Shun NagaiYour pet food prototype is finished, and there are no problems with its quality or palatability. Now you want to move into mass production.
But there is one thing to watch out for here.
Being able to make a good prototype and being able to keep making a product of the same quality in large volumes are two different things.
For example, a dry food that had no problems in a 100 kg trial may show variation in kibble size, hardness and moisture content once production is switched to a 3-tonne run.
Moreover, even if the manufacturing itself succeeds, faulty bag seals or problems with the best-before date could leave you with products that cannot be sold.
That is why, in pet food OEM, it is important to confirm after the prototype is completed whether the same product can be supplied consistently once it goes into mass production.
This article explains, with concrete examples, what changes when you move from prototype to mass production and what preparation is needed.
What you will learn in this article
- What changes between prototyping and mass production.
- Five points to check before starting mass production.
- How much to re-check when the factory or production line changes.
- How to build an annual production plan and update it in line with actual results.
- Ten questions to ask the factory, and how to sort the decision on starting mass production.
How is prototyping different from mass production?
The first thing to understand is that prototyping and mass production have different purposes.
The main purpose of prototyping is to confirm that you can make the product you are aiming for.
Mass production, on the other hand, requires being able to keep manufacturing products of a defined quality, in the quantities needed, on an ongoing basis.
Suppose, for example, that you made 100 kg of dry food as a prototype and got good results.
When you next make 3 tonnes, it is not simply a matter of multiplying the ingredients by 30.
As production volume increases, three things in particular may change.
1. The equipment changes
Prototypes are sometimes made with small mixers or development equipment.
In mass production, however, larger equipment is used, so the way the ingredients mix and the heating and drying conditions may change.
For example, ingredients that mixed evenly in a small mixer will not necessarily mix evenly in a large mixer in the same amount of time.
So rather than applying the prototype settings to the production equipment as they are, you need to confirm manufacturing conditions that suit the actual equipment.
2. The quantity made at one time changes
As production volume increases, the production time and the equipment’s operating conditions also change.
For dry food, the main things to check are mixing, extrusion, drying and the addition of fats and oils.
For example, if the drying conditions are not appropriate, the product’s moisture content and hardness may vary.
Quality may also differ between the start and the end of a run, so you check whether quality is stable throughout the whole run, not just in part of the finished product.
3. The packaging method changes
For prototypes, small quantities of product are sometimes bagged by hand.
In mass production, by contrast, automatic packaging machines are often used, so you also have to check the bag seal, the fill quantity, the printing of the best-before date and so on.
Even if the contents are of good quality, a packaging problem may cause the product’s quality to deteriorate during storage or transport.
In other words, in mass production it is important to check quality as a finished, packaged product that is ready for sale, not just the contents.
| Item compared | What to check in prototyping | What to check in addition for mass production |
|---|---|---|
| Manufacturing equipment | Whether you can make the target product | Whether the same quality can be achieved on the actual equipment |
| Production volume | Whether a small quantity can be made without problems | Whether quality stays stable in large-volume, continuous production |
| Packaging | Whether the product can be put into the desired bag | Whether sealing, printing and fill quantity can be controlled on the actual packaging line |
Note that not all prototypes are made on small equipment. Some factories make prototypes on production equipment from the start.
What matters is comparing the equipment, manufacturing conditions and packaging method used to make the prototype and the mass-produced product.
Five points to check before starting mass production
So what should you base the decision on whether to actually move into mass production?
Here, we organise the items worth checking when moving an OEM product into mass production into five points.
Point 1: How much do you expect to sell?
The first thing to check is the planned sales volume.
For example, if you plan to sell 10,000 bags of a 200 g pet food every month, that comes to 2 tonnes of product a month, or 24 tonnes a year.
However, aiming to sell 24 tonnes a year does not mean you need to make 24 tonnes from the start.
OEM factories may set a minimum order quantity (MOQ) — the minimum quantity they will produce per run.
If the minimum production quantity per run were 4 tonnes, ordering 2 tonnes every month might be difficult.
In that case, one option is to produce two months’ worth at once.
