Flexible Plastic Packaging Industry in the United States Set to Reach USD 46.3 Billion by 2035, Driven by Sustainability, E-commerce, and Innovation

The United States flexible plastic packaging industry is entering an era of transformation. Valued at USD 35.8 billion in 2025, the sector is projected to climb to USD 46.3 billion by 2035, charting a steady CAGR of 2.6%. As industries from food and beverage to pharmaceuticals embrace lightweight, durable, and customizable solutions, flexible packaging has become a cornerstone of modern product delivery.

This growth story is fueled by established leaders, such as Amcor Plc, Berry Global, and Huhtamaki Oyj, as well as agile innovators like ePac Holdings and Glenroy, Inc., all investing in sustainable technologies, digital printing, and consumer-centric packaging designs. Together, they are shaping the future of packaging in a market that is rapidly adapting to consumer preferences, environmental expectations, and the digital economy.

A Market Poised for Steady Expansion

The U.S. flexible plastic packaging market thrives on its unique ability to combine cost efficiency, adaptability, and durability. Compared to rigid packaging formats, flexible alternatives consume fewer resources, weigh less, and lower transportation costs—an advantage amplified in the booming e-commerce sector.

“Flexible packaging is no longer just about protecting products. It’s about delivering convenience, sustainability, and brand value,” says a market analyst at Future Market Insights. “From resealable snack packs to high-barrier pharmaceutical films, the U.S. market is innovating to meet consumer and industry demands simultaneously.”

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Key stats highlight this resilience:

• 2025 Market Value: USD 35.8 billion
• 2035 Forecast Value: USD 46.3 billion
• Forecast CAGR (2025–2035): 2.6%
• Leading Segment (2025): Pouches at 38.6% share

Why Pouches Lead the Way

Among product types, pouches dominate with nearly 39% share in 2025. Their lightweight structure, resealable options, and compatibility with sustainable materials have made them the preferred choice in food, beverage, and personal care packaging.

For e-commerce and retail, pouches offer an unbeatable mix: they are compact for shipping, adaptable for various volumes, and capable of high-quality graphics for branding. Innovation in recyclable and biodegradable pouches has further accelerated adoption.

By 2035, the segment is expected to create a supplementary potential of USD 3.35 billion, reinforcing its leadership in the U.S. packaging landscape.

Oil-Based Polymers Remain Dominant but Under Pressure

On the material front, oil-based polymers hold 85.4% market share. Their mechanical strength, cost-effectiveness, and compatibility with high-speed machinery make them indispensable for large-scale packaging applications.

However, with sustainability pressures mounting, companies are rethinking strategies. Industry leaders like Berry Global and ProAmpac are channeling investments into circular economy initiatives and lightweighting technologies. The push for recyclable solutions is expected to define competition in the next decade, balancing the performance of oil-based polymers with eco-conscious alternatives.

Barrier Packaging Secures Food Freshness

Food safety and shelf life remain top priorities, making general barrier packaging the largest type segment at 57.8%. These solutions protect against oxygen, light, and moisture—vital for preserving freshness in packaged snacks, beverages, and frozen meals.

Technological advancements in multi-layer films and bio-based coatings are raising the bar. With U.S. consumers demanding both longer shelf life and eco-friendly packaging, this segment will continue to anchor revenue growth.

E-Commerce: A Game-Changer for Flexible Packaging

The explosive rise of online shopping has created an entirely new demand dynamic. From lightweight mailer bags to shock-resistant films, flexible packaging ensures that products arrive intact while reducing shipping costs.

Companies such as ePac Holdings and Printpack are capitalizing on this trend with customizable digital printing technologies that support small-batch runs, enabling brands to cater to niche audiences while maintaining cost efficiency.

Growth Drivers: Food, Beverage, and Healthcare

The U.S. food and beverage industry continues to be the largest consumer of flexible plastic packaging, accounting for nearly two-thirds of demand. From resealable pouches for snacks to lightweight beverage films, the sector thrives on packaging that balances convenience with shelf appeal.

The pharmaceutical and healthcare sectors are also driving adoption, particularly with stringent requirements for sterility, dosing accuracy, and tamper resistance. With rising demand for personalized medicine and wellness products, the role of flexible packaging in healthcare is expected to grow significantly by 2035.

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Industry Challenges

Despite its strong outlook, the U.S. flexible plastic packaging industry faces hurdles:

• Environmental scrutiny over single-use plastics
• Regulatory restrictions driving a shift to sustainable materials
• Rising raw material costs due to oil price fluctuations
• Supply chain disruptions that impact production timelines

These challenges are pushing manufacturers to double down on innovation, collaboration, and sustainability.

Recent Developments and Strategic Moves

The competitive landscape is buzzing with activity, as both global giants and regional players seek growth through acquisitions, partnerships, and facility expansions:

• Amcor Plc partnered with Tyson Foods (April 2025) to launch more sustainable flexible films for consumer products.
• Berry Global Group Inc. expanded its film manufacturing facility in Lewisburg, Tennessee (April 2025), signaling confidence in U.S. demand.
• Winpak Films, Inc. acquired 44 acres in Senoia, Georgia (October 2025) for potential future expansion.
• ePac Holdings LLC introduced flat-bottom pouches and deepened its partnership with Totani, enhancing its position in premium pouch manufacturing.

These strategic moves underscore how manufacturers—both established leaders and nimble innovators—are aligning with sustainability and e-commerce-driven growth.

Outlook: A Decade of Innovation and Sustainability

The U.S. flexible plastic packaging industry has already proven its resilience, recording a historical CAGR of 1.5% between 2020 and 2025. Now, as sustainability and consumer convenience dominate, the industry is set for a new chapter.

Key opportunities lie in:

• Eco-friendly alternatives like bioplastics and compostable films
• Smart packaging technologies to improve safety and engagement
• Advanced printing solutions for personalization and branding
• E-commerce-focused packaging that enhances unboxing experiences

Industry leaders are investing heavily in R&D to strike a balance between performance, sustainability, and cost efficiency. For new entrants, the market offers fertile ground, especially in niche applications and innovative material solutions.

About Future Market Insights (FMI)

Future Market Insights, Inc. (ESOMAR certified, recipient of the Stevie Award, and a member of the Greater New York Chamber of Commerce) offers profound insights into the driving factors that are boosting demand in the market. FMI stands as the leading global provider of market intelligence, advisory services, consulting, and events for the Packaging, Food and Beverage, Consumer Technology, Healthcare, Industrial, and Chemicals markets. With a vast team of 400 analysts worldwide, FMI provides global, regional, and local expertise on diverse domains and industry trends across more than 110 countries. 

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