The barrier packaging market size in USA is estimated to be worth USD 3,964.7 million in 2024 and is anticipated to reach a value of USD 5,503.9 million by 2034. Sales are projected to rise at a CAGR of 3.3% over the forecast period between 2024 and 2034.
The revenue generated by barrier packaging in 2023 was USD 3,854.7 million. The industry is anticipated to exhibit a Y-o-Y growth of 2.9% in 2024.
Barrier packaging materials and products are used to a larger extent across the food industry than in any other of the end-use industries. The food sector alone accounted for 62.6% of the total market share in 2024.
The reason for this is the essence and purpose of barrier packaging to offer the right amount of protection and preservation of the product without compromising on quality and freshness. Barrier packaging helps in the preservation of the food quality by creating a barrier to the elements, which include moisture, oxygen and light that can spoil the food quality.
USA Barrier Packaging Industry Forecast
| Attributes | Key Insights |
|---|---|
| Historical Size, 2023 | USD 3,854.7 million |
| Estimated Size, 2024 | USD 3,964.7 million |
| Projected Size, 2034 | USD 5,503.9 million |
| Value-based CAGR (2024 to 2034) | 3.3% |
Barrier packaging is used in numerous applications such as oxygen barriers, aroma barriers, and oil/grease barriers among others. Here, oxygen barriers are expected to lead the application within the segments and hold slightly above 57% of the total market share in the assessment period.
Oxygen is one of the primary causes of food spoilage. Oxygen when in contact with food products causes oxidation which leads to several antagonistic effects including discoloration and off-flavors, loss of nutritional value, and microbial proliferation.
In terms of packaging formats available in the market, stand-up pouches accounted for the largest share of 25.1% of the total market in 2024 compared to other packaging formats such as retort pouches, blister packs, flow wraps, sachets and many others.
This is primarily attributed to the scope of application and ease of use in sectors such as food, pharmaceutical, agro, and chemical industries. These pouches can be used for a variety of products and can be enhanced with the addition of resealable zippers and spouts for further optimization.
The barrier packaging market in the USA is set to experience profitable growth during the forecast period. It is projected to create an incremental opportunity of USD 1,649.2 million and is predicted to rise 1.4 times the current value through 2034.
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The below table presents the expected CAGR for the USA barrier packaging market over several semi-annual periods spanning from 2024 to 2034.
| Particular | Value CAGR |
|---|---|
| H1 | 3.2% (2023 to 2033) |
| H2 | 3.4% (2023 to 2033) |
| H1 | 3.1% (2024 to 2034) |
| H2 | 3.5% (2024 to 2034) |
In the first half (H1) of the decade from 2023 to 2033, the business is predicted to surge at a CAGR of 3.2%, followed by a slightly higher growth rate of 3.4% in the second half (H2) of the same decade. Moving into the subsequent period, from H1 2024 to H2 2034, the CAGR is projected to decrease slightly to 3.1% in the first half and remain relatively moderate at 3.5% in the second half. In the first half (H1) the market witnessed a decrease of 10 BPS while in the second half (H2), the market witnessed an increase of 10 BPS.
Rising Demand for Convenient Foods Boosts Barrier Packaging Market in USA
As daily schedules become more hectic, consumers are presented with the option of ready-to-eat foods that do not require long preparation times and facilitate eating on the move.
This trend is notable in particular because it has increased the demand for barrier packaging, which is important in keeping these products fresh, tasty and safe. Food is kept attractive and secure, due to the barrier packaging which protects food items from moisture, oxygen, and light.
Moreover, the inclination of consumers to eat healthy meals has led to the need for healthy meal boxes that are satisfactory meal solutions without losing their convenience. For this reason, the producers are focusing on value-added barrier packaging solutions to improve the product visibility system without violating any food safety law.
The food service represents around 25.6% of the overall sales of convenience stores in the country. This division includes convenience food types like ready meals, commissary food, and different hot, cold, and frozen drinks that always have high demand, as stated by National Association of Convenience Stores (NACS) in 2022.
The interrelationship of convenience, quality, and nutrition continues to expand the growth of consumer preferences thereby increasing the need for more advanced barrier packaging solutions in response to modern lifestyle needs.
