Form-Fill-Seal (FFS) Films Market By Application Type (Sachets & Pouches, Bags & Sacks), Material (Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET)), Layer Structure (Monolayer Films, Multilayer Films) & Region - Forecast to 2021- 2031

Form-Fill-Seal Films Market Snapshot

[236 Pages Report] The form-fill-seal (FSS) films market is expected to register strong growth through 2031. Future Market Insights (FMI) has forecast it to register year-on-year growth of 4% during 2020-2021. Increasing demand for higher strength at low thickness and good thermal barrier will drive the consumption of these films, enabling growth at 5.1% CAGR between 2021 and 2031.

FMI also projects the form-fill-seal market to total US$ 40.7 Bn, by the end of 2031. The food industry is expected to remain leading end user, accounting for 2/3 of the share in the global market.

2014-2020 Form-Fill-Seal Films Market Outlook Compared to 2021-2031 Forecast

Driven by high demand for sustainable packaging from the food and pharmaceutical industry across the globe, the form-fill-seal films market is anticipated to expand at a steady 5.1% CAGR from 2021 to 2031.

Form-fill-seal films are one of the most flexible, cost-effective, and sustainable packaging solutions. These films are ideal for automatic packaging of consumer goods and food products, as they provide exceptional protection against moisture, oxygen, and UV.

Pouches, sachets, and bags made of form-fill-seal films are easy-to-use, lightweight, sturdy and facilitate mess-free dispensing. They are usually compatible with horizontal and vertical form-fill-seal machines and are suited for mass production. Incorporating FSS films in packaging also improves work efficiency and saving packaging costs.

Rising concerns regarding carbon emissions are compelling manufacturers to adopt sustainable forms of packaging. This is expected to drive sales of form-fill-seal films over the forecast period.

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How is Increasing Consumption of Packaged Food Driving Form-Fill-Seal Films Sales?

Working professionals account for maximum demand for ready-to-eat meals and packaged foods since they are unable to invest time in cooking meals due to their hectic and busy schedules.

Form-fill-seal films are ideal for packaged food products as they protect the ingredients from moisture, oxygen, and light. They keep food products fresh for a longer duration and eliminate the need for preservatives, while retaining the aroma and taste of food.

Adoption of horizontal and vertical form-fill-seal films is gaining traction as they are suitable for packaging various products such as seafood, meats, bakery, dairy, poultry, condiments, soups and sauces. Growing preference for packaged food products is expected to continue pushing sales of FFS films through 2031, opines FMI.

Will Rising Demand for Sustainable Packaging Solutions Influence Sales of Form-Fill-Seal Films?

Stringent government regulations implemented to curb emissions caused by manufacturing and disposal of plastic products are compelling consumers and manufacturers to opt for recyclable packaging formats.

After recycling, form-fill-seal films can be used again to produce new plastic products. Form-fill-seal films bags are not discarded as residual waste and are collected as valuable raw material. To meet the sustainability objective, manufacturers are launching innovative products to improve sales of form-fill-seal films. For instance:

• SealedAir CRYOVAC® brand’s form-fill-seal films offer optimal food safety, space-saving, reduces carbon footprint, and end-of-life material recovery.

• In April 2021, Trio World Company developed Trioloop, an FFS flat film made from 80% recycled polyethylene, where 65% is PCR, and 15% is PIR material. The company’s FFS flat film is 100% recyclable, offering superior quality, ensuring strong pallet stability, and reducing downtime.

What is the Impact of COVID-19 Pandemic on the Form-Fill-Seal Films Market?

The onset of the COVID-19 pandemic has profoundly impacted several industries by hampering production, disrupting the supply chain, and drastically reducing sales. The food packaging industry has also suffered significantly due to stringent lockdown and travel restrictions.

Demand for food and beverages witnessed an uptick as they are considered essential products during the pandemic. Fast-food and ready-to-eat food packaging witnessed high demand due to work-from-home culture and long working hours.

Pouches, and bags made from form-fill-seal films are safe, reliable, and hygienic. These films  can handle raw, frozen, and processed foods products and offer protection  against moisture, oxygen, and light. Growing concern about consuming contamination-free, healthy, and safe food are anticipated to propel demand for form-fill-seal films in the forthcoming years.

