US Thermoform Packaging Market Size, Share & Growth Analysis (2025-2035)
The US thermoform packaging market is a dynamic and evolving sector driven by changing consumer preferences, regulatory demands, and rapid technological advancements in packaging. The industry encompasses a range of packaging types such as blister packaging, clamshell, trays, lids, and more, serving applications across food & beverages, pharmaceuticals, electronics, and industrial sectors. As US companies emphasize sustainability, cost-effectiveness, and scalability, the demand for thermoformed solutions is on the rise. The forecast period up to 2035 expects robust growth, fueled by increased adoption of automation, eco-friendly materials, and e-commerce expansion.
Understanding the Impact of Tariffs on "US Thermoform Packaging".
Latest Market Dynamics
Key Drivers
- Rising consumer demand for lightweight and convenient packaging, particularly in the food and beverage segment – exemplified by the recent expansion of Amcor plc's food packaging operations in 2024.
- Heightened focus on sustainable packaging options, highlighted by Berry Global Group's 2024 investment in recyclable thermoform solutions, driving growth and differentiation.
Key Trends
- Increased integration of recycled content and shift to circular packaging models, illustrated by Sonoco introducing post-consumer recycled (PCR) material trays in early 2024.
- Adoption of advanced automation technologies for high-volume thermoform production, like Pactiv LLC installing new automated lines for improved efficiency in 2024.
Key Opportunities
- Growth in e-commerce and direct-to-consumer channels triggering demand for protective and custom thermoformed packaging, with D&W Fine Pack expanding its online offerings in May 2024.
- Expansion in pharmaceutical packaging, where Tekni-Plex launched innovative blister packs tailored for temperature-sensitive drugs in June 2024.
Key Challenges
- Managing volatile raw material costs, as indicated by Anchor Packaging reporting increased polymer prices impacting margins in early 2024.
- Meeting evolving regulatory and sustainability standards, illustrated by Sealed Air Corporation adapting machinery to comply with new US recycling mandates in mid-2024.
Key Restraints
- Competition from alternative packaging formats such as flexible packaging limiting share growth, observed with increased preference for pouches in certain segments.
- Complexity in recycling multi-material thermoform products, with Silgan Holdings noting ongoing R&D expenses to enhance recyclability in 2024.
US Thermoform Packaging Market Share (%) by Type, 2025
Blister packaging leads the US thermoform packaging market thanks to its widespread application in pharmaceuticals and consumer goods, providing excellent product protection and visibility. Clamshell packaging follows, driven by demand in the electronics and retail sectors for tamper-evident packaging. Trays are also prominent due to their extensive usage in food service and industrial applications. Together, these top types account for a significant portion of the total market in 2025, underlining the versatility and adaptability of thermoform solutions in meeting industry requirements.
US Thermoform Packaging Market Share (%) by Application, 2025
Food & beverages represent the largest application segment for thermoform packaging in the US for 2025, driven by increased takeaway, frozen, and convenience food consumption. Pharmaceuticals is the second-largest segment, with stringent safety and hygiene requirements fueling growth for blister and clamshell solutions. Personal care products also show strong adoption, following increased demand for custom, protective packaging formats. These segments underline the broad applicability of thermoform packaging across varied US industries.
US Thermoform Packaging Market Revenue (USD Million), 2020-2035
The US thermoform packaging market demonstrates a robust upward trajectory between 2020 and 2035. Revenue is set to increase from $6,100 Million in 2020 to an estimated $16,200 Million by 2035, reflecting a strong compound annual growth rate. This sustained growth is attributed to ongoing innovation in materials, heightened sustainability focus, and the expansion of high-value sectors such as food service and pharmaceuticals, which rely on efficient, customizable packaging solutions.
US Thermoform Packaging Market Year-over-Year (%) Growth, 2020-2035
The year-over-year (YOY) growth rate for the US thermoform packaging market stays positive throughout the forecast period, peaking during high-investment phases. Growth rates fluctuate between 5.1% and 7.3% due to economic conditions, evolving regulations, and adoption of new materials and automation. The market remains resilient, with temporary slowdowns in 2028 and 2032 offset by strong growth from e-commerce and sustainable packaging advancements.
US Thermoform Packaging Market Share (%) by Region, 2025
The Northeast region holds the highest market share for thermoform packaging in 2025, driven by the concentration of pharmaceutical firms and packaged food manufacturers. The South follows, benefiting from rapid industrialization and expansion of manufacturing bases. The Midwest, with its strong food processing industry presence, is also a significant contributor. Regional dynamics are shaped by consumer trends, proximity to key industries, and logistics infrastructure.
US Thermoform Packaging Market Players Share (%), 2025
Amcor plc leads the US thermoform packaging market in 2025 with its extensive portfolio, production capabilities, and global footprint. Sonoco Products Company and Berry Global Group also hold significant shares due to their innovation and scale in both food and pharma applications. These major players collectively account for almost half of the market, with the rest distributed among other regional and niche suppliers who provide specialized solutions in response to diverse customer needs.
US Thermoform Packaging Market Buyers Share (%), 2025
In 2025, food & beverage companies constitute the largest segment of buyers for thermoform packaging, followed by pharmaceutical companies that require secure and tamper-proof solutions. Retailers, online sellers, and personal care brands are also significant buyers, responding to trends in branding, customization, and convenience. The chart underlines the multi-industry relevance and growing acceptance of thermoform packaging across tier-1 and niche buyer segments alike.
Study Coverage
| Metrics | Details |
|---|
| Years | 2020-2035 |
| Base Year | 2025 |
| Market Size | 9000 |
| Regions | Northeast, South, Midwest, West |
| Segments | By Type, By Application, By Technology, By Distribution Channel, By Organization Size |
| Players | Amcor plc, Sonoco Products Company, Berry Global Group, Inc., Pactiv LLC, D&W Fine Pack, Anchor Packaging LLC, Dart Container Corporation, Genpak LLC, Fabri-Kal, Tekni-Plex, Inc., Tray-Pak Corporation, Placon Corporation, Silgan Holdings Inc., Sealed Air Corporation, Sabert Corporation |
Key Recent Developments
- June 2024: Tekni-Plex introduced new temperature-stable blister packs for the US pharmaceutical market, targeting increased drug safety.
- July 2024: Berry Global Group announced a strategic investment in a recyclable thermoform line to enhance sustainable product offerings.
- August 2024: Pactiv LLC completed the installation of automated production lines in Illinois to boost output and efficiency.
- September 2024: Sonoco Products Company launched a new line of PCR material-based thermoforming trays for the foodservice market.
- October 2024: Sealed Air Corporation upgraded its US production site to meet updated local and national recycling standards.
