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US demand for protective packaging is projected to increase 4.4% per year to $7.5 billion in 2024. Gains will be driven by:
While e-commerce has seen robust growth in the past decade, its share of retail sales remains fairly small, suggesting considerable room for further penetration. Going forward, e-commerce will continue to provide growth opportunities as consumers become more comfortable ordering fragile, high-value, and temperature-sensitive items – such as alcoholic beverages, groceries, pharmaceuticals, and consumer electronics – online. These items require added protection and thus more packaging to ensure safe transport.
However, e-commerce trends aimed at improving efficiency – e.g., right-sized and e-commerce ready packaging – will hinder faster growth.
Flexible protective packaging products, such as air pillows and protective mailers, are expected to register the fastest growth through 2024, in large part due to their dominance in e-commerce. In addition to air pillows, paper fill is seeing significant usage in e-commerce as it both performs well and is environmentally friendly. In manufacturing applications, flexible products are finding increased use due to their light weight and recyclability. Inflatable products can also be shipped flat in a manner similar to plastic films then inflated before use, increasing shipment and storage efficiency.
Despite widespread perception of the adverse environmental impact of foam products such as expanded polystyrene, the low cost, versatility, and strong performance characteristics of these products have helped them retain a significant market position in manufacturing applications. Specialized foam products such as insulated shipping containers for temperature-sensitive pharmaceuticals offer above average growth prospects.
However, sustainability trends will lead producers to increase use of paperboard protectors and molded pulp packaging, both of which are already widely employed in manufacturing applications because they are both made from recycled materials and recyclable:
Study Coverage
This study analyzes the following US protective packaging markets: durable goods manufacturing, nondurable goods manufacturing, e-commerce, and retail and other markets. Products covered include:
Historical data (2009, 2014, and 2019) and forecasts for 2024 are presented for protective packaging demand in current US dollars (including inflation). Sales are broken out by the above product types and markets, as well as by material (i.e., plastic, paper/paperboard, other). (E-commerce includes both sales by internet-only distributors and online sales made by brick-and-mortar establishments.)
The study also provides comprehensive corporate analysis including market share and competitive strategies. Additionally, it provides consumer insights based on proprietary consumer survey data and custom cross-tabs of licensed data, as well as analysis of key retail and marketing trends and innovative product introductions.
1. Executive Summary
2. Overview
Key Findings
Impact of COVID-19 Pandemic
Demand by Type
Historical Market Trends
Pricing Trends
Material Trends
Paper vs. Plastics
Demand by Material
Sustainability Goals Affecting Material Mix
Functions of Protective Packaging
Consumer Insights
Consumer Attitudes: Sustainable Packaging
Consumer Attitudes: Recycling & Environmental Responsibility
Consumer Attitudes: Recycling Packaging & Bags
Sustainability Trends
Packaging Waste Recovery
Recyclable & Biodegradable/Compostable Materials
Customization & Source Reduction
Packaging & Material Bans
E-Commerce Trends
Bricks & Clicks
Right-Sizing & Packaging Optimization
Reducing or Eliminating the Need for the Box
Legal & Regulatory Environment
Ozone-Depleting Blowing Agents
Polystyrene Feedstocks
