TABLE OF CONTENTS
SECTION PAGE
INTRODUCTION xi
I. EXECUTIVE SUMMARY 1
II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Environment 4
Consumer Income & Spending Trends 7
Demographic & Household Trends 9
Manufacturing Outlook 12
Plastic Resin Outlook 15
Historical Market Trends 18
Injection Molding Machinery & Technology 20
Electric Machines 23
Co-Injection Technology 24
Gas-Assist Technology 25
Structural Foam Molding 27
Control Systems 28
Competitive Processing Methods 28
Regulatory Considerations 32
Recycling 33
Pricing Trends 34
International Activity & Foreign Trade 38
III. RESINS 40
General 40
Thermoplastic Resins 41
Polypropylene 43
Consumer 46
Packaging 47
Motor Vehicles 49
Other 50
High Density Polyethylene 50
Packaging 51
Nonpackaging 55
Polystyrene 57
Consumer 60
Packaging 61
Electrical & Electronic 62
Other 62
Low Density Polyethylene 63
ABS/SAN 66
Motor Vehicles 69
Consumer 70
Electrical & Electronic 71
Other 72
Polyvinyl Chloride 73
Polycarbonate 76
Electrical & Electronic 78
Motor Vehicles & Other 80
Nylon 81
Motor Vehicles 83
Electrical & Electronic 84
Industrial 84
Consumer 85
Other 85
Thermoplastic Polyester 86
Other Thermoplastic Resins 90
Thermoset Resins 92
Unsaturated Polyester 95
Phenolics 98
Urea 101
Melamine 102
Other Thermoset Resins 104
IV. MARKETS 106
General 106
Packaging 108
Packaging Outlook 108
Resins 111
Applications 114
Consumer Packaging 115
Caps & Closures 116
Polypropylene 119
Low Density Polyethylene 120
Polystyrene 120
Other Resins 121
Containers & Other Markets 121
Industrial Packaging 123
Consumer 126
Resins 127
Applications 129
Housewares & Personal Care Products 131
Appliance Outlook 134
Resins 135
Toys & Recreational 139
Other Consumer Markets 141
Motor Vehicles 143
Motor Vehicle Outlook 144
Resins 146
Vehicle Types 149
Applications 150
Producers 154
Electrical & Electronic 156
Electrical & Electronic Equipment Outlook 156
Resins 159
Applications 162
Housings 164
Components & Other 167
Medical 170
Medical Products Outlook 171
Applications & Resins 174
Construction 177
Building Construction Outlook 177
Applications 179
Resins 181
Industrial 183
Machinery Industry Outlook 183
Applications & Resins 184
Furniture & Furnishings 187
Furniture Industry Outlook 187
Applications & Resins 189
Other Markets 191
V. INDUSTRY STRUCTURE 194
General 194
Types of Molders 198
Market Share 200
Collins & Aikman 201
Delphi Automotive Plastics 202
Lear 202
Berry Plastics 203
Visteon 203
Plastech Engineered Products 203
Other Leaders 204
Mergers & Acquisitions 204
Marketing Strategies 209
Channels of Distribution 211
Research & Development 212
Competitive Strategies 214
Cooperative Agreements 216
Company Profiles 220
A&E Products Group, see Mainetti SpA
Alcoa Incorporated 221
Andover Industries Incorporated, see Plastech
Engineered Products Incorporated
AptarGroup Incorporated 223
Atlantic Automotive Components LLC, see Visteon
Automotive Components Holding LLC, see Ford Motor
Bemis Manufacturing Company 226
Berry Plastics Corporation 227
Blackhawk Automotive Plastics Incorporated 231
BWAY Corporation 232
Cadence Innovation LLC 233
Cascade Engineering Incorporated 234
CCL Dispensing Systems, see AptarGroup
CK Technologies LLC, see Cascade Engineering
Collins & Aikman Corporation 237
Covalence Specialty Materials Corporation 240
DDM Plastics, see Flex-N-Gate Corporation
Decade Products LLC, see Cascade Engineering
Decoma International Incorporated, see Magna International
Decostar Industries Incorporated, see Magna International
Delphi Corporation 241
Flex-N-Gate Corporation 243
Ford Motor Company 245
Goody Products Incorporated, see Newell Rubbermaid
Graco Children s Products Incorporated, see Newell
