4. If necessary, products are blast-frozen in final packaging. 
5. The finished product is stored either refrigerated or frozen. 

As illustrated in Figures 1–3, products marketed as “fresh” or “gently cooked” do still undergo thermal cooking steps during manufacturing to ensure safety. Because the term is not formally defined by regulators, it can apply to products made through a variety of processing approaches.   

Fresh pet food is one of many product formats that can deliver complete-and-balanced nutrition when formulated and manufactured by experts. Kibble, canned, freeze-dried, and fresh foods all rely on science-driven formulation, ingredient selection, and process control to meet the needs of pets and their owners. By understanding the process of how pet food is made, pet parents can make more informed decisions about what type of product will fulfill both their own preferences and their pet’s needs.  

BSM Partners works across all pet food formats, including raw, frozen, “fresh”, and shelf-stable products. Our cross-functional expertise allows us to support companies at every stage of pet food development, from ingredient sourcing and supplier verification to food safety programs, process validation, and consumer education.  

Whether evaluating pathogen reduction strategies, strengthening preventive controls, or refining how processing and safety are communicated to pet parents, our team helps ensure approaches are scientifically sound, compliant, and aligned with brand goals. 

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About the Author

Ada-Miette Thomas is a senior analyst at BSM Partners. She received both bachelor’s and master’s degrees in food science with an emphasis on nutrition. Ada-Miette conducted research with a focus on human nutrition and studied the effects of carbohydrate sources on markers of Metabolic Syndrome in adults.