Country-wise Insights

How Will the Form-Fill-Seal Films Market Expand Across the U.S.?

As per FMI, the U.S. is estimated to account for 90% of the North America market in 2031. According to the Flexible Packaging Association, flexible packaging is lightweight than other materials, reducing waste and source. The form-fill-seal films are considered the most preferred flexible packaging solution as they offer multi-functional benefits such as lightweight, high product-to-package ratio, and product protection.  

Shifting consumer preference for recyclable packaging in food and consumer goods is pushing manufacturers to launch new and improved flexible packaging solutions. In response to this, U.S.-based Indevco Plastics has launched polyethylene form-fill-seal films with up to 50% recycled (PCR & PCR) resins, environment-friendly water-based inks, and 100% recyclable form-fill-seal films.

These developments are indicative of lucrative growth prospects for manufacturers operating in the FFS market in the U.S.

Why is Demand for Sustainable FFS Films Rising in Germany?

The form-fill-seal films market in Germany is expected to hold 1/5 of the Europe FFS films market share in 2031. Form-fill-seal films extend the shelf life of the products and provide high visibility of ingredients, making them stand out on shelfs and attractive to customers.

According to Plastics Europe, plastics packaging protects and preserves perishable foods hygienically and helps reduce waste and maintains nutritional value and taste. FFS films enhance the product’s shelf life and provide good heat-sealing strength to the product, making them a suitable packaging choice for consumer goods and food products.

Increasing demand for convenient and ready-to-eat meals in Germany is anticipated to continue pushing sales of FFS films over the assessment period

How will Expansion of Ecommerce Sector Propel Demand for FFS Films in India?

In 2031, India is estimated to account for 41% of FFS films sales in South Asia. According to the Indian Flexible Packaging and Folding Carton Manufacturers Association, the Indian packaging industry is setting new business trends. Expansion of the e-commerce sector, and emergence of new digital retail platforms are spurring demand for innovative and sturdy packaging solutions.

Apart from this, increasing demand for convenience foods and rising concerns regarding food contamination is compelling manufacturers to launch innovative FFS films. For instance:

• Max Specialty Films Limited has developed “Max Shield,” a revolutionary antimicrobial BOPP film that eliminates 99.9% of microbes such as fungus, bacteria, yeast, viruses, mold, etc., that contact the film.

Increasing demand for innovative, flexible and durable packaging will continue pushing sales of form-fill-seal film in India over the forecast period.

Will China Emerge as an Attractive Form-Fill-Seal Films Market?

Consumption of form-fill-seal films in China is estimated to surpass4 Mn Tonnes by 2031.  Emergence of e-commerce and increasing reliance on online retail are spurring demand for effective packaging solutions in China.

Form-fill-seal films are contamination-free, leak-resistant and protect food ingredients from environmental impact. Consumers are more concerned about taste and freshness of food products. This, in turn, is propelling demand for FFS films in China.

According to Trade Map, China has exported 917 ‘000 Tonnes of FFS films in 2020, and the trend is expected to continue over the forecast period.

How Will FFS Films Sales fare Across Australia?

The form-fill-seal films market in Australia is forecast expand at a 3% CAGR over the assessment period. Form-fill-seal films have high visibility and strong product protection during transportation. These films are a prime solution for the automatic packaging of various food products.

According to the Food Packaging Forum, the Australian government has announced a national plastic plan in April, 2021, and outlined an approach to increase plastics recycling to find an alternative for plastic and reduce the environmental impact. This is expected to continue pushing sales of FFS films in Australia through 2031.

Category-wise Insights

Applications of FFS Films for Sachets and Pouches to Gain Traction

The sachets and pouches segment is projected to account for more than half of the total FFS films value share during 2021-2031. Flexible bags and pouches are cost-effective and sustainable packaging solutions for snacks and ready-made food packs.

Form-fill-seal films protect contents from light, oxygen, moisture, and improve overall toughness and offer excellent sealing properties. Pouches and sachets made from FFS films keep food fresh for longer and offer an eye-catchy finish and aesthetic look.

These films are an integrated solution with all processes done in one compact system. The film is cut from continuous reel depending upon the product’s size and volume, then filled and sealed before its ready for dispatch, making them an ideal format for automatic packaging of consumer goods and food products. 

