The Flexible Packaging Association (FPA), an advocate for the US flexible packaging industry, has announced the publication of its 2025 State of the US Flexible Packaging Industry Report. The annual report provides converters, suppliers, investors, and analysts with a comprehensive view of industry performance over the past year.

According to FPA’s analysis, the US flexible packaging industry reached $42.6 billion in annual sales in 2024, up from $41.4 billion in 2023 – a 2.9% growth rate. These values are calculated using US Census data and other industry sources and reflect industry output rather than shipments.

The report focuses on the segment of the industry that adds significant value through processes such as printing, laminating, coating, extrusion, and bag and pouch manufacturing. This value‑added segment is estimated at $34.1 billion in 2024, excluding retail shopping bags, consumer storage bags, and trash bags.

The FPA bases its annual report on data from converter and supplier members, along with several US Census components, and the survey results were tabulated in mid-2025. Much of the reported data is for 2024, with some projections for 2025.

Key Findings

•           Flexible packaging accounts for roughly 20% of the total US packaging market, making it the second-largest packaging segment behind corrugated.

•           FPA members project 4.8% industry growth in 2025, bringing the market to an estimated $44.6 billion.

•           Films, paper, and resins remain the largest converter input costs, representing nearly 75% of material purchases.

•           Flexography continues to dominate printing technologies, representing 76% of shipments, followed by unprinted (12%), gravure (11%), and digital (1%).

•           Food remains the largest end-use market, generating $19 billion in annual revenue—about 45% of the total market.

•           The industry recorded 34 domestic M&A transactions in 2024, up from 31 in 2023.

•           The U.S. flexible packaging trade deficit grew to $2.6 billion, with $3.9 billion in exports and $6.5 billion in imports, a 24% increase from 2023.

•           Converter members again identified the labor pool as their top challenge, while suppliers cited growth and new materials.

The 2025 report provides a detailed analysis of:

·        Industry performance, including growth, profitability, and capital spending

·        Materials and processes, including printing technologies and material usage

·        End-use market trends and forecasts

·        Industry structure, consolidation, and M&A activity

·        Import/export dynamics and trade outlook

·        Key challenges and long-term industry vision

The report also includes insights from a complementary 2025 US flexible packaging industry economic impact study commissioned by FPA. Data is sourced from FPA converter and supplier members, the US Census Bureau’s Annual Integrated Economic Survey, the US Departments of Labor and Commerce, industry analysts, and investment banking reports.

FPA gathered the information contained in the report through several reliable industry sources, including the FPA State of the US Flexible Packaging Industry Survey; the Annual Integrated Economic Survey (AIES), published by the US Census Bureau; the US Department of Labor; the US Department of Commerce; industry analysts; and investment banking reports. Data collected from these sources provides a more complete picture of the US flexible packaging industry and helps cross-check information on industry size, structure, market segments, and key packaging products.