California & New York City: End-of-Life Labeling & EPS Loose Fill
3. Protective Packaging Markets
Key Findings
Demand by Market
Durable Goods Manufacturing
Nondurable Goods Manufacturing
E-Commerce
E-Commerce: Market Size
E-Commerce: Demand by Product
Retail & Other Markets
4. Flexible Protective Packaging
Key Findings
Demand by Product
Flexible Protective Packaging Suppliers
Protective Mailers
Protective Mailers: Scope
Protective Mailers: Characteristics & Applications
Protective Mailers: Demand by Type & Market
Protective Mailers: Suppliers
Bubble Packaging
Bubble Packaging: Scope
Bubble Packaging: Characteristics & Applications
Bubble Packaging: Demand by Market
Bubble Packaging: Suppliers
Air Pillows
Air Pillows: Scope
Air Pillows: Characteristics & Applications
Air Pillows: Demand by Market
Air Pillows: Suppliers
Paper Fill
Paper Fill: Scope
Paper Fill: Characteristics & Applications
Paper Fill: Demand by Market
Paper Fill: Suppliers
Dunnage Bags
Dunnage Bags: Scope
Dunnage Bags: Characteristics & Applications
Dunnage Bags: Demand by Material & Market
Dunnage Bag: Suppliers
Surface Protection Films
Surface Protection Films: Scope
Surface Protection Films: Characteristics & Applications
Surface Protection Films: Demand Outlook
Surface Protection Film: Suppliers
Other Flexible Protective Packaging Products
Other Flexible Protective Packaging Products: Demand Outlook
Other Flexible Products: Suppliers
5. Foam Protective Packaging
Key Findings
Demand by Product
Foam Protective Packaging Suppliers
Insulated Shipping Containers
Insulated Shipping Containers: Scope
Insulated Shipping Containers: Characteristics
Insulated Shipping Containers: Applications
Insulated Shipping Containers: Demand by Application & Market
Insulated Shipping Containers: Suppliers
Molded Foam
Molded Foam: Scope & Characteristics
Molded Foam: Demand by Material & Market
Expanded Polystyrene Molded Foam: Demand Outlook
Polyolefin Molded Foam: Demand Outlook
Polyurethane Molded Foam: Demand Outlook
Molded Foams: Suppliers
Foam-in-Place Polyurethane
Foam-in-Place Polyurethane: Scope
Foam-in-Place Polyurethane: Characteristics & Applications
Foam-in-Place Polyurethane: Demand by Market
Foam-in-Place: Suppliers
Polyolefin Rolled Foam
Polyolefin Rolled Foam: Scope
Polyolefin Rolled Foam: Characteristics & Applications
Polyolefin Rolled Foam: Demand by Market
Polyolefin Rolled Foam: Suppliers
Loose Fill
Loose Fill: Scope & Characteristics
Loose Fill: Demand by Material & Market
Expanded Polystyrene Loose Fill: Demand Outlook
Biodegradable Plastic Loose Fill: Demand Outlook
Loose Fill: Suppliers
Other Foam Protective Packaging Products
Other Foam Protective Packaging Products: Demand Outlook
Other Foam Products: Suppliers
6. Rigid Protective Packaging
Key Findings
Demand by Type
Rigid Protective Packaging Suppliers
Paperboard Protectors
Paperboard Protectors: Scope
Paperboard Protectors: Characteristics & Applications
Paperboard Protectors: Demand by Market
Paperboard Protectors: Suppliers
Molded Pulp
Molded Pulp: Scope
Molded Pulp: Characteristics & Applications
Molded Pulp: Demand by Market
Molded Pulp: Suppliers
Other Rigid Protective Packaging Products
Other Rigid Protective Packaging Products: Demand by Market
Other Rigid Products: Suppliers
7. Industry Structure
Key Findings & Industry Composition
Market Share
Mergers & Acquisitions
Marketing & Distribution
Competitive Strategies
Cooperative Agreements
List of Industry Participants
8. Appendix
Scope
Definitions
Abbreviations
Freedonia Methodology
Study-Specific Methodology
Sources
Related Freedonia Group Studies
Macroeconomic Assumptions
Economic Environment
Demographics
Manufacturers' Shipments
Retail Sales & E-Commerce Outlook
2. Overview
Table 2-1 | Protective Packaging Demand by Type, 2009 - 2024 (million dollars)
Table 2-2 | Protective Packaging Demand by Material, 2009 - 2024 (million dollars)
