The USA sales of flexible plastic packaging are estimated to be worth USD 26,010.0 million in 2025 and anticipated to reach a value of USD 37,045.7 million by 2035. Sales are projected to rise at a CAGR of 3.6% over the forecast period between 2025 and 2035. The revenue generated by flexible plastic packaging in 2024 was USD 25,400.4 million. The industry is anticipated to exhibit a Y-o-Y growth of 3.3% in 2025.
The largest volume generator for the USA flexible plastic packaging market comes from the food and beverage sector, which forms a large percentage up to 56.2%, since packaged products are in great demand because of their longer shelf life, easy usage, and sustainability advantages.
Food product categories that use high-barrier films and Modified Atmosphere Packaging in the USA include fresh produce, frozen foods, and processed meals.
This company has counted in spouted pouches and shrink films for the beverage section, particularly juices, dairy products, and ready-to-drink energy beverages, to meet the demand of customers who consume light, easily handled products. They have also faced the challenges along with logistics - transportation efficiency and waste reduction.
USA Flexible Plastic Packaging Industry Assessment
| Attributes | Key Insights |
|---|---|
| Historical Size, 2024 | USD 25,400.4 million |
| Estimated Size, 2025 | USD 26,010.0 million |
| Projected Size, 2035 | USD 37,045.7 million |
| Value-based CAGR (2025 to 2035) | 3.6% |
Oil-based polymers are a leader in the USA flexible plastic packaging market because they are cost-effective and possess excellent material properties. They are being used extensively for films, wraps, pouches, and rigid packaging solutions. In films and wraps, polyethylene is the major choice, especially for moisture-sensitive items such as fresh produce and bakery products.
Polypropylene is widely used for pouches and rigid containers because it has excellent heat resistance and clarity, which allows it to be used for snack foods, frozen products, and beverages.
Since these materials can easily fit the high-speed production processes, their ability to cater to various packaging requirements has resulted in the high growth of this market. It is estimated that, by 2025, the USA flexible plastic packaging market would grow up to more than USD 12,094.7 million, with an enormous share of the entire country's packaging industries.
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The below table presents the expected CAGR for the USA flexible plastic packaging market over several semi-annual periods spanning from 2025 to 2035. In the first half (H1) of the decade from 2024 to 2034, the business is predicted to surge at a CAGR of 3.0%, followed by a higher growth rate of 4.2% in the second half (H2) of the same decade.
| Particular | Value CAGR |
|---|---|
| H1 | 3.0% (2024 to 2034) |
| H2 | 4.2% (2024 to 2034) |
| H1 | 2.6% (2025 to 2035) |
| H2 | 4.6% (2025 to 2035) |
Moving into the subsequent period, from H1 2024 to H2 2035, the CAGR is projected to decrease slightly to 2.6% in the first half and increase to 4.6% in the second half. In the first half (H1) the market witnessed a decrease of 40 BPS while in the second half (H2), the market witnessed an increase of 40 BPS.
Adoption of Recyclable Materials in the USA Flexible Plastic Packaging Industry
The USA flexible plastic packaging industry has gained more recycle quality as it leads ahead to join support for the environment. Major brand leaders including brands like PepsiCo and Unilever that set the first front in pioneering single-material pouches along with other varieties of plastics -based package structures have been well-embraced consumers demand for greener packaging options for circulation and nondeposition wastes from landfills.
Growth of E-commerce and Impact on Flexible Packaging
The e-commerce industry in the United States has been a major boost to the flexible plastic packaging market. E-commerce retailers require strong and protective packaging solutions to shield against the stresses of transportation, including bubble mailers and flexible polybags. Companies like Amazon and Walmart have taken lightweight, cost-effective packing solutions that can ensure the safe delivery of products while minimizing shipment costs and environmental impact.
Challenges in Recycling Flexible Plastic Packaging
Recycling flexible plastic packaging is a huge challenge even in the USA market. One of the reasons is that the multi-layered structures commonly used to provide improved barrier properties hinder recycling. Now, new technologies are emerging in the direction of developing single-material recyclable packaging solutions.
The real improvement, however, requires huge investment in recycling infrastructure. Consumer education is also crucial regarding appropriate disposal methods for the improvement of recycling rates.
The USA flexible plastic packaging industry recorded a CAGR of 2.4% during the historical period between 2020 and 2024. The growth of the flexible plastic packaging industry was positive as it reached a value of USD 25,400.4 million in 2024 from USD 23,101.5 million in 2020.
Increased adoption by the food and beverages industry, based on requirements in that area, such as longer shelf lives, ease in portability and consumer convenience for plastic packaging Flexible, mainly The market should be expected to continue shifting, especially towards solutions with recyclable and compostable packaging as more prominence is given on being sustainable; The market growth rate will exhibit an exponential scale till 2035, where consumer preference combined with environmental stringent regulations are continuously being increased.