Rubbermaid
Guardian Industries Corporation 246
Guide Corporation 247
Ing. Erich Pfeiffer GmbH, see AptarGroup
InteSys Technologies, see Moll Industries
Johnson Controls Incorporated 248
Kerr Group Incorporated, see Berry Plastics
Key Plastics LLC 251
Lacks Enterprises Incorporated 252
Lear Corporation 254
Letica Corporation 256
LINPAC Group Limited 257
Mack Group Incorporated 258
Magna International Incorporated 259
Mainetti SpA 261
Maui Foodservice Packaging, see Letica
Meridian Automotive Systems Incorporated 262
Moll Industries Incorporated 263
Neaton Auto Products Manufacturing Incorporated, see
Nihon Plast Company Limited
Nescor Plastics Corporation, see Blackhawk Automotive
Plastics Incorporated
New Venture Holdings LLC, see Cadence Innovation LLC
Newell Rubbermaid Incorporated 265
Nihon Plast Company Limited 270
North America Packaging Corporation, see BWAY
Nypro Incorporated 271
NYX Incorporated 274
Olsonite Seat Company, see Bemis Manufacturing
Owens-Illinois Group Incorporated 275
Phillips Plastics Corporation 277
Plastech Engineered Products Incorporated 279
Plastic-Plate Incorporated, see Lacks Enterprises
Portola Packaging Incorporated 281
Profile Plastics LLC, see Nypro Incorporated
Pyper Products Corporation, see Cascade Engineering
Ropak Packaging, see LINPAC Group Limited
Sanford North America, see Newell Rubbermaid
Seaquist Closures LLC, see AptarGroup
Siegel-Robert Incorporated 283
Solo Cup Company 284
Sterilite Corporation 285
Sweetheart Cup Company Incorporated, see Solo Cup
Systex Corporation, see Cascade Engineering
Trend Technologies LLC 286
TrimQuest LLC, see Johnson Controls Incorporated and
Plastech Engineered Products Incorporated
Tubed Products LLC, see Berry Plastics
Tupperware Brands Corporation 287
21st Century Plastics Corporation, see Cascade
Engineering
Tyco International Limited 288
United Plastics Group Incorporated 290
Valois SA, see AptarGroup
Visteon Corporation 291
LIST OF TABLES
TABLE NUMBER PAGE
SECTION I -- EXECUTIVE SUMMARY
Summary Table
3
SECTION II -- MARKET ENVIRONMENT
1 Macroeconomic Indicators 7
2 Personal Consumption Expenditures 9
3 Residential Population & Households 12
4 Manufacturers Shipments 15
5 Plastic Resin Supply & Demand 17
6 Injection Molded Plastic Market, 1995-2005 19
7 Plastic Resin Demand by Process 31
8 Injection Molded Plastic Resin Pricing Trends 38
SECTION III -- RESINS
1 Injection Molded Plastics Demand by Type 41
2 Injection Molded Thermoplastics Demand by Resin 42
3 Injection Molded Polypropylene Demand by Market 45
4 Injection Molded High Density Polyethylene Demand
by Market 51
5 Injection Molded High Density Polyethylene Demand
in Packaging by Market 54
6 Injection Molded High Density Polyethylene Demand in
Nonpackaging by Market 56
7 Injection Molded Polystyrene Demand by Market 59
8 Injection Molded Low Density Polyethylene Demand
by Type & Market 65
9 Injection Molded ABS/SAN Demand by Type & Market 68
10 Injection Molded Polyvinyl Chloride Demand by Market 75
11 Injection Molded Polycarbonate Demand by Market 77
12 Injection Molded Nylon Demand by Market 82
13 Injection Molded Thermoplastic Polyester Demand by
Market 89
14 Other Injection Molded Thermoplastics Demand by Market92
15 Injection Molded Thermosets Demand by Resin 94
16 Injection Molded Unsaturated Polyester Demand by Market97
17 Injection Molded Phenolics Demand by Market 100
18 Injection Molded Urea Demand by Market 102
19 Injection Molded Melamine Demand by Market 103
20 Other Injection Molded Thermoset Demand by Market 105
SECTION IV -- MARKETS
1 Injection Molded Plastics Demand by Market 107
2 Packaging Shipments by Material 111
