Converted Flexible Packaging Market - Global Industry Size, Share, Trends, Opportunity, and Forecast, 2021-2031

The Global Converted Flexible Packaging Market is projected to expand from USD 313.01 Billion in 2025 to USD 432.08 Billion by 2031, growing at a CAGR of 5.52%. Converted flexible packaging involves transforming raw materials like aluminum foil, paper, and plastic films into finished containment products such as sachets, bags, and pouches using processes like laminating, printing, and coating. The market is largely driven by the increasing need for extended product shelf life to minimize food waste and the lightweight nature of these materials, which offers substantial cost savings in logistics and transportation compared to rigid packaging options.

Despite these benefits, the industry encounters a major hurdle regarding the recycling of complex multi-layer structures, as existing infrastructure often struggles to process these materials effectively. Highlighting the sector's significant economic scale, the Flexible Packaging Association estimated that the value-added segment of the U.S. flexible packaging industry generated $35.6 billion in sales in 2023. This figure underscores the market's vast size even as it navigates intensifying pressure to enhance circularity and comply with increasingly stringent environmental regulations.

Market Drivers

The growth of the processed food and beverage industry serves as a primary catalyst for the global converted flexible packaging market, fueled by consumer demand for convenient, shelf-stable, and lightweight containment options. This sector relies heavily on flexible formats like films and pouches to prolong shelf life through superior barrier properties while lowering transportation costs relative to rigid alternatives. The dominance of this segment is evident in the Flexible Packaging Association's August 2024 presentation, 'State of the U.S. Flexible Packaging Industry,' which noted that food packaging applications comprised approximately 52% of total industry revenue. Similarly, the Mondi Group reported in its February 2024 'Full Year Results 2023' that its Flexible Packaging business segment alone achieved revenues of €3.9 billion.

Simultaneously, the market is being reshaped by technological advancements in biodegradable and sustainable materials as manufacturers adopt circular economy models to address environmental concerns. Converters are increasingly substituting difficult-to-recycle multi-layer structures with high-performance mono-material films that preserve essential barrier qualities while facilitating easier recycling. This strategic pivot is reflected in the portfolios of major players; for instance, Amcor's October 2024 '2024 Sustainability Report' indicated that 94% of its flexible packaging portfolio by area was classified as recycle-ready, demonstrating a rapid industry-wide transition toward more sustainable material architectures.

Market Challenges

The difficulty in efficiently processing complex multi-layer structures presents a significant barrier to the expansion of the converted flexible packaging market. These materials, which typically combine layers of paper, aluminum, and plastic to ensure barrier protection, are generally incompatible with standard mechanical recycling systems that require mono-material inputs. Consequently, the lack of adequate infrastructure means the vast majority of flexible packaging remains unrecyclable in practice, creating a critical bottleneck that conflicts with the global shift toward circular economy models. As consumer goods companies face stricter regulatory mandates to prove packaging recyclability, the absence of viable end-of-life solutions for multi-layer films forces a reconsideration of these formats, stalling adoption in sustainability-focused regions.

The severity of this infrastructure gap is highlighted by recent data illustrating the economic instability of processing these materials. According to 'Plastics Recyclers Europe,' the European plastics recycling sector faced a significant contraction in 2024, with polyolefin films accounting for 25% of the total recycling facility closures observed between 2023 and 2024. This trend suggests that even where processing capacity exists, the financial and technical complexity of recycling flexible films often leads to operational failure, thereby increasing investment risks and hampering the industry's ability to position converted flexible packaging as a long-term sustainable solution.

Market Trends

A pivotal trend is the rise of barrier-coated paper-based packaging, where manufacturers combine the sustainability of cellulosic fibers with protective functionality traditionally associated with plastics. This development involves advanced coatings that provide necessary oxygen and moisture resistance, allowing for the replacement of non-recyclable multi-layer plastic structures with renewable alternatives. Major converters are aggressively scaling production to meet this demand; for example, the Mondi Group's 'Integrated report and financial statements 2024', released in February 2025, noted that the company launched a new paper machine at its Štětí mill in December 2024, designed to produce 210,000 tonnes of kraft paper annually for functional barrier applications.

In parallel, the optimization of flexible packaging for e-commerce distribution is reshaping the market as retailers focus on material efficiency and waste reduction. This trend drives the adoption of right-sized flexible mailers and void-fill solutions that minimize dimensional weight, often replacing rigid boxes or unrecyclable materials to streamline logistics. The push for efficient fulfillment compels suppliers to innovate with protective formats that are both lightweight and curbside recyclable. Highlighting this impact, Amazon's July 2025 '2024 Sustainability Report' stated that the corporation achieved a 16.4% global reduction in single-use plastic delivery packaging in 2024 by replacing plastic air pillows with paper fillers and optimizing fulfillment operations.

Key Players Profiled in the Converted Flexible Packaging Market

• ProAmpac Holdings Inc.
• Amcor PLC
• Sealed Air Corporation
• Sonoco Products Company
• Constantia Flexibles Group GmbH
• Graphic Packaging Holding Company
• Bischof+Klein SE & Co. KG
• Honeywell International Incorporated
• Tekni-Plex, Inc.
• Transcontinental Inc.

Report Scope

In this report, the Global Converted Flexible Packaging Market has been segmented into the following categories:

Converted Flexible Packaging Market, by Material:

• Plastic Film
• Paper
• Aluminum Foil
• Others

Converted Flexible Packaging Market, by Application:

• Retail
• Food & Beverage
• Pharmaceutical
• Non-Food
• Others

Converted Flexible Packaging Market, by Region:

• North America
• Europe
• Asia-Pacific
• South America
• Middle East & Africa

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the Global Converted Flexible Packaging Market.

Available Customization

The analyst offers customization according to your specific needs. The following customization options are available for the report:

• Detailed analysis and profiling of additional market players (up to five).

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