Converted Flexible Packaging to 2017

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Date: 30-Nov-2013
No. of pages: 477
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US demand to exceed $21 billion in 2017

Demand for converted flexible packaging in the US market is expected to rise 3.5 percent annually to more than $21 billion in 2017, or 9.1 billion pounds. Growth will be driven by the packaging market’s ongoing investment in specialty film and advanced materials for higher-value offerings. These offerings emphasize longer shelf life, performance features, source reduction and protection from outside contaminants. The converted flexible packaging market also is boasting greater acceptance from major brand owners. With a proliferation of new products on the retail market in a variety of niche applications, high volumes of a single package are not as critical, diminishing the advantages of rigid packaging and its ability to produce more packages at lower cost. Furthermore, consumer buying behavior also is playing a role, as shoppers demand packages offering portability and ease of handling. Recent market penetration in such categories as soups, condiments, baby food, noncarbonated beverages, foodservice containers, fresh-cut produce, and snack food bode well for continued gains.

Pouches to be fastest growing

The pouch market will continue to showcase above-average gains, penetrating segments that had once been considered hallmarks of rigid packaging. Standup pouches offer the most promise for growth in converted flexible packaging, and a large variety of new pouches with specialty features has entered the retail market. Bolstering the pouch’s repeated gains over rigid alternatives have been new technology introductions that include innovative fitments and closures and more sophisticated reseal features, which bring higher value to pouches. The use of thinner film, fewer coextrusion layers and laminates, and a new focus on recyclable materials are driving sustainability efforts and lowering production and freight costs. Many producers are considering mono-material structures that avoid the use of foil or other barrier materials, helping enhance production and potential recyclability. Advances in metalized and oriented films have improved both barrier and decorative qualities. The pet food market, once considered the province of multiwall bags, has become a key area of emphasis, as are snack foods, frozen food, confectionery, and meat and poultry. Pouches are expected to continue their rapid acceleration and take share from rigid packaging.

Bags to remain largest product segment

Bags, both in plastic- and paper-based materials, will not grow as quickly as pouches but represent the largest segment of converted flexible packaging. Many applications in this segment are stable and face limited competition from other materials, but they are also in maturing market sectors. Higher barrier and reclosability features and the high graphics appeal of certain films will help plastic bags record gains from multiwall paper alternatives, especially for pet food, home improvement, and lawn and garden products. New medical and pharmaceutical applications also offer ripe opportunities for bags. Paper bags will remain a stable, healthy format, and the material’s recyclability advantages and use of natural materials will help them continue to carve a strong niche among environmentally minded consumers. In overwraps, the advent of modified atmosphere packaging, perforated, and breathable structures has led to newer applications in meat and poultry and cheese packaging, helping stem the issue of food spoilage and align with safety concerns.

Company Profiles

Profiles for US industry players such as Bemis, Berry Plastics, Exopack, Graphic Packaging, Printpack and Sealed Air

Additional Information

This study examines the converted flexible packaging industry in the United States. Historical (2002, 2007, and 2012) data and forecasts for 2017 and 2022 are presented for materials, products, and markets. Data for products are presented in dollars and data for primary materials are presented in pounds, with data for markets presented in both dollars and pounds. Demand (apparent consumption) is defined as production plus imports less exports, and includes both captive and merchant markets. In addition, the key strategic and competitive variables affecting the US converted flexible packaging industry are discussed, and the industry’s key players are identified and profiled. US market share is also presented. The entire study is framed within the context of overall economic conditions, as well as developments and technologies affecting the converted flexible packaging industry and its end users.

Converted flexible packaging generally consists of a single ply or multiple plies of paper, plastic film, or foil (in various combinations) which are  laminated together by an adhesive system. Coextruded, oriented, and metallized plastic film is also included. Paper includes all grades and finishes except paperboard and molded pulp. Converting operations include coating, waxing, laminating, printing, and the fabrication of bags, pouches, and other preformed packages or rollstock that is converted into such forms. Slitting alone is not considered a converting process. Wrappers — which are unconverted flexible materials such as shrink and stretch film, plain film and foil wrapping paper, unbleached kraft paper, and related products — are also not included, although printed, coated, or otherwise converted overwraps are included. Data also do not encompass any uncoated single web paper, film, or foil that is neither preformed nor printed.

This study includes primary packaging only and excludes secondary and transport packaging. Primary packaging is defined as materials in direct contact with food or other products and which function to contain, protect, and store products for future consumption (e.g., pasta pouches or candy wrap). Also excluded are products such as retail, grocery and novelty bags and sacks; paper yard waste and refuse sacks; trash bags; household and institutional plastic storage bags and rolls of waxed paper, film, or foil; money bags; mailing envelopes; sausage casings; shrink sleeve and other labels; lidding; and foodservice disposable packaging, such as sandwich wrap or stretch wrap.