Table 2-3 | Protective Packaging Product Functionality
Table 2-4 | Consumer Attitudes about Sustainable Packaging by Gender & Age Group, 2019 (percent of respondents)
Table 2-5 | Consumer Attitudes about Recycling & Environmental Responsibility by Gender, 2019 (percent of respondents & index)
Table 2-6 | Consumer Attitudes about Recycling & Sustainable Packaging by Gender & Age Group, 2019 (percent of respondents)
3. Protective Packaging Markets
Table 3-1 | Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Table 3-2 | Durable Goods Manufacturing Protective Packaging Demand by Type & Product, 2009 - 2024 (million dollars)
Table 3-3 | Nondurable Goods Manufacturing Protective Packaging Demand by Material & Product, 2009 - 2024 (million dollars)
Table 3-4 | E-Commerce Protective Packaging Demand by Type & Product, 2009 - 2024 (million dollars)
Table 3-5 | Retail & Other Markets Protective Packaging Demand by Type & Product, 2009 - 2024 (million dollars)
4. Flexible Protective Packaging
Table 4-1 | Flexible Protective Packaging Demand by Product, 2009 - 2024 (million dollars)
Table 4-2 | Flexible Protective Packaging: Selected Suppliers
Table 4-3 | Protective Mailers: Advantages, Disadvantages, & Key Applications
Table 4-4 | Protective Mailer Demand by Type & Market, 2009 - 2024 (million dollars)
Table 4-5 | Bubble Packaging: Advantages, Disadvantages, & Key Applications
Table 4-6 | Bubble Packaging Demand by Market, 2009 - 2024 (million dollars)
Table 4-7 | Air Pillows: Advantages, Disadvantages, & Key Applications
Table 4-8 | Air Pillow Demand by Market, 2009 - 2024 (million dollars)
Table 4-9 | Paper Fill: Advantages, Disadvantages, & Key Applications
Table 4-10 | Paper Fill Demand by Market, 2009 - 2024 (million dollars)
Table 4-11 | Dunnage Bags: Advantages, Disadvantages, & Key Applications
Table 4-12 | Dunnage Bag Demand by Material & Market, 2009 - 2024 (million dollars)
Table 4-13 | Surface Protection Films: Advantages, Disadvantages, & Key Applications
Table 4-14 | Surface Protection Film Demand, 2009 - 2024 (million dollars)
Table 4-15 | Other Flexible Protective Packaging Demand, 2009 - 2024 (million dollars)
5. Foam Protective Packaging
Table 5-1 | Plastic Foam Protective Packaging Demand by Product, 2009 - 2024 (million dollars)
Table 5-2 | Foam Protective Packaging: Selected Suppliers
Table 5-3 | Insulated Shipping Containers: Advantages, Disadvantages, & Key Applications
Table 5-4 | Insulated Shipping Container Demand by Application & Market, 2009 - 2024 (million dollars)
Table 5-5 | Molded Foam: Advantages, Disadvantages, & Key Applications
Table 5-6 | Molded Foam Protective Packaging Demand by Material & Market, 2009 - 2024 (million dollars)
Table 5-7 | Foam-in-Place Polyurethane: Advantages, Disadvantages, & Key Applications
Table 5-8 | Foam-in-Place Polyurethane Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Table 5-9 | Polyolefin Rolled Foam: Advantages, Disadvantages, & Key Applications
Table 5-10 | Polyolefin Rolled Foam Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Table 5-11 | Loose Fill: Advantages, Disadvantages, & Key Applications
Table 5-12 | Loose Fill Protective Packaging Demand by Material & Market, 2009 - 2024 (million dollars)
Table 5-13 | Other Plastic Foam Protective Packaging Demand, 2009 - 2024 (million dollars)
6. Rigid Protective Packaging
Table 6-1 | Rigid Protective Packaging Demand by Type, 2009 - 2024 (million dollars)
Table 6-2 | Rigid Protective Packaging: Selected Suppliers
Table 6-3 | Paperboard Protectors: Advantages, Disadvantages, & Key Applications
Table 6-4 | Paperboard Protector Demand by Market, 2009 - 2024 (million dollars)
Table 6-5 | Molded Pulp: Advantages, Disadvantages, & Key Applications
Table 6-6 | Molded Pulp Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Table 6-7 | Other Rigid Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
