The USA sales of blister packaging are estimated to be worth USD 6.6 billion in 2025 and anticipated to reach a value of USD 8.5 billion by 2035. Sales are projected to rise at a CAGR of 1.6% over the forecast period between 2025 and 2035. The revenue generated by blister packaging in 2024 was USD 6.4 billion. The industry is anticipated to exhibit a Y-o-Y growth of 1.4% in 2025.
Pharmaceutical applications lead in using blister packaging since a higher and more substantial percentage demand exists here as well with this increasing, greater need from prescriptions, mostly prescription drugs; a requirement would now include it having the options to be either tamper evident and/or resistant with possibly more as required including to be in sterilized containers as well.
The pharmaceutical end-use segment will hold more than 30% market share in the market valuation that reaches USD 2.1 billion by the end of 2025. Personal-care medicines will demand increasing, more health-related awareness will grow, and compliance with the regulatory packaging requirement will be enforced by the FDA due to stricter regulations.
USA Blister Packaging Industry Assessment
| Attributes | Key Insights |
|---|---|
| Historical Size, 2024 | USD 6.4 billion |
| Estimated Size, 2025 | USD 6.6 billion |
| Projected Size, 2035 | USD 8.5 billion |
| Value-based CAGR (2025 to 2035) | 1.6% |
The USA blister packaging market is moving ahead with great progress toward the adaptation of thermoforming technology. This technology benefits from cost-effective and versatile features, capable of offering high-quality customized packaging solutions. The demand for this technology is mainly for blister packs used in pharmaceutical products and consumer goods and electronics manufacturing.
This is because of the accurate molding of plastic materials such as PVC, PET, and PP that are often used in the packaging of tablets, capsules, and small consumer electronics. Such a technique and technology called Thermoforming are in demand in application examples where there would be massive output, consistent quality of products, and high speed.
This Technology or segment under it shall reach about 2.1% until 2025 wherein further demand from society shall call for strong safety, and product protection that shall differentiate by looks. It produces a lot of positives because it can be shaped into any desired shape with the needed material end, which in turn yields a high degree of flexibility along their respective lines in the packaging world.
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The below table presents the expected CAGR for the USA blister 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 1.4%, followed by a higher slight high growth rate of 1.8% in the second half (H2) of the same decade.
| Particular | Value CAGR |
|---|---|
| H1 | 1.4% (2024 to 2034) |
| H2 | 1.8% (2024 to 2034) |
| H1 | 0.2% (2025 to 2035) |
| H2 | 3.0% (2025 to 2035) |
Moving into the subsequent period, from H1 2025 to H2 2035, the CAGR is projected to decrease to 0.2% in the first half and increase to 3.0% in the second half. In the first half (H1) the market witnessed a decrease of 120 BPS while in the second half (H2), the market witnessed an increase of 120 BPS.
Blister Packaging Powers Nutraceutical Growth with Precision and Convenience
With this trend in the USA towards health and wellness, nutraceutical sales have skyrocketed significantly from years ago, especially in the vitamins and dietary supplement market. It has been caused and fueled solely by consumer demand to ensure their overall health, immune function, and individual health benefits through consumption of the products.
This sector has opted for large-scale proportions for blister packaging as it is thought to make sure that there is accurate dose to be taken by the consumer on a vitamin or supplement product. Blister packs are also good for single-dose packaging, which is convenient for hectic busy lifestyles. The product further ensures great protection against moisture, light, and air to assure the potency and freshness of supplements.
In a bid to provide consumers with increased convenience, safety, and product integrity among consumers, companies in the United States are beginning to shift towards blister packaging for vitamins and nutraceuticals. All these aspects become very important in an emerging health and wellness marketplace.
Blister Packaging Enhances Sterility and Safety in Medical Devices
An important driving factor in the adoption of blister packaging in the medical device industry is a higher demand in the medical device industry for sterile packaging. Since the growth of the healthcare sector, maintaining sterility and safety from medical devices have become significantly essential today.
This effective prevention of blister packing an item stops contaminants from touching the single use of medical devices, such as syringes, scalpels, or even diagnostic instruments for maintaining sterility in actual usage. Especially patient-contacting items come under a greater threat when the sterilization level drops since these may deteriorate one's health later. Medical device manufacturers, more so in places like the Midwest, have also used blister packaging to meet the demands of stringent regulation by the FDA.
Blister packaging ensures that these products are properly protected, and easy to manage, while the industry standards comply with all relevant regulations, thereby contributing to the enhanced safety of the patient and reliability of the product.
California's Waste Laws Challenge Blister Packaging Industry’s Sustainability Shift
The raging waste management laws of California-such as the California Recycling and Plastic Pollution Reduction Act-are being used to seek a massive decrease in plastic utilization, particularly of single-use plastics, amidst growing concerns on plastic pollution.
The most affected are those industries that rely on old blister packaging made of non-recyclable material, like PVC and PET in specific forms, because these are not easily recyclable and thus end up in landfill waste. In an effort to achieve the ambitious state sustainability goals, the blister packaging industry continues to feel pressure by the California state to switch its use of blister packs to environmentally more friendly alternatives, particularly recyclable or biodegradable, and failure to do so risks facing penalties and reputational loss.
This shift in direction toward eco-friendly packaging needs must be carried out, where cost-effective plastics in blister-based packaging have given in to more challenging business considerations regarding the longstanding protective properties and efficiency. Companies innovate in sustainable materials or invest in sustainable materials with the necessary change in policies toward state government rules.
