USA Thermoformed Containers Market Set for Sustainable Growth with Smart-Factory Advances

The thermoformed containers market is on an impressive growth trajectory, projected to expand from USD 52.5 billion in 2025 to USD 78.4 billion by 2035, recording a CAGR of 4.1% during the forecast period. Sales in 2024 were USD 50.6 billion, setting a strong foundation for this steady rise. This growth is being driven by surging demand for lightweight, cost-effective, and sustainable packaging across industries such as food and beverages, pharmaceuticals, and personal care.

From fresh produce trays to ready-to-eat meal packaging, thermoformed containers have become a staple for manufacturers and retailers who prioritize durability, hygiene, and sustainability.

Quick Stats of the Thermoformed Containers Market

• Market Value (2025): USD 52.5 billion
• Forecast Value (2035): USD 78.4 billion
• CAGR (2025–2035): 4.1%
• Material Leader (2025): Polypropylene (38.6%)
• Top End-Use Industry: Food & Beverages (44.2% share)
• Fastest-Growing Market: India (6.8% CAGR in Asia-Pacific)

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Sustainability and Technology Redefining the Industry

Sustainability has become the defining theme of the thermoformed packaging sector. Manufacturers are rapidly adopting eco-friendly materials, lightweight designs, and closed-loop recycling systems to reduce environmental impact.

At the same time, smart technologies are transforming production floors. With AI-driven inspection systems, digital twins, and predictive maintenance, packaging manufacturers are unlocking efficiencies and slashing material waste. For instance, WM Thermoforming Machines’ inline AI module claims defect-detection accuracy ten times higher than manual checks, while Simularge’s plug-and-play digital twins have already helped appliance manufacturers cut scrap by 50%.

These changes are ushering in a smart-factory era where packaging lines are not just efficient but also sustainable.

Industry Moves: Strategic Shifts and Acquisitions

April 2025 marked a major shift when Sonoco Products Company sold its Thermoformed and Flexibles Packaging business to TOPPAN Holdings Inc. for USD 1.5 billion in proceeds. Howard Coker, Sonoco’s CEO, emphasized that this divestment strengthens the company’s focus on sustainable metal and fiber packaging.

Meanwhile, Amcor Plc has announced plans to merge with Berry Global Group, a move expected to create the world’s largest plastic packaging entity. Smaller players like Biocup are also entering new geographies, with the Mexican eco-packaging company expanding into the U.S. with biodegradable and compostable thermoformed products.

This mix of consolidation and niche expansion highlights the industry’s dual trajectory: global giants scaling capabilities while startups innovate with greener alternatives.

Why Food & Beverage Dominates

The food and beverage industry, with a 44.2% share in 2025, is the backbone of demand for thermoformed containers. Ready-to-eat meals, bakery products, dairy cups, and fresh produce trays rely heavily on clamshells, bowls, and high-barrier packaging.

Convenience, hygiene, and shelf appeal are major drivers. Multi-compartment trays prevent cross-contamination, while microwave and freezer compatibility enhance consumer experience. Meanwhile, modified atmosphere packaging (MAP) in thermoformed formats extends shelf life—a vital edge for perishable food categories.

Sustainability pressures are also strong. Retailers such as Walmart, Aldi, and REWE are pushing suppliers toward recyclable PET, rPET, and compostable bio-based containers, phasing out foam-based trays.

Polypropylene Leads Material Choices

Polypropylene (PP) is projected to hold 38.6% of the market in 2025, owing to its heat resistance, durability, and lightweight properties. Its applications span food trays, sterile pharmaceutical packaging, and cosmetics containers.

Beyond performance, PP aligns with sustainability goals. Recyclable PP resins and post-consumer recycled (PCR) grades are gaining traction, while lightweighting initiatives reduce overall plastic use. This balance of practicality and eco-responsibility makes PP the undisputed leader in thermoforming materials.

Regional Growth Hotspots

• United States: Growth at 3.9% CAGR, driven by strong demand for fresh produce and dairy packaging, particularly for berries and salads. Retailers insist on recyclable PET and rPET packaging.
• Germany: Growth at 2.1% CAGR, led by sustainable dairy packaging. Stricter regulations like the Verpackungsgesetz (Packaging Act) are pushing manufacturers toward recyclable PP and rPET-based dairy cups.
• India: The fastest-growing market with 6.8% CAGR, supported by rising demand for hygiene-focused and convenient food packaging in urban centers.
• China: A strong 5.4% CAGR, reflecting the expansion of food delivery services and retail-ready formats.
• Brazil: 5.1% CAGR, fueled by growing processed food consumption and retail modernization.

Market Segmentation at a Glance

• By Material: PET, PP, PS, PVC, PLA, and biodegradable paper-based options.
• By Product: Trays, clamshells, cups, blisters, bowls, and lids.
• By End Use: Food & beverages, pharmaceuticals, cosmetics, electronics, retail, and industrial packaging.

This wide segmentation shows how thermoformed containers are embedded in nearly every consumer-facing industry.

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Competitive Landscape: Leaders and New Challengers

The market is fragmented yet competitive, with multinational giants, regional specialists, and local innovators all contributing.

• Tier 1 Leaders: Amcor, DS Smith, Huhtamaki, Mondi, Sealed Air, and Berry Global dominate with advanced technologies and global supply chains.
• Tier 2 Players: Winpak, Anchor Packaging, Tekni-Plex, and Sonoco leverage strong overseas presence and compliance expertise.
• Tier 3 Niche Manufacturers: Small-scale innovators like Lindar Corporation and Easy Pak serve localized needs, particularly in specialty packaging segments.

For emerging players, focusing on eco-materials, automation, and niche applications is the key to gaining traction.

Strategic Payoffs for Brands and Policymakers

Thermoformed containers are more than just packaging—they are becoming part of global sustainability and compliance strategies.

• Resin savings of 5–15% help companies meet regulations without escalating costs.
• Inline analytics shorten product design cycles, giving brands flexibility for seasonal launches.
• Traceability data strengthens claims on recycled content, now crucial in winning government and retail contracts.

For FMCG brands and policymakers alike, thermoformed containers are proving to be a smart choice that balances consumer convenience with environmental responsibility.

Looking Ahead

The thermoformed containers market is on a path of steady, innovation-led growth. With AI-driven smart factories, sustainable material breakthroughs, and regional market expansion, the industry is entering a new era.

As established leaders like Amcor, Huhtamaki, and Berry Global push boundaries in automation and sustainability, and emerging players like Biocup champion bio-based solutions, the sector is redefining what packaging can achieve—for brands, consumers, and the planet.

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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