Home/Case Studies/USA Dog Waste Bags & Kraft Boxes
Custom Case Study
How a U.S. Customer Developed Custom Compostable Dog Waste Bags with Kraft Retail Boxes
A client in the United States is developing a retail-ready line of compostable pet waste bags, featuring custom-printed, compostable dog waste bags packaged in natural kraft paper.
This project involved more than just manufacturing compostable dog waste bags. The client required specific customizations, including a uniform color for the bags, double-sided printing, a compact roll size, and a retail box designed to neatly hold eight rolls of bags.
The manufacturing process encompassed reviewing existing bag designs, matching custom film colors, coordinating the printing of the kraft paper boxes, finalizing the packaging configuration, and arranging overseas shipping.
Here is how ORIZON Biomaterials collaborated with the client to make key production and packaging decisions.
Project Snapshot
| Project Detail | Final Specification |
|---|---|
| Customer Market | United States |
| Product | Customized dog poop bags |
| Bag Size | 230 × 330 mm |
| Thickness | 18 μm |
| Bag Structure | Flat-top, flat-bottom |
| Bag Color | Custom neutral color based on an approved reference |
| Bag Printing | One-color black printing on both sides |
| Material | PBAT, PLA and corn starch blend |
| Roll Configuration | 15 bags per roll |
| Retail Packaging | 8 rolls per kraft paper box |
| Retail Box Size | 133 × 70 × 65 mm |
| Retail Box Material | 300 gsm natural brown kraft paper |
| Retail Box Printing | Single-color printing |
| Final Shipment | 10,240 rolls / 153,600 bags |
| Retail Boxes | 1,280 boxes |
| Export Packing | 43 cartons on one pallet |
| Shipping Arrangement | DDP sea freight to the United States |
1. The Customer's Goal: A Coordinated Retail Product
The client has already completed an initial sampling run for the waste dog bags and now wishes to scale up production.
The primary objective is to create a product where the bags and their retail packaging are perfectly aligned in terms of both aesthetics and functionality.
Several specific details are critical:
The bags must maintain the dimensions and thickness previously discussed, and the film color must strictly match the specified color standard. Each bag will feature the same black design printed on both sides.
For the retail packaging, the client prefers natural brown kraft paper rather than fully coated or laminated paperboard boxes.
The packaging must also be compact enough for retail display, with each box designed to hold eight rolls of dog waste bags.
These requirements mean that the production of the bags—including printing and rolling—must be coordinated with the manufacturing of the retail boxes, rather than being treated as separate, independent decisions.
2. Confirming the Bag Specifications and Printing
The final specifications for the doggie waste bags are 230 × 330 mm, with a thickness of 18 microns.
The client opted for a flat-top, flat-bottom bag design, with 15 bags per roll.
A key requirement was the customization of the film color.
Rather than selecting from existing stock colors, the client requested that the bags be produced according to an approved color reference.
This necessitated the preparation of a custom-matched color masterbatch prior to mass production.
Consequently, the production schedule had to account for the lead time required to obtain this custom masterbatch.
For projects requiring a specific film color, our Pantone color matching guide for dog poop bags explains the practical considerations involved in developing custom-colored compostable film.
Once the material was available, the factory could proceed with the confirmed bag specifications.
The artwork was also reviewed before production. Because the customer was retaining an existing design, the previously prepared printing plates could be reused without unnecessary changes to the printing layout.
The final printing arrangement was:
- One-color black printing
- The same artwork on both sides
- Custom-colored compostable film
- 15 bags per roll
- Green arrow roll stickers
The approved color reference was treated as a production target, with normal manufacturing color tolerances taken into account.
3. Developing the Natural Kraft Retail Box
The retail packaging box is an essential component of this project.
The client wanted the dog waste bag packaging to complement the printed bags while maintaining a minimalist, natural aesthetic.
After evaluating the packaging requirements, the final specifications for the box were determined as follows:
| Feature | Specification |
|---|---|
| Box Dimensions | 133 × 70 × 65 mm |
| Structure | Horizontal double tuck end |
| Paper Material | 300 gsm natural brown kraft paper |
| Printing | Single-color |
| White Ink | Not required |
| Lamination | None |
| Special Surface Finish | None |
| Capacity | 8 rolls |
The retail box was developed as part of a coordinated private-label product. Our private label dog poop bags page explains how bag specifications, printing, roll formats, and retail packaging can be planned together.
Inside each retail box, the eight rolls were arranged in two rows, with four rolls per row.
