The Bemis Company (now Merged with Amcor) in New London, Wisconsin, was a forerunner developing multi-level films for flexible packaging for the high-barrier food, healthcare, and specialty packaging for pharmaceuticals. Amor has multiple plants across Wisconsin. Wisconsin is home to over 58 Flexible Packaging Companies with multiple plants across Wisconsin. The Wisconsin Flexible Packaging Industry and the Converting Industries are the leaders in the USA. The Converting Industry has over three hundred companies supporting the Packaging, Paper, Printing, and Corrugated Industries.
We have seen the growth of flexible packaging ranging from 6.25% – 8.25% CAGR with projected growth through 2035. The driving force is:
- Sustainability
- Low cost
- Growth of e-commerce
- Increasing demand for convenient ready-to-eat meals.
- Recycling
- Shelf-Life Extension
- New Material Developments
- Digital Technologies
- Mono-material to simplify recycling with the mechanical recycling processes.
- The demand for paper-based packaging where fiber recovery infrastructure and consumer perception strongly favor paper.
Market Snapshot & Key Metrics
- The U.S. Flexible Packaging Industry reached $42.6 Billion in Annual Sales in 2024
- CAGR Average (2026 – 2036) 7%
- Leading End Use: Food and Beverage 48.5% share, Pharmaceuticals, Healthcare, Personal Care, and Industrial Packaging.
- Top Market: PET (35.5% share)
- High-Growth Regions: Asia Pacific, North American, and Europe.
Stricter regulations now require greater transparency, use of recycled materials, and precise labeling. We are witnessing Europe leading the way with more pressure on the USA to put in place new regulation on industry. The industry is evolving because of changing consumer demand and pricing, driven by rising inflation pressures on consumers!
By using Sustainable materials and incorporating smart design, companies can significantly reduce the packaging on the environment, and human health. According to the EPA, packaging accounts for one- third of municipal waste generated in the USA. In the United States, plastic packaging accounts for 18% of waste, yet less than 14% is recycled. A UNEP report from 2023 states that more than 13,000 chemicals are associated with the production of plastics. These statistics illustrate the importance of designing sustainable packaging to minimize environmental and human health impacts. We will witness strong regulatory frameworks including packaging waste directives, circular economy policies, and recycled content targets. Customers awareness and established recycling infrastructure are reinforcing demand for innovative solutions to the packaging industry.
We have witnessed the Extended Producer Responsibility (EPR) with 7 U.S. States – California, Colorado, Maine, Minnesota, Maryland, Oregon, and Washington enacting mandatory EPR for packaging, moving from planning to active compliance.
