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Converted Flexible Packaging to 2019

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Date: 28-Oct-2015
No. of pages: 481
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US demand to exceed $20 billion in 2019

Demand for converted flexible packaging in the US is forecast to exceed $20 billion in 2019. The market will benefit from the inherent cost and performance advantages of lightweight bags and pouches. Further market penetration will be influenced by the incorporation of features aimed at enhancing the overall consumer experience, leading to higher retail volumes. Gains will also be driven by the need for value added barrier materials for enhanced product protection. Converted flexible packaging’s source reduction, space savings, and lower production and shipping costs will be increasingly advantageous in light of the growing importance among major retailers and packaged goods firms of supply chain sustainability as a competitive advantage.

Pouches to outpace bags

Growth for pouches will outpace the converted flexible average and will be fueled by continued opportunities for stand-up pouches stemming from function, sustainability, and marketing advantages over alternative packaging media. Also supporting gains will be the visual appeal of stand-up pouches on store shelves due to their large front-panel billboard spaces and the perception of pouches as a more contemporary packaging format than traditional container types, such as cans, bottles, and cartons. Newer constructions will provide expanded opportunities with heavier weight contents.

Bag demand will increase more slowly than that for pouches due to the presence of mature markets and competition from pouches and rigid formats such as clam-shells and blister packs. Above average prospects will exist in pharmaceutical and medical products, where advancements in sealing and protection, as well as strong handling capabilities, are driving gains. Beverage applications will experience solid gains due to the growing popularity of 1.5- and 3-liter sizes of bag-in-box packaging for higher quality wines.

In the pet food market, woven polypropylene (WPP) bags will capture a rising share of bulk and other larger-sized pack-ages based on their relatively low cost, high strength, and good performance with dry pet foods. Despite strong competition from stand-up pouches and WPP bags, multiwall paper bags will remain the largest material type for pet food bags. The addition of more complex closure mechanisms on bags will extend value to bags and spur sales.

Rigid packaging to lose share in food applications

In food applications, pouches and bags will continue to supplant rigid packaging. Advantages such as reclosability and easy opening have contributed to acceptance with a variety of food and beverage products. Advances in materials and barrier properties for multilayer flexible substrates provide converted flexible packaging a shelf life on par with rigid packages. The fastest growing food packaging markets for converted flexible packaging will be beverages, meat and related products, and pet food.

In nonfood applications, the pharmaceu-tical and medical product markets will record the most rapid gains, fortified by a steadily aging population, the significance of unit-of-use packaging, and improvements in barrier and ease-of-use properties. Growth in chemical applications will be aided by rising consumer interest in new flexible formats for laundry detergents, cleaning solutions, and personal care products that replace heavier rigid bottles. The increasing presence of spouts on pouches will im-prove their convenience.

Company Profiles

Profiles over 35 Industry players such as Bemis, Berry Plastics, Coveris, Mondi Group, Printpack, sealed Air & Sigma Plastics

Additional Information

This study examines the converted flexible packaging industry in the United States. Historical (2004, 2009, and 2014) data and forecasts for 2019 and 2024 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.

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 metalized 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.

Converted Flexible Packaging to 2019

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 13
Food & Beverage Industry Overview 16
Consumer Preferences 20
Distribution Trends 22
Retail Sales Outlook 24
Packaging Trends 28
Paper 30
Plastic 31
Metal 32
Glass & Wood 33
Performance 34
Aesthetics 35
Competitive Packaging 36
Pricing Trends 38
Technological Developments 42
Environmental & Regulatory Factors 46
International Outlook 50

III. Materials 54
General 54
Plastic Film 57
Polyethylene Film 60
Polypropylene Film 77
Polyester Film 89
Polyvinyl Chloride Film 96
Nylon Film 102
Polystyrene Film 105
Polyvinylidene Chloride Film 108
Biopolymer Films 110
Ethylene Vinyl Alcohol Film 116
Other Films 120
Paper 122
Kraft & Sulfite 123
Glassine & Greaseproof 133
Oiled & Waxed 138
Aluminum Foil 141

IV. Product & Market Overview 147
General 147
Bags 152
Pouches 156
Wraps & Other 160

V. Food Packaging 163
General 163
Meat & Related Products 167
Meat & Related Products Outlook 168
Converted Flexible Packaging Demand 170
Materials 176
Baked Goods 181
Baked Goods Outlook 182
Converted Flexible Packaging Demand 183
Materials 187
Snack Food 190
Snack Food Outlook 191
Converted Flexible Packaging Demand 193
Materials 196
Produce 200
Fresh Fruit & Vegetable Outlook 201
Converted Flexible Packaging Demand 203
Materials 207
Candy & Confections 211
Candy & Confections Outlook 212
Converted Flexible Packaging Demand 213
Materials 217
Pet Food 221
Pet Food Product Outlook 222
Converted Flexible Packaging Demand 223
Materials 229
Frozen Food 232
Frozen Food Outlook 232
Converted Flexible Packaging Demand 234
Materials 238
Dairy Products 241
Dairy Products Outlook 242
Converted Flexible Packaging Demand 244
Materials 249
Beverages 252
Beverage Products Outlook 252
Converted Flexible Packaging Demand 255
Materials 260
Grain Mill Products 261
Grain Mill Products Outlook 261
Converted Flexible Packaging Demand 263
Materials 265
Other Foods 267
Converted Flexible Packaging Demand 268
Materials 272

