US flexible packaging market hits 42.6bn USD

The US flexible packaging industry reached 42.6 billion USD in annual sales in 2024, up 2.9 percent from 41.4 billion USD in 2023, according to the Flexible Packaging Association's 2025 State of the US Flexible Packaging Industry Report.

The value-added segment of the industry, covering processes including printing, laminating, coating, extrusion and bag and pouch manufacturing, is estimated at 34.1 billion USD in 2024. FPA members project 4.8 percent growth in 2025, bringing the market to an estimated 44.6 billion USD.

Flexible packaging accounts for roughly 20 percent of the total US packaging market, making it the second-largest segment behind corrugated. Food remains the largest end-use market, generating 19 billion USD in annual revenue, around 45 percent of the total.

Flexography continues to dominate print technologies, representing 76 percent of shipments, followed by unprinted at 12 percent, gravure at 11 percent and digital at 1 percent. Films, paper and resins remain the largest converter input costs, representing nearly 75 percent of material purchases.

The industry recorded 34 domestic mergers and acquisitions in 2024, up from 31 in 2023. The US flexible packaging trade deficit grew to 2.6 billion USD, with 3.9 billion USD in exports and 6.5 billion USD in imports, a 24 percent increase from 2023. Converter members again identified the labor pool as their top challenge, while suppliers cited growth and new materials.

The full report is available to FPA members at flexpack.org and for purchase by non-members.