The form fill seal machine market is slated to register a CAGR of 3.4% over the period from 2024 to 2034. Demand is estimated to be worth USD 12.2 billion in 2024. By 2034, sales are anticipated to have reached USD 17.1 billion.
The primary factor driving the growth is the flourishing food and beverage sector. With the food packaging market set to reach near about USD 600 billion by 2034, there are numerous opportunities present. Makers of form-fill seal machines, also known as FFS, are capitalizing on these trends as these machines significantly reduce the burden of food sector customers, performing many functions simultaneously.
Form-filling sealing machines are recognized for their eco-friendly qualities. The savings in energy and reduction in plastic provided by these machines help customers fulfil sustainability goals. Manufacturers are going further and making their machines even more environmentally geared. For instance, Concetti Spa has optimized its FFS machines to save energy and be functional when handling biodegradable materials.
| Attributes | Description |
|---|---|
| Estimated Global Form Fill Seal Machine Market Size (2024E) | USD 12.2 billion |
| Projected Global Form Fill Seal Machine Market Value (2034F) | USD 17.1 billion |
| Value-based CAGR (2024 to 2034) | 3.4% |
Several countries across the globe, such as Brazil and Germany, are faced with labor shortages. This problem plagues the packaging industry too. Hence, FFS machines are being incorporated as machine’s multitasking reduce labor costs. These machines also help industrialists cope with high employee turnover.
Increasing demand for flexible packaging is another key factor benefitting the form-fill seal machine market. As online sales grow, the need for flexible packaging like bags, pouches, and containers is accumulating. FFS machines are well-equipped to deal with the growing demand for flexible packaging, producing goods in pouches and bags at a rapid rate.
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The table below highlights the CAGRs for the form fill seal machine market for the periods from 2023 to 2033 and 2024 to 2034. The periods are broken down into two semi-annual periods, the first half (H1) comprising January to June, while the second half (H2) comprises July to December.
For the 2023 to 2033 period, the CAGR for H1 is predicted to be 3.7%. A substantial decrease is predicted for H2 however, with the CAGR coming down to 3.3%.
| Particular | Value CAGR |
|---|---|
| H1 | 3.7% (2023 to 2033) |
| H2 | 3.3% (2023 to 2033) |
| H1 | 3.1% (2024 to 2034) |
| H2 | 3.6% (2024 to 2034) |
The CAGR for H1 is set to be 3.1% in the 2024 to 2034 period. Unlike the 2023 to 2033 period, however, H2 of the 2024-2034 period is set to see a substantial increase in CAGR, projected to be 3.6%.
Technological Advancement and Innovation to Fuel Form Fill Seal Machine Demand
The form-fill seal machine market relies on new innovative solutions to keep the demand flowing. Companies invest heavily in research and development to construct new machines that are faster and more efficient than before.
Horizontal form-fill sealing machines especially provide a playground for manufacturers to innovate. These machines are already recognized for their quickness and new technology is helping them become even speedier.
However, technology integration is not limited to horizontal versions of the machines as vertical versions too are becoming more efficient. For instance, Matrix unveiled its MVI-280E vertical form-fill-seal machine in May 2024. The machine is designed to handle bags 2 to 11 inches in width and 2 to 15 inches in length.
Application in the Pharmaceutical Industry to Improve FFS Machines’ Sales
While food packaging remains the primary end use for these machines, other industries also utilize FFS machines for their packaging. Prominent among them is pharmaceutical packaging.
Like food and beverage products, there is a strong emphasis on reducing contamination during the packaging process for pharmaceutical items. Form-fill seal machines prove ideal for this, their resistance to outside influences ensures the safety of the products in the packaging stage.
FFS machines also come in handy during the packaging of sterile products, where the risk of contamination is even more profound. Tablets, capsules, powders, and more pharmaceutical products are being increasingly packaged with the help of form-fill seal machines. Another application in the pharmaceutical sector is the packaging of I.V. infusion bottles.
Reduction of Down Time: Modern Machines Ease Maintenance
A problem with FFS machines that was highlighted earlier was the significant maintenance costs that needed to be undertaken. The time required for maintenance was also significant, leading to downtime and further increases in costs. However, manufacturers have addressed this shortcoming of the machines.
Techniques manufacturers have used to reduce downtime include making the product more compact and using lighter materials. This has led to machines that do not require constant maintenance, generally only once a year. This has led to more enterprises adopting FFS machines without worrying about downtime and maintenance costs.
Incompatibility with Materials Stunts Growth
There is a limitation to the type of materials that are handled by form-fill seal machines, which limits market growth itself. The most significant among the incompatible materials is paper.
Sustainability is a prominent concern in the packaging sector. There is growing disdain over and increasing sanctions over the use of plastic. A significant number of stakeholders are thus turning to eco-friendly alternatives such as paper. With FFS machines being best suited for plastic material and being unable to handle paper, eco-friendly customers are hesitant about adopting them.
Form-fill seal machines are also unsuitable for liquid packaging. Hence, a major portion of the food industry is cut off from the customer base. Other materials that the machine is ill-equipped to handle include aerated powders and multi-ply materials.
Principal Consultant
The form fill seal machine market was USD 10.8 billion in 2019. The market registered a CAGR of 2.3% during the historical period, ending up at USD 11.9 billion by 2023.
There were significant hurdles in the market’s path during the historical period but it was also a time for growth. Manufacturers came up with innovative products that took the packaging industry forward. For example, in 2022, ROVEMA GmbH launched REVO. The machine was advertised to form fill and seal 130 bags of frozen food per minute.
Another highlight was the expansion of facilities and scope for market players. For instance, in 2021, Scholle IPN invested in new horizontal form fill seal packaging equipment.