This arrangement helped establish the box dimensions and ensured that the packaging was designed around the actual roll configuration.
The decision to use single-color printing directly on natural kraft paper also avoided additional white ink and surface finishing processes.
For this project, the objective was not elaborate packaging decoration, but a coordinated and practical retail presentation.
Packaging material, printing methods, and order quantity can all influence the final packaging cost. We discuss these considerations further in our custom dog poop bag packaging cost guide.
4. Coordinating Bag and Box Production
One of the manufacturing challenges was coordinating two different production processes.
The compostable bags required custom-colored film, printing, bag conversion, and roll winding.
The retail boxes were produced separately using the approved box structure and artwork.
The custom color masterbatch required approximately one week of preparation and delivery before bag production could proceed.
At the same time, the retail boxes were scheduled with the packaging supplier.
The production timeline also needed to account for the factory’s existing order schedule.
Throughout this stage, ORIZON Biomaterials communicated updates to the customer regarding material availability, production progress, and packaging preparation.
This coordination helped keep the customer informed while the different components were being completed.
5. Planning the Export Cartons and Pallet
Once the finished rolls and retail boxes are ready, the next step is to consider export packaging.
Each retail box contains 8 rolls of pet poop bags, and the standard export carton is designed to hold 30 retail boxes.
This results in the following packaging configuration:
30 retail boxes × 8 rolls = 240 rolls per full export carton.
The final shipment consists of 1,280 retail boxes.
The export packing was arranged as follows:
| Packing Detail | Final Quantity |
|---|---|
| Full Export Cartons | 42 |
| Retail Boxes per Full Carton | 30 |
| Rolls per Full Carton | 240 |
| Partial Export Carton | 1 |
| Retail Boxes in Partial Carton | 20 |
| Rolls in Partial Carton | 160 |
| Total Export Cartons | 43 |
| Total Rolls | 10,240 |
All 43 export cartons were consolidated onto one plastic pallet for sea freight shipment.
The final palletized dimensions were approximately 1.14 × 1.14 × 1.05 m.
The packing arrangement was confirmed using the actual finished quantities rather than relying only on the preliminary packing estimates.
6. Arranging Overseas Shipment
The customer requested a delivered shipping arrangement to the United States.
The order was therefore handled under DDP terms, with overseas transportation, import clearance arrangements, and final delivery coordinated through the logistics provider.
After production and palletization, the shipment was dispatched by sea.
Shipping updates were shared with the customer, including vessel scheduling and subsequent customs clearance progress.
The shipment was reported as customs-cleared and released, with final delivery follow-up continuing afterward.
This was an important part of the project because the customer needed visibility into the shipment timeline after the manufacturing stage had been completed.
7. Project Outcome
Following the completion of the production and packaging stages, the final output is as follows:
- 153,600 compostable dog waste bags
- 10,240 finished rolls
- 1,280 custom-made kraft paper retail boxes
- 43 export cartons
- Consolidated pallets prepared for international shipping
The final product features custom-colored compostable waste bags, double-sided printing, and natural kraft paper retail packaging.
The project also demonstrated how several relatively small design and production decisions can affect the finished retail product.
The film color needed to be prepared separately, the printing artwork had to remain consistent, the retail box needed to fit the finished rolls, and the export cartons had to accommodate the final production quantity.
By coordinating these details throughout manufacturing and packing, ORIZON Biomaterials completed the custom production and prepared the order for international delivery.
For a different approach to retail packaging, see our Australian custom dog waste bag case study, which involved custom-colored bags, branded roll labels, and four-roll retail boxes without direct bag printing.
What This Project Demonstrates
For businesses developing private-label compostable dog waste bags, retail packaging should be considered early in the product development process.
Bag dimensions, thickness, winding configuration, printing, and box dimensions all influence one another.
This project highlights three practical considerations:
Custom film colors require production planning. A specified color reference may require a dedicated masterbatch and additional preparation time.
Retail box dimensions should be confirmed against finished rolls. The number of rolls per box and their arrangement determine the packaging structure.
Final export packing should reflect actual production quantities. Carton counts, partial cartons, pallet dimensions, and shipment details should be verified before dispatch.
These considerations are relevant to other businesses developing custom compostable dog waste bags with branded retail packaging.
Planning a similar produce bag roll?
If you are developing compostable dog waste bags with custom film colors, logo printing, or branded retail boxes, explore our custom dog poop bags service to learn more about the available manufacturing and packaging options.