Converted Flexible Packaging to 2017

Table Of Contents

Introduction XIII

I.Executive Summary 1

II.Market Environment 4
General 4
Macroeconomic Outlook 5
Demographic & Household Trends 9
Consumer Income & Spending 12
Food & Beverage Industry Overview 15
Consumer Preferences 18
Distribution Trends 20
Retail Sales Outlook 22
Packaging Trends 26
Paper 29
Plastic 29
Metal 30
Glass & Wood 31
Performance 32
Aesthetics 33
Competitive Packaging Materials 34
Pricing Trends 36
Technological Developments 39
Environmental & Regulatory Factors 43
International Outlook 48

III.Materials 52
General 52
Plastic Film 56
Polyethylene Film 59
Polypropylene Film 77
Polyester Film 89
Polyvinyl Chloride Film 97
Nylon Film 102
Polystyrene Film 106
Polyvinylidene Chloride Film 109
Ethylene Vinyl Alcohol Film 111
Biopolymer Films 114
Other Films 120
Paper 123
Kraft & Sulfite 124
Glassine & Greaseproof 134
Oiled & Waxed 140
Aluminum Foil 143

IV.Product & Market Overview 148
General 148
Bags 154
Pouches 158
Other 163

V.Food Packaging 166
General 166
Meat & Related Products 171
Meat & Related Products Outlook 172
Converted Flexible Packaging Demand 174
Materials 180
Baked Goods 186
Baked Goods Outlook 187
Converted Flexible Packaging Demand 188
Materials 192
Snack Food 195
Snack Food Outlook 196
Converted Flexible Packaging Demand 198
Materials 201
Produce 205
Fresh Fruit & Vegetable Outlook 206
Converted Flexible Packaging Demand 208
Materials 211
Candy & Confections 214
Candy & Confections Outlook 215
Converted Flexible Packaging Demand 217
Materials 221
Frozen Food 224
Frozen Food Outlook 225
Converted Flexible Packaging Demand 227
Materials 231
Dairy Products 234
Dairy Products Outlook 234
Converted Flexible Packaging Demand 236
Materials 240
Pet Food 243
Pet Food Product Outlook 243
Converted Flexible Packaging Demand 245
Materials 248
Beverages 251
Beverage Products Outlook 252
Converted Flexible Packaging Demand 254
Materials 258
Grain Mill Products 260
Grain Mill Products Outlook 260
Converted Flexible Packaging Demand 262
Materials 264
Other Foods 266
Converted Flexible Packaging Demand 267
Materials 272

VI.Nonfood Packaging 275
General 275
Pharmaceuticals 277
Pharmaceuticals Industry Outlook 278
Converted Flexible Packaging Demand 279
Materials 285
Medical Products 289
Medical Products Outlook 290
Converted Flexible Packaging Demand 292
Materials 299
Paper & Textile Products 302
Paper & Textile Products Outlook 303
Converted Flexible Packaging Demand 306
Materials 310
Agricultural & Horticultural Products 312
Agricultural & Horticultural Industry Outlook 313
Converted Flexible Packaging Demand 315
Materials 319
Chemicals 321
Chemical Products Outlook 321
Converted Flexible Packaging Demand 324
Materials 330
Rack & Counter 331
Converted Flexible Packaging Demand 332
Materials 334
Other Nonfood Markets 335
Converted Flexible Packaging Demand 336
Materials 339
VII.Industry Structure 342
General 342
Market Share 345
Acquisitions & Divestitures 354
Marketing Strategies 359
Channels of Distribution 360
Research & Development 361
Competitive Strategies 365
Cooperative Agreements 366
Company Profiles 371
Accutech Films, see Hilex Poly Amcor Limited 372
American Packaging Corporation 376
American Synthetics, see Hood Companies Ampac Packaging LLC 378
Applied Extrusion Technologies, see Taghleef Industries Bancroft Bag Incorporated 381
Bemis Company Incorporated 383
Berry Plastics Corporation 388
Bryce Corporation 392
Cedex Plastics, see Coveris Clear Lam Packaging Incorporated 394
Clondalkin Group Holdings BV 396
Coating Excellence International LLC 397
Constantia Flexibles Group GmbH 399
Coveris 402
Cryovac, see Sealed Air Curwood, see Bemis Cyber Graphics, see Bryce Dow Chemical Company 407
DuPont (EI) de Nemours 409
Excel-Pac, see Prolamina Exopack Holding, see Coveris Expera Specialty Solutions LLC 413
Exxon Mobil Corporation 415
FlexSol Packaging, see Sigma Plastics Fortune Plastics, see Hilex Poly Graphic Packaging Holding Company 418
Hilex Poly Company LLC 420
Honeywell International Incorporated 422
Hood Companies 424
Innovia Films Limited 427
InterFlex Group Incorporated 430
ISO Poly Films, see Sigma Plastics Jen-Coat, see Prolamina Johnson Bryce, see Bryce Kuraray Company Limited 432
Liqui-Box Corporation 434
McNeely Plastic Products, see Sigma Plastics Mercury Plastics, see Sigma Plastics Milprint, see Bemis Mitsubishi Chemical Holdings Corporation 435
Monarch Imaging, see Bryce Mondi Group 437
MonoSol, see Kuraray Noltex, see Mitsubishi Chemical Holdings Nordenia International, see Mondi Omega Plastics, see Sigma Plastics Oracle Packaging Incorporated 441
Perfecseal, see Bemis Poly Plastics, see Sigma Plastics Printpack Incorporated 443
Prolamina Corporation 445
Republic Bag, see Sigma Plastics Santa Fe Packaging, see Sigma Plastics Scholle Corporation 447
Sealed Air Corporation 450
Shields Bag and Printing Company 452
Sigma Plastics Group 454
Sonoco Products Company 457
Taghleef Industries LLC 459
Terphane Holdings, see Tredegar Thilmany, see Expera Specialty Solutions Toray Industries Incorporated  462
Tredegar Corporation 464
Vacumet, see Scholle Wausau Specialty Papers, see Expera Specialty Solutions Wihuri Oy 466
Winpak, see Wihuri Additional Companies Mentioned in the Study 468

