US Converted Flexible Packaging Report

Report Overview

US Flexible Packaging Market Advances Amid Cost, Equipment, and Sustainability Pressures

High upfront equipment investments, evolving material requirements, and consumer scrutiny of plastic waste are reshaping strategies in key growth categories such as pouches and skin packaging

Key Themes Covered in this Report:

• How sustainability mandates and consumer expectations are accelerating the shift to recyclable, compostable, and monomaterial flexible packaging
• Why growth in ready-to-eat meals, on-the-go snacking, and e-commerce is boosting demand for lightweight, resealable, and high-barrier flexible packaging formats
• The evolving role of flexible packaging in food, beverage, and pharmaceutical markets—balancing performance advantages with equipment investment needs and competition from alternative formats

Featuring 112 Tables & 73 Figures

Demand for converted flexible packaging reached $25.3 billion in 2024 and is forecast to increase 2.9% per year to $29.2 billion in 2029. Growth will be driven by:

• sustainability pressures, which are driving a shift to higher-value recyclable and compostable materials to meet EPR mandates and reduce regulatory costs
• the increasing popularity of premium features, such as high-barrier and resealable products
• faster growth in nonfood markets as flexible packaging gains share in household, pet care, and durable goods applications

Sustainability Pressures Are Accelerating Material Redesign

Extended Producer Responsibility (EPR) laws and rising retailer expectations are forcing a shift away from non-recyclable, multi-material laminates. Flexible packaging producers are responding by developing recyclable monomaterials and compostable formats that align with real-world recovery systems. While there will be steady growth across all product types, future competitiveness will depend on how successfully producers pivot to monomaterial and compostable options – particularly for pouches and bags, which make up the bulk of market demand. The regulatory environment is not only a risk factor but also a driver of long-term product transformation.

Value Over Volume: Premium Features Power Flexible Packaging Revenue

While volume gains will be steady, much of the industry’s recent revenue growth has come from higher per-pound pricing. This reflects rising input costs, but also greater use of value-added features such as resealability, high-quality graphics, and eco-friendly materials. As market expansion slows, packaging producers will need to differentiate not through scale alone but through functional and sustainable enhancements that justify premium pricing.

Nonfood Markets Offer New Growth Opportunities

As packaging requirements evolve, flexible packaging continues to expand beyond its traditional base in food markets. While food will remain the largest outlet for converted flexible packaging, nonfood applications are expected to increase their share of the market. Growth will be supported by greater use of flexible formats in household products, pet food, and consumer durables, where light weight, durability, and shipping efficiency are valued, particularly in e-commerce and omnichannel distribution. Products like chubs and skin packaging are also gaining popularity due to their protective properties and ability to enhance product presentation.

US Converted Flexible Packaging Report Details

Leading Companies Driving Trends in the US ConvertedFlexible Packaging  Industry

What Drives Flexible Packaging Demand in the US?

Demand for converted flexible packaging on a year-to-year basis is determined by a number of factors, primarily those related to the production and marketing of packaged goods. These activities, in turn, are influenced by:

• demographic trends such as age, average household size, and levels of disposable income
• the health of the overall economy
• changes in consumer incomes and spending on retail products
• changes in industrial production, especially in key sectors that rely on packaging for safety or product protection such as pesticides, construction materials, adhesives or coatings

In addition, a number of competitive variables determine the mix of packaging types used and their costs, including:

• competition from rigid packaging
• raw material costs and availability
• changes in the mix of products being packaged
• trends in packaging size and format, such as shifts toward smaller, single-use packages; family size units; or multipacks
• sustainability initiatives, including source reduction, the use of recycled content, and recyclability
• growth in e-commerce and packaging requirements for direct-to-consumer shipping
• consumer preferences based on factors such as convenience or functionality
• regulations such as extended producer liability (EPR) laws or restrictions on the use of certain types of packaging
• technological innovations making certain types of packaging more competitive

Converted Flexible Packaging Report Scope

This report analyzes the US converted flexible packaging market.

• Flexible packaging is defined as packaging made of flexible or easily yielding materials that can readily change shape – even when filled or closed.
• Flexible packaging is produced from paper, plastic film, aluminum foil, textiles, mesh, cellulose, or any combination of these materials.
• Products made from mixed materials are categorized by their primary material. For instance, a foil-lined plastic bag would be considered a plastic bag.

Nearly all flexible packaging is converted in some way from basic film, paper, or foil raw materials to create finished, functional packaging solutions. Converting operations include:

• cutting or slitting into individual units
• coating
• waxing
• laminating
• printing
• fabrication of bags, pouches, and other preformed packages

Flexible packaging products covered in the scope of this report include:

• bags and sacks, including liners
• pouches
• wrap
• other flexible packaging (such as skin packaging, chubs, lidding, strip packs, interleaving, flexible baking, candy and pastry cups and liners, and a variety of other flexible packages)

This study focuses on primary and secondary packaging and excludes most bulk and transit packaging. Other products excluded from the scope of this report include:

• foodservice disposable packaging, such as sandwich wrap or stretch wrap
• grocery store bags on a roll used in deli, produce or bakery departments
• household and institutional plastic storage bags
• flexible intermediate bulk containers (FIBCs)
• labels including shrink sleeve labels
• mailing envelopes (mailers)
• money bags
• novelty bags
• pallet wrap
• paper yard waste and refuse sacks
• protective packaging, such as bubble packaging or paper fill
• retail bags, also known as shopping bags, grocery bags, or merchandise bags
• rollstock
• sausage casings
• semi-rigid packaging
• stretch and shrink film for transport packaging
• tape
• trash bags

For packaging products that contain both flexible and rigid components, only the flexible portion of the package is counted in the scope of this report. For example, for bag-in-box systems only the flexible bladder is included here and for vacuum skin packaging only the flexible film components would be included.

Market segments are segmented by food and nonfood.

Food markets include:

• meat, poultry, and seafood
• baked goods
• snack food
• fresh produce
• candy and confections
• dairy products
• other foods, such as processed fruits and vegetables, grain mill products, baby food, coffee and tea, sauces and condiments, dry mixes, sugar, energy bars, spices, soups meal replacements and protein shakes, cannabis-infused foods, and meat alternatives

Nonfood markets include:

• pharmaceuticals
• medical products
• agricultural and horticultural
• pet food
• beverages
• chemicals
• paper and textile products
• rack and counter
• other nonfood (includes building materials, personal care products, auto chemicals, plastic and rubber products, tobacco products, leather goods, furniture, military supplies, and books)

Materials are segmented by:

• plastic
• paper
• aluminum foil
• other materials, including textiles, mesh, and cellophane