PetMate Vari Kennel: Airline-Approved Dog Travel Crate 

If you’re preparing your dog for airline travel or simply need a safe, durable kennel for everyday use, the Petmate Vari Kennel is one of the most trusted dog travel crate options out there.

Petmate has been making dog crates for over 60 years, and this hard-sided dog travel crate has long been considered the standard for flying pets in cargo.

I’ve flown with my Labradors before, including one transatlantic trip from the U.S. to the U.K. many years ago! I remember labeling the crate, securing extra food, and double-checking every requirement. It was a smooth experience because the kennel I used was sturdy and thoughtfully designed.

For this review, I tested the Petmate Vari Kennel with my current dog, Burt, to see how it performs for real-world travel and everyday use. Here’s everything you need to know to decide if this crate is right for your dog.

What Is the Petmate Vari Kennel?

The Petmate Vari Kennel is a hard-sided plastic dog travel crate designed for safety, durability, and airline cargo travel. It’s available in multiple sizes, from small to giant, and meets most International Air Transport Association (IATA) requirements for travel with your pets. 

Key features of this crate include:

• Heavy-duty plastic shell
• Metal grated door
• Ventilation on all three sides, plus the door
• Airline-required holes to zip-tie the door securely
• Easy assembly with included hardware (no tools required)
• A secure latch that stays in place during transport

While soft-sided carriers are popular for in-cabin flights, dogs flying in cargo must have a rigid, plastic kennel with a metal door, and the Vari Kennel is designed exactly for that purpose.

So does the Petmate Vari Dog Kennel deliver the safety, comfort, and convenience dog owners need for both travel and everyday use? That’s what we set out to determine in this review.

How to Choose the Right Size Dog Travel Crate

Choosing the correct crate size is essential for comfort and safety. Your dog should be able to: Stand without their head touching the top Turn around comfortably Lie down in a natural position

• You want the crate to be airline-approved for flying

Petmate provides a clear sizing chart by dog weight and breed. Most Labradors do well in the 40" XL kennel, while giant breeds may need the 48" size.

The XL size fit my Labrador Burt comfortably with room to turn around and lie down.

One logistical note: Once assembled, the XL crate was too tall to fit upright in the cargo area of my VW Tiguan. Fortunately, the top nests inside the bottom for transport, and because assembly is so easy, I could put it together at the airport if needed.

I don’t see this as a flaw, just something to keep in mind if you plan to travel with a larger kennel.

Is the Petmate Vari Kennel Airline Approved?

Based on my research, the Petmate Vari Kennel does meet most airline and IATA guidelines. Requirements do vary, so always compare your kennel with your airline’s most up-to-date list.

Typical IATA or Airline Requirements:

• Rigid plastic construction
• Metal grated door
• Ventilation on three sides for domestic flights and four sides for international flights
• Metal hardware
• Holes around the door for zip-tying the door securely shut

United and American Airlines specify that dog travel crates must have no wheels, cannot crack under pressure, and must include ventilation at least halfway up the sides.

The Petmate Vari Kennel checks all these boxes with its durable construction and pre-drilled holes for zip ties.

Important: Always contact your specific airline before booking and again before travel. Requirements change frequently, and confirming your kennel size, hardware, and documentation multiple times will ensure a smooth travel experience.

My Hands-On Review of the Petmate Vari Kennel

Assembly & Build Quality

The Vari Kennel arrives in two nesting pieces. It took me less than 10 minutes to assemble using the included hardware. The plastic shell feels solid, and the metal door locks securely.

Overall, it’s simple, functional, and built for safety, which is exactly what Petmate is known for.

Comfort & Use With a Large Dog

Burt had plenty of space to lie down. I was also happy to see that the intermediate-size crate mat I already own fit perfectly in this kennel.

The built-in ventilation holes provide excellent airflow and visibility for your pet on all 4 sides.

Safety & Practicality for Travel

The Petmate Vari Kennel is built for both everyday use and travel, with tie-down strap holes that make it easy to secure in your vehicle or add extra stability when preparing for air travel.

Its durable, airline-friendly design meets most requirements for hard-sided kennels, but it’s important to note that many airlines require metal nuts and bolts rather than the standard plastic hardware. Swapping in metal fasteners is simple and ensures the kennel is fully compliant for flight.

Portability & Storage

The XL kennel does not have a top handle, unlike some smaller sizes. With an 80-pound dog inside, I wouldn’t use a handle anyway, but this is something to be aware of. Like most hard-sided crates, it’s bulky but manageable.

What I Love about the Vari Kennel

• Extremely durable
• Trusted by airlines Excellent ventilation
• Secure metal door
• Easy to clean
• Easy to assemble with no tools needed

What Could Be Better

• XL and Giant sizes may not fit assembled in smaller SUVs
• Not fully collapsible, so storage can be bulky
• May require airline-specific modifications
• No handle on larger sizes

Petmate Vari Kennel vs. Other Crates

Here’s how the Vari Kennel compares to other popular travel crates: Wire Crates: Not airline approved. Soft Carriers: For in-cabin travel only.

• Diggs Crates: Beautiful for home use, but not approved for cargo flights.
• Gunner Kennels: Extremely durable, but expensive (up to $900). Requires tools for assembly and is not simple to disassemble for storage.

Is the Petmate Vari Kennel Safe and Practical for Travel?

If you plan to fly with your dog in cargo, the Petmate Vari Kennel is one of the best choices available. It’s durable, airline-friendly, and designed with safety in mind from the original kennel brands on the market.

After testing it with my dog Burt, I can confidently recommend it to any pet parent preparing for air travel.

It’s also a great everyday crate for home or car travel, depending on the size you need.

Best For:

• Dogs traveling in airline cargo
• Medium to giant breeds
• Dogs who need a secure crate
• Pet parents who want durability and simplicity

Not Ideal For:

• In-cabin travel
• Those who need a collapsible crate for tight storage

Where to Buy & Pricing

Petmate makes it easy for pet parents to purchase the Vari Kennel. It is available on Amazon, Chewy, and Petmate. Depending on your dog’s size, prices range from $70 to $400, with smaller dogs in the lower range and larger or ultra models in the $ 350+ range.

Petmate offers replacement parts, including doors, handles, and hardware, directly on their site and through their online parts collections. Replacement hardware, such as tri-wing screws and nuts suitable for Vari Kennels, is available for purchase through Petmate's parts listings.

Petmate has a long-standing reputation for customer service, availability, and replacement support. Warranty coverage varies by product and retailer.

Final Verdict: Is the Petmate Vari Dog Kennel Worth It?

The Petmate Vari Kennel is a reliable, well-designed, time-tested travel crate that continues to set the standard for airline-approved kennels. It performs exactly the way a cargo-travel crate should: safe, sturdy, and built to meet most airline rules with minimal modification.

After testing this dog travel crate with my dog Burt, and having flown with large dogs before, I am confident recommending it to any pet parent preparing for air travel.

If you’re planning a trip with your dog, this kennel is absolutely worth considering. Just remember to double-check your airline’s specific requirements before you fly.

Note: The writer also included two short videos to be included in the review