But if sales do not go according to plan, you will be left holding inventory. The more you produce, the more important inventory value, storage costs and best-before date management become.
So when you build a sales forecast, you need to consider confirmed orders, past sales results and future sales expectations separately.
Documents to check:
Sales volume forecast by product, confirmed orders, current inventory, and the factory’s MOQ and lead-time conditions.
Point 2: Can you make the same quality as the prototype?
Once the prototype is complete, the next step is to make clear what you will treat as “the same product.”
For dry food, for example, not only the ingredients and nutrient content but also kibble size, shape, colour, moisture content and hardness are part of product quality.
The key here is not to settle for simply asking the factory to “make it the same as the prototype.”
How much variation in kibble size will you accept? Within what range will moisture content be controlled? By what method will nutrients be measured?
Share these conditions with the factory and put them into a product specification that allows pass/fail decisions.
If you sell the product as a complete and balanced food, nutritional verification is also essential.
In Japan, the Fair Competition Code on Pet Food Labelling sets out, for labelling a product as a “complete and balanced food,” matters such as the growth stage of the target dog or cat and nutritional substantiation by analytical testing or feeding trials.
If the formulation or processing method changes significantly when moving from prototype to mass production, do not use the earlier analysis results as they are; analyse the product again. Where the “complete and balanced food” label is based on a feeding trial, or where the formulation is changed, also check the formulation-change conditions set out in the Code’s Enforcement Regulations and the details of the trial reported to the Pet Food Fair Trade Council.
Documents to check:
Final product specification, ingredient and formulation information, nutrient analysis results, and the label content and its substantiation.
Point 3: Is quality stable on the production equipment?
Once the product specification is decided, the next thing to check is the manufacturing process.
For dry food, for example, the finished product may vary depending on the ingredient mixing time, the extrusion temperature and pressure, the drying conditions and so on.
The points to check differ by product type, such as the heating and sealing steps for wet food or the freezing and drying steps for freeze-dried food.
What matters here is not to judge by the finished product alone.
Even if a production trial yields good-quality samples, they do not necessarily represent all the products made.
One approach, for example, is to take samples from the beginning, middle and end of the run and check whether quality differs.
Reviewing manufacturing records such as mixing time and heating temperature also lets you link product quality to the manufacturing conditions.
How many trial runs to make and where to take samples from are decided with the factory according to the risks of the product and process.
Documents to check:
Information on the equipment used, manufacturing conditions for mass production, process records, and test results from production trials.
Point 4: Are there any problems with the packaging and best-before date?
When moving to mass production, packaging is an important thing to check, not just the product inside.
For example, even a product that had no problems at the prototype stage may keep differently after switching to production packaging materials.
The material and thickness of the packaging and the sealing method affect how well it protects the product from oxygen, moisture and the like.
So you check the seal, the printing and so on using the bags and packaging equipment that will be used in mass production.
The best-before date also needs a basis.
According to the Ministry of Agriculture, Forestry and Fisheries’ explanation of Japan’s Pet Food Safety Act, best-before dates need to be set on a scientific and rational basis.
Storage tests, and comparisons of specifications (including processing steps) with products that use similar ingredients and production methods, can serve as the basis for that judgment.
With overseas OEM, it also takes time to transport the product from manufacture to Japan, clear customs, store it in a domestic warehouse and deliver it to customers.
Even if there is ample shelf life at the time of manufacture, if transport and storage take time, the product may not meet the remaining shelf life that customers require.
Documents to check:
Packaging material specifications, packaging check results such as seal tests, the basis for the best-before date, and transport and storage conditions.
Point 5: Can you respond if there is a quality problem?
The last thing to check is quality control and record-keeping after production.
With pet food, the work does not end once it has been made.
You need to make clear whether the products made meet the standards, who checks this, and under what conditions shipment is approved.
For example, consider a case where a product sold in Japan is suspected of containing foreign matter.
Which factory made the product, and when? Which shipment was it part of? Have products from the same production lot also been delivered to other customers?
If you cannot trace this information, investigating and responding to a problem when it occurs becomes difficult.
