Protective Packaging to 2019

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Date: 23-Dec-2015
No. of pages: 313
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Demand to increase 4.9% per annum through 2019

Demand for protective packaging in the US is forecast to rise 4.9 percent per year to $6.8 billion in 2019, driven primarily by the robust outlook for Internet shopping. Continued economic recovery following the 2007-2009 recession will also provide opportunities for protective packaging. These factors will contribute to the growth for cost-effective packaging used to limit the effects of shock, vibration, temperature abuse, and other damaging effects during shipping and handling.

Flexible protective packaging to remain as leading type

Flexible protective packaging will continue to be the leading protective packaging type through 2019, as flexible products are highly prized for their light weight, versatility, and aesthetic advantages over other materials such as plastic foams. The category is comprised of items such as protective mailers, which are the leading protective packaging product, and air pillows, which are expected to show the most rapid gains as users in every market looking for ways to eliminate excess package weight and cost often opt for air pillows over loose-fill alternatives. Also included in this category are bubble packaging products, paper fill, and dunnage bags.

Foam products are the second leading protective packaging type, with insulated shipping containers posting the fastest gains. These products are traditionally manufactured from expanded polystyrene or polyurethane foam and are used to protect temperature-sensitive products such as pharmaceuticals and food. Rigid protective packaging will comprise the smallest share of demand, although green initiatives will lead to above average gains for molded pulp and other niche products that are substituted for molded foam products as concerns regarding the environmental sustainability of foams continue to stifle demand.

Manufacturing markets to continue as top applications

Despite continued advances by the nonmanufacturing sector, protective packaging applications in manufacturing markets will continue to lead in value terms. Healthy growth in durable goods manufacturing for products such as appliances, motor vehicle parts, and industrial machinery will contribute to a high level of demand for protective packaging for these products and others that require cushioning and bracing during shipment. Demand for protective packaging intended for nondurable goods manufacturing will be driven by growing specialized handling requirements for temperature-sensitive pharmaceuticals, leading to a greater need for insulated shipping

containers, products that can be manufactured from foam or a wide range of both flexible and rigid materials.

As the volume of products ordered online continues to grow, the number of shipments from both large retailers such as Amazon and small online marketplace contributors on sites such as Etsy will lead to rapid gains in demand for costeffective and visually appealing protective products for the Internet and catalog market. In addition, the burgeoning online grocery and meal delivery industry will drive demand for insulating material effective in controlling temperature but also environmentally friendly, as many consumers have concerns with the sustainability practices of these services.

Company Profiles

Profiles over 40 US industry players such as Pregis, Sealed Air, Storopack, Free-Flow Packaging International, Signode Industrial Group & WestRock

Additional Information

This study analyzes the protective packaging industry in the US. Historical data for 2004, 2009, and 2014 and forecasts for 2019 and 2024 are provided for flexible products (protective mailers, bubble packaging, air pillows, paper fill, dunnage bags, and other), rigid products (paperboard protectors, molded pulp, and other), and plastic foam products (molded foams, foam-in-place polyurethane, polyolefin rolled foam, insulated shipping containers, loose fill, and other). An overview is also presented for protective packaging by material (paper and paperboard, plastic foams, other plastics, other materials), function (cushioning, blocking and bracing, insulation, void fill, and wrapping), and market (manufacturing and non-manufacturing).

For the purposes of this study, demand by function is calculated based on the primary functions for each product, though many products may perform more than one function at a time. Historical and forecast sales are provided in current dollars and pounds. Excluded from the scope of this study are surface protection films and active insulated shipping containers employing electricity or other power sources to maintain a temperature-controlled environment inside an insulated enclosure. Retail packaging such as blister packs and clamshells are also excluded.

Protective Packaging to 2019

Table of Contents

Introduction IX

I. Executive Summary 1

II. Market Environment 4
General 4
Macroeconomic Outlook 5
Consumer Income & Spending Trends 9
Demographic Trends 12
Manufacturing Outlook 16
Electronic & Computer Trends 21
Appliance Trends 24
Retail Sales Outlook 26
E-commerce & Catalog Sales Outlook 30
Packaging Industry Outlook 35
Box Industry Outlook 37
Plastic Resin Outlook 40
Plastic Foams Outlook 44
Environmental Considerations 47
Regulatory Considerations 52
Pricing Trends 55
International Activity 58

III. Overview 61
General 61
Products 62
Materials 65
Functions 68
Cushioning 71
Blocking & Bracing 72
Insulation 73
Void Fill 75
Wrapping 77
Markets 78
Manufacturing 80
Non-Manufacturing 82

IV. Flexible Protective Packaging 85
General 85
Protective Mailers 88
Materials & Applications 91
Producers 92
Bubble Packaging 95
Materials & Applications 96
Producers 97
Air Pillows 100
Materials & Applications 102
Producers 103
Paper Fill 106
Materials & Applications 107
Producers 108
Dunnage Bags 111
Materials & Applications 112
Producers 113
Other Flexible Protective Packaging 114

V. Plastic Foam Protective Packaging 117
General 117
Insulated Shipping Containers 120
Materials & Applications 122
Producers 125
Molded Foam 128
Expanded Polystyrene 129
Materials & Applications 131
Producers 133
Polyolefins 136
Materials & Applications 137
Producers 138
Polyurethane 141
Materials & Applications 142
Producers 143
Foam-in-Place Polyurethane 144
Materials & Applications 145
Producers 146
Polyolefin Rolled Foam 148
Materials & Applications 149
Producers 149
Loose Fill 152
Expanded Polystyrene Loose Fill 153
Biodegradable Plastic Loose Fill 156
Other Foams 159