7. Industry Structure
Table 7-1 | US Protective Packaging Sales by Company, 2019 (million dollars)
Table 7-2 | Selected Mergers & Acquisitions
Table 7-3 | Selected Cooperative Agreements
Table 7-4 | Selected Industry Participants
8. Appendix
Table 8-1 | Study Scope: US Protective Packaging Products & Markets
Table 8-2 | Relevant HS Codes
Table 8-3 | Relevant Industry Codes
Table 8-4 | Abbreviations & Acronyms Used in Study
Table 8-5 | Macroeconomic Indicators, 2009 - 2024 (billion 2012 dollars)
Table 8-6 | Population & Households, 2009 - 2024 (million persons)
Table 8-7 | Manufacturers' Shipments, 2009 - 2024 (billion dollars & billion 2012 dollars)
Table 8-8 | Retail & E-Commerce Sales, 2014 - 2024 (billion dollars)
1. Executive Summary
Figure 1-1 | Key Trends in the US Protective Packaging Market
2. Overview
Figure 2-1 | Key Trends in the US Market for Protective Packaging
Figure 2-2 | Protective Packaging Demand by Market, 2009 - 2019 (million dollars)
Figure 2-3 | Protective Packaging Demand Share by Material, 2019 (billion dollars)
Figure 2-4 | Intertape Polymer Group & HexcelPack's Curby Mailer
Figure 2-5 | Ecovative Design's Mushroom-Based Foam Packaging
3. Protective Packaging Markets
Figure 3-1 | Key Trends for Protective Packaging Markets
Figure 3-2 | Durable Goods Manufacturing: Protective Packaging Demand Share by Type, 2009 - 2024 (million dollars)
Figure 3-3 | Nondurable Goods Manufacturing: Protective Packaging Demand Share by Type, 2009 - 2024 (million dollars)
Figure 3-4 | E-Commerce Share of Retail Sales & Annual Growth, 2014 - 2019 (percentage)
Figure 3-5 | E-Commerce Protective Packaging Demand Share by Type, 2009 - 2024 (million dollars)
Figure 3-6 | Retail & Other Markets: Protective Packaging Demand Share by Type, 2009 - 2024 (million dollars)
4. Flexible Protective Packaging
Figure 4-1 | Key Trends for Flexible Protective Packaging
Figure 4-2 | Protective Mailer Product Example
Figure 4-3 | Bubble Packaging Product Example
Figure 4-4 | Air Pillow Product Example
Figure 4-5 | Paper Fill Product Example
Figure 4-6 | Dunnage Bag Product Example
Figure 4-7 | Surface Protection Film Product Example
5. Foam Protective Packaging
Figure 5-1 | Key Trends for Foam Protective Packaging
Figure 5-2 | Insulated Shipping Containers Product Example
Figure 5-3 | Molded Foam Product Example
Figure 5-4 | Molded Foam Protective Packaging Demand Share by Material, 2009 - 2024 (million dollars)
Figure 5-5 | Expanded Polystyrene Molded Foam Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Figure 5-6 | Polyolefin Molded Foam Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Figure 5-7 | Polyurethane Molded Foam Protective Packaging Demand by Market, 2009 - 2024 (million dollars)
Figure 5-8 | Foam-in-Place Polyurethane Product Example
Figure 5-9 | Polyolefin Rolled Foam Product Example
Figure 5-10 | Loose Fill Product Example
Figure 5-11 | Loose Fill Protective Packaging Demand Share by Material, 2009 - 2024 (million dollars)
6. Rigid Protective Packaging
Figure 6-1 | Key Trends in Rigid Protective Packaging
Figure 6-2 | Paperboard Protectors Product Example
Figure 6-3 | Molded Pulp Product Example
7. Industry Structure
Figure 7-1 | US Protective Packaging Market Share by Company, 2019 (billion dollars)
Figure 7-2 | US Protective Packaging Market: Leading Supplier, 2019
Figure 7-3 | US Protective Packaging Market: Second Leading Supplier, 2019
Figure 7-4 | US Protective Packaging Market: Third Leading Supplier, 2019
Figure 7-5 | US Protective Packaging Market: Fourth Leading Supplier, 2019
8. Appendix
Figure 8-1 | Annual Growth in Real GDP, 2000 - 2019, Compared to 1980 - 2005 Average (percent)
Figure 8-2 | Annual Population Growth, 2004 - 2019 (percent)
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