Surging USA Pharma Exports Boost Demand for Barrier Packaging
As the exports of pharmaceuticals from the USA continue to increase, the use of more sophisticated barrier packaging systems has also risen. The distribution and storage of drugs in all regions of the world are mainly dependent on their packaging considering.
Many pharmaceutical products are sensitive to numerous environmental factors and may alter the formulations and also affect the functional capability. It is therefore understandable that export activities related to pharmaceutical goods call for appropriate packaging that would maintain the stability and effectiveness of the products along the supply chain.
These are specialized solutions that shield products from such forces and therefore enhance the quality and extend the shelf life of medicines in transportation.
The export of pharmaceutical preparations reached USD 90 billion in 2022 as per the study from Pharmaceutical Research and Manufacturers of America. These figures further indicate the necessity for better packaging that translates the need for international quality and regulatory standards barrier packaging formats.
The growth in exports has a direct relationship with the rising need for advanced barrier packaging solutions that are essential for the safety of products that are transported over long distances and through extreme climates. Consequently pushing the demand for barrier packing across regions in the USA
High Material Costs May Impede Barrier Packaging Growth
The high cost associated with barrier packaging is due to the use of complex multilayered films, special coatings, and high-performance plastics that are essential for protection against moisture, oxygen, and other such elements.
All these materials are effective but very expensive when compared with other primary packaging products. This is due to complicated production techniques and the multiple layers or specific coatings required to make their barrier properties. Furthermore, the prices of raw materials used to produce plastics and consumable coatings, as well as the coatings themselves, do not remain constant, because of risks such as global supply chain breakdowns, wars, and market downturns.
These factors lead to increased manufacturing costs which tend to increase the price of the end product, which makes barrier packaging an expensive form of packaging, especially for small and medium-sized enterprises (SMEs) with cost constraints. This may limit the adoption in any cost-sensitive industry and may hamper the growth of the barrier packaging market in the USA
The USA barrier packaging market recorded a CAGR 1.7% during the historical period between 2019 and 2023. Market growth of barrier packaging was positive as it reached a value of USD 3,854.7 million in 2023 from USD 3,602.0 million in 2019.
The period spanning from 2019 to 2023 saw the USA barrier packaging market grow at a steady rate of growth, which is attributed to increased consumer inclination towards convenience and longer shelf life of products.
Product innovation in terms of materials and design improved the protection of the products and met the needs of various industries such as food, drugs, and cosmetics.
Looking ahead over the forecast period, barrier packaging demand is expected to remain on the upswing. The reasons behind this include the drive towards sustainable practices, the growing and changing technology, as well as demand for superior product protection.
Improved concern for reducing food wastage as well as a paradigm shift from conventional to green materials and enhancing e-commerce activities are all anticipated to change the course of the market. These aspects will provide great opportunities for growth and innovation especially at the time when industries are keen to satisfy the consumers’ needs for ease and environmental friendliness.
Tier 1 companies comprise market leaders with a market revenue of above USD 200 million capturing significant market share of 33.7% - 36.3% in USA barrier packaging market. These market leaders are characterized by high production capacity and a wide product portfolio.
These market leaders are distinguished by their extensive expertise in manufacturing across multiple packaging formats and a broad geographical reach, underpinned by a robust consumer base.
They provide a wide range of series including 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., Sealed Air Corporation, Amcor plc and Novolex Holdings, LLC.
Tier 2 companies include mid-size players with revenue of USD 50 to 200 million having presence in specific regions and highly influencing the local market. These 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 global reach. Prominent companies in tier 2 include Graphic Packaging International, Huhtamäki Oyj, Winpak Ltd, and Mondi plc.
Tier 3 includes the majority of small-scale companies operating at the local presence and serving niche markets having revenue below USD 50 million. 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.
The section contains information about the leading segments in the industry. In terms of end use, food industry is estimated to account for a share of 64.7% by 2034. By barrier type, High Barrier (OTR <1cc/m2*day) segment is projected to dominate by holding a share of 40.7% by the end 2034.
| End Use | Food |
|---|---|
| Value CAGR (2034) | 3.7% |
The food industry among other end users is expected to lead the barrier packaging market during the forecast period. The food industry is anticipated to rise at a CAGR of 3.7%, generating an incremental growth opportunity worth USD 1,157.5 million by 2034.