In Japan, businesses that manufacture or import pet food, or sell it to other businesses (sales directly to pet owners are excluded), must keep the records specified by law for two years.
With overseas OEM, it is important to manage the factory’s production lot information and your own import, inventory and delivery records as one linked chain.
Documents to check:
Lot-by-lot test results, shipment release records, production lot information, import and delivery records, and procedures for handling abnormalities.
What if the factory or production line changes?
When moving to mass production, you may increase volume at the same factory, or you may move production to a different line or a different factory.
The point to note here is that even with the same formulation, the finished product may change if the manufacturing equipment or conditions change.
So how much needs to be re-checked?
Increasing volume at the same factory on the same line
First, check whether increasing production volume changes the process conditions.
For example, if production runs become longer, check that there are no problems with the equipment’s operating condition or with quality variation.
Existing evaluations of the equipment and process can sometimes be used, but the deciding point is whether those evaluations cover the current manufacturing conditions.
Switching to a different line at the same factory
A different production line may have different equipment capacity and processing conditions.
So separate the parts where earlier test results can be used as they are from the parts that need additional checks.
For example, if the formulation is the same but the dryer changes, you might focus on checking moisture content and the degree of drying.
Manufacturing at a different factory
Moving to a different factory may change not only the equipment but also the ingredient suppliers, working methods and quality control system.
So sharing the product specification alone is not enough.
Check how the new factory will control everything from the ingredients used, the manufacturing process and the testing methods to packaging and shipment release.
That said, changing factories does not necessarily mean redoing every test across the board.
The rational approach is to identify what is changing and to decide on the checks and tests needed according to the impact of those changes on quality and safety.
If the country of manufacture also changes, re-check the import conditions for Japan and the product labelling as well.
Factory selection itself is also covered in the article below, “3 Missing Perspectives Common Among Companies That Fail When Selecting Overseas OEM Factories.”
How should you build an annual production plan?
Once the mass production setup is in place, the next thing to consider is the annual production plan.
The key here is to keep the annual sales forecast separate from the quantities you actually order from the factory.
For example, suppose you plan to sell 120,000 bags a year of a 200 g pet food.
In product weight, that is 24 tonnes a year.
But these 24 tonnes are only a sales forecast. Orders for 24 tonnes have not actually been confirmed.
If the factory’s minimum production quantity were 4 tonnes, one approach would be to make 4 tonnes first and place additional orders while monitoring sales.
Of course, in practice you also need to take into account production lead times, packaging order quantities, transport times and so on.
Update the annual plan in line with actual sales
After mass production starts, regularly compare the original sales forecast with actual results.
For example, suppose a product you expected to sell 10,000 bags a month is actually selling only 6,000.
If you keep making additional batches as originally planned in this situation, inventory may keep growing.
Conversely, if it is selling better than expected, the factory’s production slots or the procurement of ingredients and packaging may not keep up, and you may run out of stock.
So review sales results, inventory and future sales expectations monthly or at a similar interval, and revise the quantity and timing of the next order.
In particular, it is easier to manage if you distinguish between the following three.
- Annual sales forecast: A figure showing roughly how much you are likely to sell going forward.
- Confirmed order quantity: The quantity formally ordered from the factory, with the terms confirmed.
- Sellable inventory: Inventory that has completed testing and shipment release and is actually ready to be sold.
Sharing your annual forecast with the factory is useful when discussing production capacity and production slots.
However, communicating a forecast does not necessarily secure production slots or ingredients.
It is important to check in advance by when the factory requires order quantities to be confirmed, and what conditions apply to reserving production slots and securing ingredients.
Also check not only the inventory quantity but also the remaining shelf life.
Even if plenty of product remains, if it does not meet the remaining shelf life that customers require, that inventory may not sell as planned.
Think of the annual plan not as something decided once and then finished, but as something to be updated continuously in line with actual sales and the state of inventory.
Ten questions to ask the factory before starting mass production
Based on everything covered so far, we have put together a checklist of items to confirm with the factory before mass production.
