The U.S. flexible plastic packaging sector is on the cusp of an exciting transformation. The market, valued at USD 26,010 million in 2025 and projected to reach USD 37,045.7 million by 2035, growing at a CAGR of 3.6%, is ripe for both expansion and innovation.
What does this mean for manufacturers — both established names and new entrants? Simply put: this is the moment for action. As consumer demand evolves, sustainability becomes non-negotiable, and technology adoption accelerates, there is a compelling opportunity for manufacturers to scale, differentiate, and lead.
Legacy Manufacturers: Leveraging Scale and Innovation
Major players such as Berry Global Group, Inc., Sonoco Products Company, Amcor Group GmbH, Sealed Air Corporation, and Novolex Holdings Inc. anchor the upper tier of the market, each with robust production capabilities, diverse portfolios, and deep geographic reach. These companies are well-positioned to drive the next wave of growth through:
- Investment in recyclable and sustainable solutions — recyclable materials and single-material pouches are becoming the gold standard in packaging.
- Capturing growth in food & beverage — this segment accounted for approximately 56.2% of the market value in 2025 and remains the primary demand driver.
- Adopting advanced packaging types — Modified Atmosphere Packaging (MAP) alone is expected to account for nearly 48.8% of market share by 2035.
For these established manufacturers, the mandate is clear: continue to scale, invest in new material technologies, and broaden offerings in premium and sustainable flexible-packaging formats.
Emerging & Growth-Stage Manufacturers: Seizing New Opportunities
Beyond the established giants lies a fast-growing ecosystem of emerging players such as Printpack Inc., ProAmpac LLC, C-P Flexible Packaging, American Packaging Corporation, and Sigma Plastics Group Inc. These companies are leveraging agility and innovation to capture niche markets and meet evolving consumer demands. Key strategies for emerging manufacturers include:
- Specializing in single-material and mono-polymer packaging formats, aligning with recycling-friendly mandates and consumer preferences for sustainability.
- Focusing on high-growth segments such as films & wraps, which are projected to hold a 34.8% market share by 2035.
- Partnering with e-commerce brands, which need lightweight, protective, and flexible packaging optimized for logistics and delivery.
For new entrants and growth-stage firms, the message is one of opportunity: the U.S. flexible plastic packaging market is dynamic, accessible, and primed for innovation. With the right technology and sustainability strategy, meaningful growth is within reach.
Technology & Sustainability: Twin Engines of Future Growth
The next decade of packaging innovation will be powered by two major forces:
- Sustainable Material Innovation – While polyethylene and polypropylene continue to dominate due to their cost-effectiveness and durability, recyclable, mono-material, and bio-based plastics are gaining strong momentum as regulators and consumers demand greener alternatives.
- Advanced Packaging Formats – High-barrier films, MAP technologies, and customized flexible solutions for fresh produce, frozen foods, and ready-to-eat meals are expanding rapidly. These innovations are redefining both performance and environmental efficiency.
Manufacturers embracing these advancements will lead the market — those clinging to legacy methods may struggle to compete in a sustainability-driven future.
Why Now?
- A robust market base valued at USD 25,400.4 million in 2024, poised for consistent growth.
- A strong upward trajectory, expected to reach USD 37,045.7 million by 2035.
- Rapidly evolving consumer demand focused on convenience, shelf-life, and eco-friendliness.
- Growing regulatory pressures encouraging recyclability and waste reduction.
- Expanding e-commerce and food-service industries driving new packaging requirements.
These factors together create a perfect storm of innovation, scale, and opportunity — making this one of the most promising decades for packaging manufacturers.
Call to Action
For both established manufacturers and new entrants, the time to act is now. Whether expanding into new packaging formats, developing eco-friendly materials, or forming strategic partnerships, opportunities abound in every corner of the market. The U.S. flexible plastic packaging sector is not just growing — it’s transforming into a more sustainable, technology-driven ecosystem.
Those who invest in advanced technologies, align with sustainability imperatives, and swiftly respond to changing consumer trends will emerge as industry leaders. The next generation of flexible packaging innovators is being shaped today — and the most forward-thinking manufacturers will define the industry’s future.
About Future Market Insights (FMI)
Future Market Insights is a global market intelligence and consulting firm serving clients in more than 150 countries. FMI delivers reliable, forward-looking insights that help companies identify opportunities, navigate challenges, and accelerate growth across diverse industries — including packaging, materials, and sustainability.