VI. Nonfood Packaging 275
General 275
Pharmaceuticals 277
Pharmaceuticals Industry Outlook 278
Converted Flexible Packaging Demand 281
Materials 286
Medical Products 290
Medical Products Outlook 290
Converted Flexible Packaging Demand 293
Materials 298
Agricultural & Horticultural Products 302
Agricultural & Horticultural Industry Outlook 302
Converted Flexible Packaging Demand 305
Materials 309
Chemicals 311
Chemical Products Outlook 311
Converted Flexible Packaging Demand 314
Materials 319
Paper & Textile Products 320
Paper & Textile Products Outlook 321
Converted Flexible Packaging Demand 324
Materials 328
Rack & Counter 331
Converted Flexible Packaging Demand 332
Materials 333
Other Nonfood Markets 335
Converted Flexible Packaging Demand 336
Materials 339

VII. Industry Structure 342
General 342
Market Share 345
Acquisitions & Divestitures 353
Marketing Strategies 357
Channels of Distribution 359
Research & Development 360
Competitive Strategies 363
Cooperative Agreements 365
Company Profiles 369
Amcor Limited 370
American Packaging Corporation 374
Ampac Packaging LLC 376
Bancroft Bag Incorporated 380
Bemis Company Incorporated 382
Berry Plastics Corporation 387
Bryce Corporation 389
Clear Lam Packaging Incorporated 391
Coating Excellence International LLC 394
Constantia Flexibles Group GmbH 395
Coveris Holdings SA 399
Cryovac, see Sealed Air Derprosa Film SL, see Taghleef Industries Dow Chemical Company 402
DuPont (EI) de Nemours 405
Expera Specialty Solutions LLC 408
FlexSol Packaging, see Sigma Plastics Group Graphic Packaging Holding Company 410
Honeywell International Incorporated 412
Hood Companies 414
Innovia Films Limited 417
InterFlex Group Incorporated 421
ISO Poly Films, see Sigma Plastics Group Jindal Poly Films Limited 423
Kuraray Company Limited 425
Liqui-Box Corporation 427
LLFLEX LLC 429
McNeely Plastics Products, see Sigma Plastics Group Mercury Plastics, see Sigma Plastics Group
Mitsubishi Chemical Holdings Corporation 432
Mondi Group 434
Monosol, see Kuraray
Next Generation Films Incorporated 440
Novolex 442
Omega Plastics, see Sigma Plastics Group Oracle Packaging, see LLFLEX Poly Plastics, see Sigma Plastics Group Printpack Incorporated 444
Prolamina Corporation 447
Republic Bag, see Sigma Plastics Group Santa Fe Packaging, see Sigma Plastics Group Scholle Corporation 449
Sealed Air Corporation 451
Shields Bag and Printing Company 454
Sigma Plastics Group 455
Sonoco Products Company 460
Southern Film Extruders, see Sigma Plastics Group Taghleef Industries LLC 462
Tara Plastics, see Sigma Plastics Group Toray Industries Incorporated 465
Tredegar Corporation 467
Wihuri Oy 470
Winpak, see Wihuri Wisconsin Film & Bag, see Novolex Additional Companies in Converted Flexible Packaging 473

List of Tables

Section I -- Executive Summary
Summary Table 3

Section II -- Market Environment
1 Macroeconomic Indicators 9
2 Population & Households 13
3 Personal Consumption Expenditures 16
4 Food & Beverage Shipments 19
5 Retail Sales 27
6 Packaging Supply & Demand 30
7 Selected Raw Material Prices 42

Section III -- Materials
1 Converted Flexible Packaging Material Demand by Type 56
2 Plastic Film Demand in Converted Flexible Packaging by Resin 59
3 Polyethylene Film Demand in Converted Flexible Packaging by Type & Market 64
4 Polyethylene Film Demand in Converted Flexible Food Packaging by Type & Market 65
5 Polyethylene Film Demand in Converted Flexible Nonfood Packaging by Type & 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 99
14 Polyvinyl Chloride Film Demand in Converted Flexible Nonfood Packaging 101
15 Nylon Film Demand in Converted Flexible Packaging by Market 105
16 Polystyrene Film Demand in Converted Flexible Packaging by Market 107
17 Polyvinylidene Chloride Film Demand in Converted Flexible Packaging by Market 110
18 Biopolymer Film Demand in Converted Flexible Packaging by Type & Market 116
19 Ethylene Vinyl Alcohol Film Demand in Converted Flexible Packaging by Market 119
20 Other Plastic Film Demand in Converted Flexible Packaging by Market 121
21 Paper Demand in Converted Flexible Packaging by Type & Market 123
22 Kraft & Sulfite Paper Demand in Converted Flexible Packaging by Market 126
23 Kraft & Sulfite Paper Demand in Converted Flexible Food Packaging 130
24 Kraft & Sulfite Paper Demand in Converted Flexible Nonfood Packaging 132
25 Glassine & Greaseproof Paper Demand in Converted Flexible Packaging by Market 135
26 Glassine & Greaseproof Paper Demand in Converted Flexible Food Packaging 137
27 Glassine & Greaseproof Paper Demand in Converted Flexible Nonfood Packaging 138
28 Oiled & Waxed Paper Demand in Converted Flexible Packaging by Market 141
29 Aluminum Foil Demand in Converted Flexible Packaging by Market 144