3 Packaging Markets for Injection Molded Plastics by Resin 114
4 Packaging Markets for Injection Molded Plastics by
Application 115
5 Consumer Packaging Markets for Injection Molded Plastics
by Product 116
6 Caps & Closures Markets for Injection Molded Plastics
by Resin 119
7 Containers & Other Packaging Markets for Injection
Molded Plastics by Resin 123
8 Industrial Packaging Markets for Injection Molded Plastics
by Product 126
9 Consumer Markets for Injection Molded Plastics by Resin 129
10 Consumer Markets for Injection Molded Plastics by
Application 130
11 Housewares & Personal Care Markets for Injection Molded
Plastics by Resin 133
12 Appliance Shipments 135
13 Appliance Markets for Injection Molded Plastics by Resin 138
14 Toys & Recreational Markets for Injection Molded Plastics
by Resin 141
15 Other Consumer Markets for Injection Molded Plastics
by Resin 143
16 Motor Vehicle Production & Sales 145
17 Motor Vehicle Markets for Injection Molded Plastics
by Resin 148
18 Motor Vehicle Markets for Injection Molded Plastics by
Vehicle Type 150
19 Motor Vehicle Markets for Injection Molded Plastics by
Application 153
20 Electrical & Electronic Equipment Shipments 158
21 Electrical & Electronic Markets for Injection Molded
Plastics by Resin 162
22 Electrical & Electronic Markets for Injection Molded
Plastics by Application 164
23 Electrical & Electronic Housing Markets for Injection
Molded Plastics by Resin 167
24 Component & Other Electrical & Electronic Markets for
Injection Molded Plastics by Market & Resin 170
25 Medical Product Shipments 173
26 Medical Markets for Injection Molded Plastics by Resin 176
27 Building Construction Expenditures 179
28 Construction Markets for Injection Molded Plastics by
Application 181
29 Construction Markets for Injection Molded Plastics
by Resin 182
30 Industrial Machinery & Equipment Shipments 184
31 Industrial Markets for Injection Molded Plastics by Resin 186
32 Furniture Shipments 189
33 Furniture & Furnishings Markets for Injection Molded
Plastics by Resin 191
34 Other Markets for Injection Molded Plastics by Resin 193
SECTION V -- INDUSTRY STRUCTURE
1 US Injection Molded Plastic Sales by Company, 2005 195
2 Selected Acquisitions & Divestitures 207
3 Selected Cooperative Agreements 218
LIST OF CHARTS
CHART NUMBER PAGE
SECTION II -- MARKET ENVIRONMENT
1 Plastic Resin Demand by Type, 2005 18
2 Injection Molded Plastic Market, 1995-2005 20
3 Plastic Resin Demand by Process, 2005 31
SECTION III -- RESINS
1 Injection Molded Thermoplastics Demand by Resin, 2005 43
2 Injection Molded Polypropylene Demand by Market, 2005 46
3 Injection Molded High Density Polyethylene Demand in
Packaging by Market, 2005 55
4 Injection Molded High Density Polyethylene Demand in
Nonpackaging by Market, 2005 57
5 Injection Molded Polystyrene Demand by Market, 2005 60
6 Injection Molded Low Density Polyethylene Demand
by Market, 2005 66
7 Injection Molded ABS/SAN Demand by Market, 2005 69
8 Injection Molded PVC Demand by Market, 2005 76
9 Injection Molded Polycarbonate Demand by Market, 2005 78
10 Injection Molded Nylon Demand by Market, 2005 83
11 Injection Molded Thermoplastic Polyester Demand by
Market, 2005 90
12 Injection Molded Thermoset Demand by Resin, 2005 95
13 Injection Molded Unsaturated Polyester Demand by Market,
2005 97
14 Injection Molded Phenolics Demand by Market, 2005 101
SECTION IV -- MARKETS
1 Injection Molded Plastics Demand by Market, 2005 107
2 Consumer Markets for Injection Molded Plastics by
Application, 2005 130
3 Motor Vehicle Markets for Injection Molded Plastics by
Application, 2005 153
SECTION V -- INDUSTRY STRUCTURE
1 US Injection Molded Plastic Market Share, 2005 201