The key is not simply to ask “Can you mass-produce this?” but to have the factory present specific manufacturing conditions and supporting documents.
| No. | Question to ask the factory or your own team | Documents to check |
|---|---|---|
| 1 | Will the equipment used differ between prototyping and mass production? | Equipment information and production line overview |
| 2 | What are the minimum and maximum production quantities per run? | MOQ, production capacity and lead-time conditions |
| 3 | Have the conditions for mixing, heating, drying and so on in mass production been set? | Process conditions and manufacturing records |
| 4 | Will a production trial be run on the actual production equipment? | Trial plan and test results |
| 5 | Have the quality standards and tolerances for the finished product been defined? | Approved product specification |
| 6 | Are there documents supporting the nutrient content and the labelling? | Nutrient analysis and labelling substantiation |
| 7 | Have the seal and the best-before date been checked using the production bags? | Packaging specifications, packaging tests, storage tests, etc. |
| 8 | Who carries out post-production testing and shipment release? | Test items and shipment release criteria |
| 9 | If a quality problem occurs, can the production lot be traced? | Lot records and traceability procedures |
| 10 | Will we be notified in advance if ingredients, equipment, packaging materials or the like are changed? | Change control, notification and approval procedures |
This checklist does not call for the same tests for every pet food.
The critical processes differ by product type, such as dry, wet or freeze-dried.
It is also important not to end the check just because you have received an answer from the factory.
For example, if the answer is “The best-before period is 18 months,” check on what basis that period was set.
If the answer is “We have mass production experience,” check whether that experience was with the same product, equipment and manufacturing conditions.
Whether there are documents backing up the answer, not just what the answer says, is what matters when deciding whether to move to mass production.
At what point can you start mass production?
Finally, let us sort out the decision on starting mass production.
The checks before mass production will not necessarily resolve every item at once.
The decision becomes easier if you sort the results into the following three categories.
1. Proceed to start mass production
The necessary checks on the product specification, nutrition, manufacturing process, packaging, quality control and so on are complete, and both the factory and the brand understand the conditions.
2. Decide after additional checks
Most of the conditions have been confirmed, but some test results or documents are missing.
Assign a person in charge and a deadline to each missing item, and decide on starting mass production once the necessary checks are complete.
3. Hold off on starting mass production
The conditions needed to start mass production are not met: for example, the product specification cannot be met, the necessary safety substantiation is lacking, or a serious quality problem has not been resolved.
In this case, the manufacturing conditions or the choice of factory need to be reviewed.
What matters is not to decide based only on numbers such as how many prototypes were made or how many tonnes could be produced.
Confirm that the quality and safety the product needs are ensured and that it can be manufactured continuously under the same conditions.
What matters in mass production is not “making a lot”
Scaling up in pet food OEM is not simply a matter of increasing production volume.
It is about building a system that can keep supplying the market with the product completed in prototyping, at the same quality and in the quantities needed.
To do this, you need to prepare from five perspectives: sales expectations, product specification, manufacturing process, packaging and best-before date, and quality control after production.
With overseas OEM in particular, if the factory and the brand do not share the same understanding of the product specification and manufacturing conditions, problems may surface after mass production begins.
By sorting out the items to confirm with the factory and gathering the necessary documents once the prototype is complete, you can reduce uncertainty when moving to mass production.
For the overall flow from product development to mass production, import and sales, see also the article below, “A 12-Month Roadmap for Launching a Pet Food Brand Through Overseas OEM Manufacturing.”
References and sources
- FEDIAF | Guide to Good Practice for the Manufacture of Safe Pet Foods — Guidance on mixing, manufacturing processes and quality control
- FEDIAF | Nutritional Guidelines for Cats and Dogs — Guidelines on nutritional evaluation and analysis
- Pet Food Fair Trade Council | On the purposes of pet food (in Japanese) — Labelling of complete and balanced food and substantiation by testing
- Ministry of Agriculture, Forestry and Fisheries | Pet Food Safety Act: materials for businesses (in Japanese) — Best-before dates, labelling, notifications, record-keeping and more
Note: The five checkpoints and the checklist in this article are a practical framework for considering the move from prototype to mass production in OEM. They are not a uniform legal standard; the tests and checks required differ by product, manufacturing conditions and country of sale.