List Of Tables

Section I -- Executive Summary
Summary Table 3

Section II -- Market Environment
1 Macroeconomic Indicators 8
2 Population & Households 12
3 Personal Consumption Expenditures 15
4 Food & Beverage Shipments 18
5 Retail Sales 26
6 Packaging Supply & Demand 28
7 Selected Raw Material Prices 39

Section III -- Materials
1 Converted Flexible Packaging Material Demand by Type 55
2 Plastic Film Demand in Converted Flexible Packaging by Resin 58
3 Polyethylene Film Demand in Converted Flexible Packaging by Type & Market 63
4 Polyethylene Film Demand in Converted Flexible Food Packaging by Type & Market 65
5 Polyethylene Film Demand in Converted Flexible Nonfood Packaging by Market 76
6 Polypropylene Film Demand in Converted Flexible Packaging by Type & Market 81
7 Polypropylene Film Demand in Converted Flexible Food Packaging 86
8 Polypropylene Film Demand in Converted Flexible Nonfood Packaging 89
9 Polyester Film Demand in Converted Flexible Packaging by Market 91
10 Polyester Film Demand in Converted Flexible Food Packaging 94
11 Polyester Film Demand in Converted Flexible Nonfood Packaging 96
12 Polyvinyl Chloride Film Demand in Converted Flexible Packaging by Market 98
13 Polyvinyl Chloride Film Demand in Converted Flexible Food Packaging 100
14 Polyvinyl Chloride Film Demand in Converted Flexible Nonfood Packaging 102
15 Nylon Film Demand in Converted Flexible Packaging by Market 106
16 Polystyrene Film Demand in Converted Flexible Packaging by Market 108
17 Polyvinylidene Chloride Film Demand in Converted Flexible Packaging by Market 111
18 Ethylene Vinyl Alcohol Film Demand in Converted Flexible Packaging by Market 114
19 Biopolymer Film Demand in Converted Flexible Packaging by Type & Market 120
20 Other Plastic Film Demand in Converted Flexible Packaging by Market 122
21 Paper Demand in Converted Flexible Packaging by Type & Market 124
22 Kraft & Sulfite Paper Demand in Converted Flexible Packaging by Market 127
23 Kraft & Sulfite Paper Demand in Converted Flexible Food Packaging 131
24 Kraft & Sulfite Paper Demand in Converted Flexible Nonfood Packaging 133
25 Glassine & Greaseproof Paper Demand in Converted Flexible Packaging by Market 136
26 Glassine & Greaseproof Paper Demand in Converted Flexible Food Packaging 139
27 Glassine & Greaseproof Paper Demand in Converted Flexible Nonfood Packaging 140
28 Oiled & Waxed Paper Demand in Converted Flexible Packaging by Market 142
29 Aluminum Foil Demand in Converted Flexible Packaging by Market 145

Section IV -- Product & Market Overview
1 Converted Flexible Packaging Demand by Type & Market 153
2 Bag Demand by Market 158
3 Pouch Demand by Market 163
4 Other Converted Flexible Packaging Demand by Market 165