The barrier packaging market in the USA is facing high demand prominently from the food industry as it prevents food products from relative humidity, oxygen, UV light and various other factors that compromise the quality and safety of the product.
These all help in preserving the moisture, freshness and nutritional status of food items by creating a barrier that prevents oxidation and spoilage. This helps in the extended shelf life of food products for long periods. This will lead to less or no food wastage. Furthermore, it also retains the flavor and protects food products from undesired adulteration of their taste, which is very important for different food items.
Since there is an increase in requests for food that is shelf-stable, convenient and low-processed, barrier packaging plays a pivotal role in meeting industry standards for safety and sustainability.
| Barrier Type | High Barrier (OTR <1cc/m2*day) |
|---|---|
| Value CAGR (2034) | 3.7% |
Within the barrier type segment, High Barrier (OTR <1cc/m2*day) is estimated to lead the barrier packaging industry in the USA It is anticipated to hold around 3.7% CAGR over the forecast period.
In the USA barrier packaging market, High Barrier Packaging has a growing preference due to its better protective characteristics and oxygen transmission rate of less than 1cc/m²*day. It restricts the permeability of gases and moisture within the packaging in a very effective manner ensuring that the products stay fresh and have a long shelf life which is especially important in the case of perishable products.
The use of high-barrier materials also increases the protection of delicate products fending off contamination and spoilage. The demand for quality and convenience from consumers is also growing. Therefore, barrier packaging manufacturers are becoming more concerned with high-barrier systems to achieve these objectives.
Furthermore, high-barrier packaging allows for longer shelf life and as a result less wastage due to spoilage, ensuring that the products remain in the form in which they are supposed to be during distribution and consumption, which makes it the most preferred packaging system by most sectors.
Key players of barrier packaging industry are developing and launching new products in the market. They are integrating with different firms and extending their geographical presence. Few of them are also collaborating and partnering with local brands and start-up companies for new product development.
Key Developments in USA Barrier Packaging Market
The USA barrier packaging industry is projected to witness CAGR of 3.3% between 2024 and 2034.
The USA barrier packaging industry stood at USD 3,854.7 million in 2023.
USA barrier packaging industry is anticipated to reach USD 5,503.9 million by 2034 end.
West is set to record a CAGR of 3.4% in assessment period.
The key players operating in the USA barrier packaging industry are Berry Global Group, Inc., Sealed Air Corporation, Amcor plc and Novolex Holdings, LLC.
Various packaging formats in the USA barrier packaging industry include stand-up pouches, retort pouches, vacuum bags, flow wraps, lidding films, sachets, blister packs, shrink wraps, pillow packs, gusseted bags, spouted pouches and bag-in-box.
Multiple materials used in USA barrier packaging market include metal film, plastic, biodegradable and paper. Metal film is further divided into aluminum foil and metallized film. Plastic is further sub-categorized into polyethylene, polypropylene, polyethylene terephthalate, polyvinylidene chloride, ethylene vinyl alcohol and nylon (polyamide). Also biodegradable is further divided into Polylactic acid and cellophane.
Some of the important barrier types in the USA barrier packaging market include low barrier (OTR100cc/m2*day), medium barrier (OTR20-50 cc/m2*day), moderate barrier (OTR<10cc/m2*day), high barrier (OTR <1cc/m2*day) and ultra-high barrier (OTR<0.1cc/m2*day).
Important applications of barrier packaging include oxygen barrier, aroma barrier and oil/grease barrier.
Some of end use industries in the USA barrier packaging market include food, healthcare, electrical & electronic, agriculture, chemicals, cosmetics and other industrial. The food segment in further divided into meat, seafood, poultry, baby food, snacks, bakery & confectionary, pet food, dairy food, ready to eat meals and other foods.
Key countries of Northeast, South West, West, South East AND Midwest are covered.
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USA Barrier Packaging Market
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