With greater dependence on advancements in material technology and recycling capacities, future growth of flexible plastic packaging is poised. Because the importance given by brands towards green practices would increasingly require inclusion of flexible plastic packaging in the strategy for a sustainable product to address the requirement set by both regulators and consumers, sustainability becomes the continuing impetus behind a market which keeps itself changing in line with developing trends.
Tier 1 company leaders are characterized by high production technology and a wide product portfolio. These market leaders are distinguished by their extensive expertise in manufacturing and reconditioning across multiple packaging formats and a broad geographical reach, underpinned by a robust consumer base.
They provide a wide range of series including reconditioning, recycling, and manufacturing utilizing the latest technology and meeting the regulatory standards providing the highest quality. Prominent companies within Tier 1 include Berry Global Group, Inc., Sonoco Products Company, Amcor Group GmbH, Sealed Air Corporation, Novolex Holdings Inc.
Tier 2 companies are characterized by a strong presence overseas and strong market knowledge. These market players have good technology and ensure regulatory compliance but may not have advanced technology and wide USA reach. Prominent companies in Tier 2 include Printpack Inc., ProAmpac LLC, C-P Flexible Packaging, American Packaging Corporation, Sigma Plastics Group Inc.
Tier 3 includes the majority of small-scale companies operating at the local presence and serving niche markets. These companies are notably oriented towards fulfilling local market demands and are consequently classified within the tier 3 share segment.
They are small-scale players and have limited geographical reach. Tier 3, within this context, is recognized as an unorganized market, denoting a sector characterized by a lack of extensive structure and formalization when compared to organized competitors.
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The section contains information about the leading segments in the industry. By material type, oil base polymers are projected to grow at a CAGR of 3.9% through 2025 to 2035. Additionally, food end uses are predicted to grow at a CAGR of 5.1%.
| Packaging Type | Value Share (2035) |
|---|---|
| MAP (Modified Atmospheric Packaging) | 48.8% |
MAP in the United States is expected to be market leader, in terms of value. There is now a significant drive towards food safety and quality, with Modified Atmosphere Packaging being applied on premium foodstuffs like fresh poultry, seafood, and artisan cheeses. They ensure that there's a controlled atmosphere which keeps the food fresh and increases shelf life.
For instance, MAP is commonly applied in the United States in organic meat packaging as well as pre-cut meal kits that offer convenience along with quality maintenance. The pattern of using MAP is also going to expand with fresh-cut fruits and ready-to-eat meals following consumer demand for freshness and convenience.
| Product Type | Value Share (2035) |
|---|---|
| Films and Wraps | 34.8% |
Films and wraps are the largest products in flexible plastic packaging in the USA. These are widely used in baked goods, frozen foods, and fresh fruits and vegetables due to their superior moisture and oxygen barrier property. For instance, polypropylene films extensively find usage for snack packaging because they maintain crunchiness and freshness.
Stretch films are widely used in the logistics and industrial sectors to hold pallet loads in place and ensure products remain safe in transit. Following the USA's sustainability goals, the demand for recyclable and biodegradable films is rising to meet both consumer and regulatory expectations for more sustainable packaging options.
Key players operating in the flexible plastic packaging market are investing in the development of innovative sustainable solutions and also entering into partnerships. Key flexible plastic packaging providers have also been acquiring smaller players to grow their presence to further penetrate the flexible plastic packaging market across multiple regions.
Recent Industry Developments in the Flexible Plastic Packaging Market
In terms of product type, the industry is divided into pouches, bags & sacks, tubes, sleeve labels, and films & wraps.
In terms of material, the industry is segregated into oil base polymers and bio-plastics.
By packaging type, the market is divided into VSP (vacuum skin packaging), MAP (modified atmospheric packaging), and general barrier.
The market is classified by end use such as food, beverages, personal care, homecare, pharmaceuticals, industrial packaging, consumer packaging, and others.
Key countries of Northeast, Southwest, West, Southeast, and Midwest have been covered in the report.
The USA flexible plastic packaging industry is projected to witness CAGR of 3.6% between 2025 and 2035.
The USA flexible plastic packaging industry stood at USD 25,400.4 million in 2024.
The USA flexible plastic packaging industry is anticipated to reach USD 37,045.7 million by 2035 end.
Northeast sub-region region is set to record the highest CAGR of 4.4% in the assessment period.
The key players operating in the USA flexible plastic packaging industry include Berry Global Group, Inc., Sonoco Products Company, Amcor Group GmbH, Sealed Air Corporation, Novolex Holdings Inc.
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USA Flexible Plastic Packaging Market
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