The USA blister packaging industry recorded a CAGR of 1.3% during the historical period between 2020 and 2024. The growth of the blister packaging industry was positive as it reached a value of USD 6.4 billion in 2024 from USD 5.9 billion in 2020.
There is a growing demand for USA blister packaging from the pharmaceutical, food, and medical device industries. Demand of USA blister packaging increased in the last two years. The last two years witnessed gains from massive demand by pharmaceutical and healthcare companies for tamper-evident, child-resistant, and sterilized solutions.
Coupling with sectors of e-commerce and consumerism along with consumers' leaning towards an environmentally friendly form of packaging summed up to fuel further growth for the blister pack market. Extremity in the case of wellness through nutraceuticals received a lot of demand towards it, focusing precisely and surely in terms of packaging. All these are very good for the market in respect of sales forecasts even in USA since the packaging of this very high-technology goes to the packing.
The demand for blister packaging will surge in the near future as evolutionary opportunities along with a further rise in new consumer trends can be witnessed in the foreseeable future. More stringent rules toward environmental regulations of states like California along with increasing focus on sustainability as well as environment-friendly material will be highly important. More growth in demand is witnessed.
Again, blister packaging in the medical device and nutraceuticals segment drives demand. Cold forming and thermo-forming increase the packaging that boost the efficiency function of blister packaging for filling more growing needs of quality by cost-effectiveness. The technique might have further potential besides increasing the opportunities of the market of blister packaging.
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 Amcor PLC, Smurfit WestRock, Constantia Flexibles GmbH, Sonoco Products Company, DuPont de Nemours, Inc., and Klöckner Pentaplast Group.
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 Tekni-Plex, Inc., Blisterpak, Inc., Honeywell International Inc., and VisiPak.
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 technology, thermoforming technology are projected to grow at a CAGR of 2.1% through 2025 to 2035. Additionally, pharmaceutical end uses are predicted to grow at a CAGR of 2.5%.
| Material Type | Value Share (2035) |
|---|---|
| Plastics | 40.5% |
Plastics is going to command a major share by the way of Polyethylene Terephthalate, Polyvinyl Chloride and Polyethylene throughout the USA blister market value. This is according to the latest published research study with which it is assessed that the plastics blister segment was also estimated to develop by 1.8% of CAGR across the forecast years. According to the report, the market is expected to touch USD 2.5 billion by 2035, as demand for blister packaging in pharmaceutical, nutraceutical, and consumer goods industry increases.
The variety, cost efficiency, and capacity to protect materials from moisture, light, and air make plastics the preferred choice for blister packaging in the United States, and the market continues to grow further with increasing needs for compliance to regulations and preference for convenient, secure packaging products.
| Product Type | Value Share (2035) |
|---|---|
| Carded Blisters | 50.3% |
Carded blisters are the most demanded blister packaging products in the United States, which are mainly for pharmaceuticals, consumer goods, and electronics sectors. These carded blister packages provide great visibility of the products, tamper-evident, and a secure package; hence, the product can be used for wide applications.
The latest study also states that carded blisters have a 1.5% CAGR during the forecast period. The target segment for 2035 is going to be about USD 3.1 billion. This will mainly be a consequence of rising demand for convenient packaging that also satisfies the user by providing safe product integrity with regulations.
A major reason behind carded blisters being in the high demand chain of the American market is their affordability along with an openness to exhibit goods clearly, thereby making this carded blister option a primary requirement for various American brands.
Key players operating in the blister packaging market are investing in the development of innovative sustainable solutions and also entering into partnerships. Key blister packaging providers have also been acquiring smaller players to grow their presence to further penetrate the blister packaging market across multiple regions.
Recent Industry Developments in the Blister Packaging Market
In March 2024, ProAmpac, a leading flexible packaging manufacturer, acquired Gelpac, a producer of high-performance paper and poly products. This strategic acquisition enhances ProAmpac's capabilities in serving high-growth markets, including pharmaceuticals, by expanding its product portfolio and production capacity.
In terms of material type, the industry is divided into below plastic, aluminum, paper & paperboard, and others. Further plastics are classified as polyvinyl chloride (PVC), polyethylene terephthalate (PET), polyethylene (PE), and others.
In terms of product type, the industry is segregated into clamshell and carded.
By technology type, the market is divided into cold forming technology and thermoforming technology.
The market is classified by end use such as food, pharmaceutical, veterinary & nutraceutical, medical devices, electronics & electrical, industrial goods, and consumer goods.
Key countries of Northeast, Southwest, West, Southeast, and Midwest have been covered in the report.
The USA blister packaging industry is projected to witness CAGR of 1.6% between 2025 and 2035.
The USA blister packaging industry stood at USD 6.4 billion in 2024.
The USA blister packaging industry is anticipated to reach USD 8.5 billion by 2035 end.
Northeast sub-region is set to record the highest CAGR of 1.8% in the assessment period.
The key players operating in the USA blister packaging industry include Amcor PLC, Smurfit WestRock, Constantia Flexibles GmbH, Sonoco Products Company, DuPont de Nemours, Inc., and Klöckner Pentaplast Group.
| Estimated Size, 2025 | USD 29.3 billion |
| Projected Size, 2035 | USD 37.9 billion |
| Value-based CAGR (2025 to 2035) | 2.6% |
| Market Value (2024) | USD 7,114.7 million |
|---|---|
| Anticipated Market Value (2034) | USD 12,983.7 million |
| CAGR (2024 to 2034) | 5.70 % |
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USA Blister Packaging Market
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