Section IV -- Product & Market Overview
1 Converted Flexible Packaging Demand by Type & Market 151
2 Bag Demand by Market 156
3 Pouch Demand by Market 160
4 Wraps & Other Converted Flexible Packaging Demand by Market 162

Section V -- Food Packaging
1 Food Packaging Markets for Converted Flexible Packaging 166
2 Meat & Related Products Consumption 170
3 Meat & Related Products: Converted Flexible Packaging Demand by Type 176
4 Meat & Related Products: Converted Flexible Packaging Demand by Material 181
5 Baked Goods Shipments 183
6 Baked Goods: Converted Flexible Packaging Demand by Type 186
7 Baked Goods: Converted Flexible Packaging Demand by Material 190
8 Snack Food Shipments 193
9 Snack Food: Converted Flexible Packaging Demand by Type 196
10 Snack Food: Converted Flexible Packaging Demand by Material 200
11 Fresh Produce Consumption 203
12 Produce: Converted Flexible Packaging Demand by Type 207
13 Produce: Converted Flexible Packaging Demand by Material 211
14 Candy & Confection Shipments 213
15 Candy & Confections: Converted Flexible Packaging Demand by Type 217
16 Candy & Confections: Converted Flexible Packaging Demand by Material 221
17 Pet Food Shipments 223
18 Pet Food Products: Converted Flexible Packaging Demand by Type 228
19 Pet Food Products: Converted Flexible Packaging Demand by Material 231
20 Frozen Food Shipments 234
21 Frozen Food: Converted Flexible Packaging Demand by Type 238
22 Frozen Food: Converted Flexible Packaging Demand by Material 241
23 Dairy Product Shipments 244
24 Dairy Products: Converted Flexible Packaging Demand by Type 249
25 Dairy Products: Converted Flexible Packaging Demand by Material 251
26 Beverage Shipments 254
27 Beverages: Converted Flexible Packaging Demand by Type 259
28 Beverages: Converted Flexible Packaging Demand by Material 261
29 Grain Mill Shipments 263
30 Grain Mill Products: Converted Flexible Packaging Demand by Type 265
31 Grain Mill Products: Converted Flexible Packaging Demand by Material 267
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 281
3 Pharmaceuticals: Converted Flexible Packaging Demand by Type 286
4 Pharmaceuticals: Converted Flexible Packaging Demand by Material 289
5 Medical Product Shipments 293
6 Medical Products: Converted Flexible Packaging Demand by Type 298
7 Medical Products: Converted Flexible Packaging Demand by Material 301
8 Selected Agricultural & Horticultural Indicators 305
9 Agricultural & Horticultural Products: Converted Flexible Packaging Demand by Type 309
10 Agricultural & Horticultural Products: Converted Flexible Packaging Demand by Material 311
11 Chemical Product Shipments 314
12 Chemicals: Converted Flexible Packaging Demand by Type 318
13 Chemicals: Converted Flexible Packaging Demand by Material 320
14 Paper & Textile Shipments 324
15 Paper & Textile Products: Converted Flexible Packaging Demand by Type 328
16 Paper & Textile Products: 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, 2014 344
2 Selected Acquisitions & Divestitures 356
3 Selected Cooperative Agreements 367

List of Charts

Section III -- Materials
1 Converted Flexible Packaging Material Demand by Type, 2014 57
2 Plastic Film Demand in Converted Flexible Packaging by Resin, 2014 60
3 Polyethylene Film Demand in Converted Flexible Food Packaging by Market, 2014 66
4 Polyethylene Film Demand in Converted Flexible Nonfood Packaging by Market, 2014 77
5 Polypropylene Film Demand in Converted Flexible Food Packaging, 2014 87

Section IV -- Product & Market Overview
1 Converted Flexible Packaging Demand by Type, 2014 152

Section V -- Food Packaging
1 Food Packaging Markets for Converted Flexible Packaging, 2014 167

Section VI -- Nonfood Packaging
1 Nonfood Packaging Markets for Converted Flexible Packaging, 2014 277

Section VII -- Industry Structure
1 US Converted Flexible Packaging Market Share, 2014 346

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