VI. Rigid Protective Packaging 162
General 162
Paperboard Protectors 164
Materials & Applications 165
Producers 168
Molded Pulp 171
Materials & Applications 173
Producers 174
Other Rigid Protective Packaging 175

VII. Industry Structure 178
General 178
Market Share 182
Acquisitions & Divestitures 188
Marketing & Distribution 192
Competitive Strategies 196
Cooperative Agreements 198
Company Profiles 202
ACH Foam Technologies LLC 203
Alpek SAB de CV 205
American Excelsior Company 206
Automated Packaging Systems Incorporated 208
Barnhardt Manufacturing Company 210
BASF SE 211
Bayer AG 212
Buckeye Corrugated Incorporated 213
Caraustar Industries Incorporated 215
Carpenter Company 218
Cascades Incorporated 219
Cellofoam North America Incorporated 224
Cold Chain Technologies Incorporated 226
Ecovative Design LLC 229
Foam Fabricators Incorporated 231
Free-Flow Packaging International Incorporated 232
Great Northern Corporation 235
Hexacomb, see Packaging of America Huntington Foam LLC 237
Huntsman Corporation 238
Induspac, see Specialized Packaging Group iVEX Protective Packaging, see Specialized Packaging Group Jarden Corporation 240
Landaal Packaging Systems Incorporated 242
LEWISBINS+, see Menasha Lifoam Industries, see Jarden Marko Foam Products Incorporated 243
Menasha Corporation 245
Newark Group, see Caraustar Industries Novacel, see Chargeurs NOVA Chemicals Corporation 247
ORBIS, see Menasha Packaging Corporation of America 249
Polar Tech Industries Incorporated 251
Polyair Inter Pack Incorporated 253
Pregis Corporation 255
Protective Packaging Solutions LLC 260
Ranpak Corporation 261
RAPAC, see Ring Companies Ring Companies 263
Rogers Foam Corporation 265
RTS Packaging, see Sonoco Products and WestRock Sealed Air Corporation 266
Signode Industrial Group LLC 273
Smurfit Kappa Group plc 277
Sonoco Products Company 281
Specialized Packaging Group LP 284
SP Fiber Holdings, see WestRock Storopack Hans Reichenecker GmbH 287
Styropek USA, see ALFAB TCP Reliable Incorporated 291
Tharco Packaging, see Packaging of America 3M Company 293
True Pack Limited 295
UFP Technologies Incorporated 296
Valley Container Incorporated 299
WestRock Company 301
Additional Companies in Protective Packaging 305

List of Tables

Section I -- Executive Summary
Summary Table 3

Section II -- Market Environment
1 Macroeconomic Indicators 9
2 Personal Consumption Expenditures 12
3 Population & Households 16
4 Manufacturers’ Shipments 20
5 Electronic & Computer Product Shipments 24
6 Major Household Appliance Shipments 26
7 Retail Sales 30
8 E-commerce & Mail Order Shopping Sales by Type & Product 34
9 Packaging Supply & Demand 37
10 Corrugated & Paperboard Box Shipments by Type 40
11 Plastic Resin Supply & Demand 44
12 Plastic Foams Demand by Resin 47
13 Protective Packaging Prices 58

Section III -- Overview
1 Protective Packaging Demand by Type 64
2 Protective Packaging Demand by Material 67
3 Protective Packaging Demand by Function 70
4 Protective Packaging Demand by Market 79
5 Manufacturing Market for Protective Packaging 82
6 Non-manufacturing Market for Protective Packaging 84

Section IV -- Flexible Protective Packaging
1 Flexible Protective Packaging Demand by Type 87
2 Protective Mailer Demand by Type & Market 90
3 Bubble Packaging Demand by Market 96
4 Air Pillow Demand by Market 101
5 Paper Fill Packaging Demand by Market 107
6 Dunnage Bag Demand by Material & Market 112
7 Other Flexible Protective Packaging Demand 116

Section V -- Plastic Foam Protective Packaging
1 Plastic Foam Protective Packaging Demand 119
2 Insulated Shipping Container Demand by Application & Market 122
3 Molded Foam Protective Packaging Demand 129
4 Molded Expanded Polystyrene Protective Packaging Demand by Market 131
5 Molded Polyolefin Protective Packaging Demand by Market 136
6 Molded Polyurethane Protective Packaging Demand by Market 142
7 Foam-in-Place Polyurethane Protective Packaging Demand by Market 145
8 Polyolefin Rolled Foam Protective Packaging Demand by Market 148
9 Loose Fill Packaging Demand by Type 153
10 Expanded Polystyrene Loose Fill Packaging Demand 156
11 Biodegradable Plastic Loose Fill Packaging Demand 159
12 Other Plastic Foam Protective Packaging Demand 161

Section VI -- Rigid Protective Packaging
1 Rigid Protective Packaging Demand by Type 163
2 Paperboard Protector Demand by Market 165
3 Molded Pulp Protective Packaging Demand by Market 173
4 Other Rigid Protective Packaging Demand 177

Section VII -- Industry Structure
1 US Protective Packaging Sales by Company, 2014 180
2 Selected Acquisitions & Divestitures 191
3 Selected Acquisitions & Divestitures 192
4 Selected Cooperative Agreements 201

List of Charts

Section III -- Overview
1 Protective Packaging Demand by Material, 2014 68
2 Protective Packaging Demand by Function, 2014 70
3 Protective Packaging Demand by Market, 2014 79

Section IV -- Flexible Protective Packaging
1 Flexible Protective Packaging Demand by Type, 2014 88

Section V -- Plastic Foam Protective Packaging
1 Plastic Foam Protective Packaging Demand, 2014 120

Section VI -- Rigid Protective Packaging
1 Rigid Protective Packaging Demand by Type, 2014 164

Section VII -- Industry Structure
1 US Protective Packaging Market Share, 2014 184

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