Tier 1 companies have taken giant strides in technology and research, allowing them to control a major portion of the share. A characteristic of tier 1 companies is their customers ranging far and wide, from food and beverage to pharmaceutical. Tier 1 companies like Bosch Packaging Technology and Tetra Pak have strong consumer retention as they come up with new products fast.
Compared to tier 1 companies, tier 2 companies are narrower in their approach. These companies focus on serving the specific needs of customers. For example, Sealed Air Corporation puts emphasis on serving its clients in the meat and dairy sectors. Another notable tier 2 company is Scholle IPN.
Tier 3 companies often focus on small-scale outfits, not unlike themselves. For instance, ACG Worldwide focuses on compact machines meant for small-scale production. PFM Packaging Machinery is another tier 3 enterprise focusing on flexibility and maneuverability.
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Horizontal Form, Fill, and Seal Machines (HFFS) have become the preferred version among customers. The food industry is where the product finds the most application.
| Segment | Horizontal Form, Fill, and Seal Machines (HFFS) (Machine) |
|---|---|
| Value Share (2024) | 69.6% |
Horizontal Form, Fill, and Seal Machines (HFFS) are estimated to account for 69.6% of the market share in 2024. In the era of automation, manufacturers prefer speed and efficiency. Compared to Vertical Form, Fill, and Seal Machines (VFFS), HFFS provides more speed. HFFS are able to pack stand-up pouches in a shorter amount of time as compared to VFFS, making them particularly useful when dealing with large loads.
Another driver for horizontal machines is the diversity of their applications. HFFS are suited to closure type bags and are also the go-to for heavy bags. They are also preferred for pouches, cartons, and bags with zippers or nozzles. Their diversity outshines that of VFFS and thus HFFS has earned the top spot over their competitor.
| Segment | Food (End Use) |
|---|---|
| Value Share (2024) | 71.9% |
Food industry is estimated to take up 71.9% of the market share in 2024. Safety is the priority for food companies when it comes to packaging and form-fill seal machines provide that in ample measure. These machines help ensure the food remains safe from contamination and unaltered in packaging.
The food industry relies on form-filled and sealed packaging for a myriad of products. From raw materials for food production like pulses and sugar to finished products like desserts and liquor, the application of the machine in the food sector is diverse. Hence, there is a continuing demand for form fill seal machines in the food industry.
Asia is set to be a lucrative region for stakeholders. The government-facilitated progress of the packaging sector is helping enterprises to thrive in various Asian countries. Europe is another significant region for progress. The continuous foreign investment and the expanding packaging facilities facilitate development in Europe.
| Countries | CAGR (2024 to 2034) |
|---|---|
| India | 4.9% |
| United States | 2.9% |
| China | 4.4% |
| Spain | 3.4% |
| Thailand | 4% |
The form fill seal machine market in India is estimated to register a CAGR of 4.9% over the forecast period. Sustainability is a key consideration for the packaging industry in India. Companies in the India’s form fill seal machine market are conscious of the commitment to sustainability.
Indian players are not only making their machines eco-friendly but also communicating with consumers their commitment to sustainability. For instance, UFlex partnered with the PHD Chamber of Commerce to organize the Global Sustainability Summit 2024. Through means, players of all sizes in India were encouraged to integrate sustainability into their working.
The United States market is anticipated to advance at a CAGR of 2.9% over the projected period. The market in the United States is a fast-moving one. With the packaging sector in the country seeing constant innovation, form-fill seal machines too are getting upgraded at a rapid rate in the country.
Expos like PACK EXPO Las Vegas keep the innovations coming. For example, TNA Solutions, originally based in Australia but with a significant presence in the United States, introduced its innovation at the 2024 version of the expo. The enterprise introduced the updated version of its Robag vertical form/fill/seal system, coming equipped with an automated splicing feature.
The Spain form fill seal machine market is set to register a CAGR of 3.4% over the period from 2024 to 2034. The Spanish market is advancing with the help of ever-expanding facilities as well as growing foreign investment. Collaboration is also a significant strategy for Spanish players.
Through partnerships with other packaging sector enterprises, Spanish companies are coming up with innovative products. For example, Barcelona-based Effytec Packaging teamed up with Dukane and Hoffer Plastics to develop a mono-material polyethylene (PE) packaging solution in 2024.
The form fill seal machine market is fairly fragmented. Although a few dominant companies have sway over a significant chunk of the market, there is room for players of all scales.
Acquisitions and partnerships are common. Giants hope to geographically expand and leverage opportunities through acquisitions. Collaborations are also common as enterprises look to take advantage of each other’s technological capabilities.
Key Industrial Developments
Based on the machine, the industry is divided into Vertical Form, Fill and Seal Machines (VFFS), and Horizontal Form, Fill and Seal Machines (HFFS).
Based on the automation, the form fill seal machine market can be divided into semi-automatic and automatic.
Based on the end use, the form fill seal machine market is divided into food and non-food. The food segment is further subdivided into chocolate & bars, cookies & crackers (biscuit), bakery, frozen, fresh produce, dairy, meat, and other foods. The non-food segment is further subdivided into healthcare, personal care & cosmetics, homecare, and cleaning & hygiene.
Based on the bag type, the form fill seal machine market can be divided into the following segments: pillow bags, gusseted bags, four-sided sealed bags, stick packs, central-seal bags, sachet bags, and vacuum bags.
The sector has been analyzed with the following regions covered: North America, Latin America, Europe, South Asia, East Asia, Oceania, and the Middle East and Africa.
The market was valued at USD 11.9 billion in 2023.
The market is set to reach USD 12.2 billion in 2024.
Global demand is anticipated to rise at 3.4% CAGR over the period from 2024 to 2034.
The industry is projected to reach USD 17.1 billion by 2034.
The market is slated to progress at 4.9% CAGR in India over the forecast period.
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