Section V -- Food Packaging
1 Food Packaging Markets for Converted Flexible Packaging 170
2 Meat & Related Products Consumption 174
3 Meat & Related Products: Converted Flexible Packaging Demand by Type 180
4 Meat & Related Products: Converted Flexible Packaging Demand by Material 186
5 Baked Goods Shipments 188
6 Baked Goods: Converted Flexible Packaging Demand by Type 192
7 Baked Goods: Converted Flexible Packaging Demand by Material 195
8 Snack Food Shipments 198
9 Snack Food: Converted Flexible Packaging Demand by Type 201
10 Snack Food: Converted Flexible Packaging Demand by Material 205
11 Fresh Produce Consumption 207
12 Produce: Converted Flexible Packaging Demand by Type 211
13 Produce: Converted Flexible Packaging Demand by Material 214
14 Candy & Confection Shipments 216
15 Candy & Confections: Converted Flexible Packaging Demand by Type 220
16 Candy & Confections: Converted Flexible Packaging Demand by Material 224
17 Frozen Food Shipments 226
18 Frozen Food: Converted Flexible Packaging Demand by Type 230
19 Frozen Food: Converted Flexible Packaging Demand by Material 233
20 Dairy Product Shipments 236
21 Dairy Products: Converted Flexible Packaging Demand by Type 240
22 Dairy Products: Converted Flexible Packaging Demand by Material 242
23 Pet Food Shipments 244
24 Pet Food Products: Converted Flexible Packaging Demand by Type 248
25 Pet Food Products: Converted Flexible Packaging Demand by Material 251
26 Beverage Shipments 253
27 Beverages: Converted Flexible Packaging Demand by Type 258
28 Beverages: Converted Flexible Packaging Demand by Material 260
29 Grain Mill Shipments 262
30 Grain Mill Products: Converted Flexible Packaging Demand by Type 264
31 Grain Mill Products: Converted Flexible Packaging Demand by Material 266
32 Other Foods: Converted Flexible Packaging Demand by Type 272
33 Other Foods: Converted Flexible Packaging Demand by Material 274

Section VI -- Nonfood Packaging
1 Nonfood Packaging Markets for Converted Flexible Packaging 276
2 Pharmaceutical Supply & Demand 279
3 Pharmaceuticals: Converted Flexible Packaging Demand by Type 285
4 Pharmaceuticals: Converted Flexible Packaging Demand by Material 289
5 Medical Product Shipments 292
6 Medical Products: Converted Flexible Packaging Demand by Type 299
7 Medical Products: Converted Flexible Packaging Demand by Material 302
8 Paper & Textile Shipments 306
9 Paper & Textile Products: Converted Flexible Packaging Demand by Type 309
10 Paper & Textile Products: Converted Flexible Packaging Demand by Material 312
11 Selected Agricultural & Horticultural Indicators 315
12 Agricultural & Horticultural Products: Converted Flexible Packaging Demand by Type 319
13 Agricultural & Horticultural Products: Converted Flexible Packaging Demand by Material 321
14 Chemical Product Shipments 324
15 Chemicals: Converted Flexible Packaging Demand by Type 329
16 Chemicals: Converted Flexible Packaging Demand by Material 331
17 Rack & Counter: Converted Flexible Packaging Demand by Type 333
18 Rack & Counter: Converted Flexible Packaging Demand by Material 335
19 Other Nonfood Products: Converted Flexible Packaging Demand by Type & Application 339
20 Other Nonfood Products: Converted Flexible Packaging Demand by Material 341

Section VII -- Industry Structure
1 US Converted Flexible Packaging Sales by Company, 2012 344
2 Selected Acquisitions & Divestitures 357
3 Selected Cooperative Agreements 369

List Of Charts

Section III -- Materials
1 Converted Flexible Packaging Material Demand by Type, 2012 55
2 Plastic Film Demand in Converted Flexible Packaging by Resin, 2012 59
3 Polyethylene Film Demand in Converted Flexible Food Packaging by Application, 2012 66
4 Polyethylene Film Demand in Converted Flexible Nonfood Packaging by Application, 2012 77
5 Polypropylene Film Demand in Converted Flexible Food Packaging, 2012 87

Section IV -- Product & Market Overview
1 Converted Flexible Packaging Demand by Type, 2012 154

Section V -- Food Packaging
1 Food Packaging Markets for Converted Flexible Packaging, 2012 171

Section VI -- Nonfood Packaging
1 Nonfood Packaging Markets for Converted Flexible Packaging, 2012 277

Section VII -- Industry Structure
1 US Converted Flexible Packaging Market Share by Company, 2012 346

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