Pouches made from form-fill-seal films are easy to use, lightweight, sturdy and facilitate  mess-free dispensing. They are  easy to carry, ideal for consumers on-the-go and e-commerce.  These pouches protect ingredients against spill and contamination. Owing to these factors, sales of FFS films in the pouch and sachets segment are projected to rise through 2031.  

Why is Polyethylene (PE) the Most Preferred Material Choice for FFS Films?

Sales of polyethylene (PE) form-fill-seal films are expected to grow at a 4% CAGR through 2031. These films are reliable and safe and are suitable for frozen food, bakery, confectionery, seafood, and ready meals. Form-fill-seal packaging films made of high-quality polypropylene are used in high-speed automatic filling line processes where high puncture and tear resistance are crucial factors.

The products made using polyethylene form-fill-seal films extend have longer shelf life, convenient in handling, and are easy to open. These films provide high-load stability during handling, storage, and transport. They also have fantastic printing quality, provide high clarity, and are suitable for robust filling processes, making them the most-preferred material choice.

Demand for FFS Films in the Healthcare and Pharmaceutical Sector to Remain High

The healthcare and pharmaceutical segment is anticipated to gain 20 BPS of current value share over the assessment period. Pharmaceutical products require robust and full-bodied protection against external environmental impact. The temperature fluctuation can reduce the efficacy of the substance and treat it as unsafe and ineffective.

Form-fill-seal films are the most effective, safe, and sterile packaging for medical and pharmaceutical products. These films stand out due to their high puncture resistance, outstanding barrier protection, and long shelf life. Form-fill-seal films used in medicine packaging with tight-fitting provides sustainable and optimal protection.

The safety of medicinal products is crucial during transport.  Form-fill-seal films act as a shield to provide safe, secure, and reliable shipping. Considering this, FMI has projected sales of FFS films to continue rising in the healthcare and pharmaceutical sector through 2031.

Why are Multilayer Form-Fill-Seal Films Most Preferred Layout Structure?

The multilayer form-fill-seal films segment is projected to gain 140 BPS during the forecast period. Multilayer form-fill-seal films comprise a mixture of more than one polymer, offering high-end sealability in finished packaging. These films are lightweight, material-efficient, and cost-effective.

Multiple coextruded form-fill-seal films provide greater strength than single-layer or non-coextruded films.  They protect contents of bags and pouches from external environmental factors and ambient hazards that may cause damage.

Using multilayer films, the modulus value such as stiffness and rigidity increase by almost 50 percent or even double. This makes bags and pouches made using FFS machines stiffer and increases the production line speed. Bags made from multilayer form-fill-seal films can offer 20 times more protection against odors and environmental hazards, making them ideal for processed food, baby food, dairy products, and medical products such as wound care, surgical kits, etc.

Competitive Landscape

Leading players iperating in the global form-fill-seal films market are focusing on research and development to launch sustainable and recyclable packaging formats to improve sales. Apart from this, players are investing in strategic collaborations, mergers and acqusitions to expand their global footprint. For instance:

• In July 2021, ProAmpac acquired Ultimate Packaging, a pioneer in flexographic printing based in the United Kingdom. With this acquisition, ProAmpac aims to strengthen its market position in food flexible packaging, expand its portfolio of sustainable solutions, and extend its market approach across the U.K.
• In July 2020, Mondi Plc partnered with meat producer Hütthaler to develop a new recyclable mono-material film for meat and sausage products that can provide barrier protection to the food and extend its shelf life.

Scope of Report

Form-Fill-Seal Films Market by Category

By Material Type:

• Polyethylene (PE)
• Polypropylene (PP)
• Polyethylene Terephthalate (PET)
• Aluminum Foil
• Others

By Layer Structure:

• Monolayer Films
• Multilayer Films

By Application:

• Sachets & Pouches
• Bags & Sacks
• Others

By End-Use:

• Food
  • Meat, Poultry & Seafood
  • Dairy Products
  • Fruits & Vegetables
  • Bakery & Confectionery
  • Others
• Healthcare & Pharmaceuticals
• Agriculture & Allied Products
• Building & Construction
• Others

By Region:

• North America
• Latin America
• Europe
• Middle East and Africa
• East Asia
• South Asia
• Oceania