The medical devices secondary packaging market is projected to grow from USD 14.3 billion in 2025 to USD 23.1 billion by 2035, registering a CAGR of 4.9% during the forecast period. Sales in 2024 reached USD 13.7 billion, reflecting steady demand across various sectors.
Growth has been driven by increasing applications in pharmaceuticals, surgical instruments, diagnostic equipment, imaging devices, and consumer health devices, where secondary packaging is essential for efficient and sustainable packaging solutions. The market's expansion is further supported by advancements in packaging technology and the rising demand for recyclable and lightweight materials.
Significant investments and expansions have been undertaken by key players in the medical devices secondary packaging market. In August 2024, UFP Technologies, Inc., a designer and custom manufacturer of comprehensive solutions for medical devices, sterile packaging, and other highly engineered custom products, announced the acquisition of AQF Limited. AQF Medical develops and manufactures custom-engineered foam and thermoplastic components used in a wide range of medical devices and packaging.
“We are excited about the addition of AQF Medical, our fourth acquisition in the past few months,” said R. Jeffrey Bailly, Chairman and CEO of UFP Technologies. “AQF Medical, with their excellent leadership team and strong reputation, brings significant value to our MedTech platform. Their expertise in converting specialty foams and films, and their strategically located factory for the MedTech market, give us the expanded European manufacturing presence our clients have requested and their joint venture facility in Singapore will enable us to support the Asian market locally.”
Environmental concerns and regulatory pressures have driven innovation in the medical devices secondary packaging market. Manufacturers are focusing on developing eco-friendly packaging compatible with sustainable materials and recyclable substrates.
Advancements in packaging technology are enabling more efficient solutions, reducing waste, and improving product protection. Collaborations between industry stakeholders are fostering the development of packaging that meets stringent environmental standards, thereby supporting the market's transition towards sustainability.
The medical devices secondary packaging market is expected to witness steady growth, driven by increasing demand in surgical instruments, diagnostic equipment, and imaging devices sectors. Manufacturers focusing on sustainable and innovative solutions are anticipated to gain a competitive edge.
Emerging markets in Asia-Pacific and Latin America are projected to offer significant growth opportunities due to rising consumer awareness and industrialization. Strategic collaborations and investments in research and development are likely to foster product innovation and market expansion. As environmental concerns continue to influence consumer behavior, the adoption of eco-friendly medical devices secondary packaging is expected to become a key differentiator in the industry.
The table below shows the projected CAGR for the medical devices secondary packaging market over multiple semi-annual timeframes between 2025 and 2035.
| Particular | Value CAGR |
|---|---|
| H1(2024 to 2034) | 5.3% |
| H2(2024 to 2034) | 4.9% |
| H1(2025 to 2035) | 4.7% |
| H2(2025 to 2035) | 5.5% |
In the first five years (H1) of the period, extending from 2024 to 2034, the market is set to grow at a Compound Annual Growth Rate (CAGR) of 5.3%, with growth slowing slightly to 4.9% for the remaining five years (H2) of the decade. From H1 2025 to H2 2035. However, this CAGR declines further to 4.7% (H1 2025) until 5.5% (H2 2035). H1 declined by 60 BPS, followed by H2, increasing by 80 BPS.
The market is segmented based on material type, product type, packaging type, end use, and region. By material type, the market includes plastic, paper/cardboard, glass, foam, and metal. In terms of product type, the market is categorized into trays, boxes, blisters, clamshells, pouches, bags, and bottles.
By packaging type, the market includes tamper-evident packaging, sterile barrier-compatible packaging, protective packaging, moisture-resistant packaging, and custom packaging solutions. In terms of end use, the market comprises surgical instruments, diagnostic equipment, implantable devices, therapeutic equipment, monitoring devices, and consumer health devices. Regionally, the market is analyzed across North America, Latin America, East Asia, South Asia & Pacific, Eastern Europe, Western Europe, Oceania, and the Middle East & Africa.
Plastic has been projected to hold a 60.5% market share in the medical devices secondary packaging market in 2025, due to its durability, barrier strength, and compatibility with sterilization methods. Materials such as polyethylene, PET, and polypropylene are widely used to ensure moisture and contamination protection during storage and transportation. These plastics offer resistance to puncture and abrasion while supporting heat sealing, which is vital for packaging sensitive devices like catheters, syringes, and diagnostic kits.
Clear plastic films and clamshell formats also enable easy visibility for product identification and verification without compromising sterility. With rising regulatory demands for safety, barrier performance, and traceability, plastic-based secondary packaging solutions are expected to remain dominant. Industry investments in medical-grade recyclable polymers are expected to further solidify plastic’s leadership in this segment.
Additionally, plastic formats align well with regulatory requirements, offering traceability, tamper evidence, and labeling space. Efforts to incorporate recycled content and reduce single-use waste through design optimization have further bolstered plastic’s relevance in the healthcare sector. Due to its functional performance, regulatory acceptance, and evolving sustainability solutions, plastic is expected to maintain its lead as the most preferred material in medical secondary packaging applications.
Surgical instruments have been estimated to account for approximately 28% of the market share in 2025, driven by strict sterility mandates and the complexity of reusable or precision instruments. These tools require robust secondary packaging to maintain cleanliness and to organize items within sterile fields across hospitals and surgical centers. Thermoformed trays, pouches with barrier films, and rigid containers are commonly used for scalpels, forceps, clamps, and endoscopic devices. These packaging systems ensure both protection from physical damage and compatibility with autoclave or ethylene oxide sterilization processes.
Secondary packaging for surgical instruments is designed not only for safety but also for workflow efficiency in sterile handling and quick access during operations. Color-coded or compartmentalized formats are often used to assist with procedural accuracy and inventory control.
The continued rise in surgical volumes, aging populations, and demand for minimally invasive procedures are expected to sustain the strong requirement for protective and functional secondary packaging tailored to surgical tools.
As surgical interventions increase globally particularly in aging populations and emerging healthcare markets the volume of instrument packaging is expected to grow. Innovations in sustainable rigid plastics and integrated RFID tracking are projected to further evolve the packaging landscape in this segment.
Rising Regulatory Compliance Requirements Drive Market Growth
The regulatory authorities like the FDA and EU MDR have set forth stringent guidelines for medical device packaging to ensure sterilisation, tamper evidence, and correct labelling of devices. This is positively impacting the demand for high-end secondary packaging solutions.
Increasing Demand for Sustainable Packaging Solutions
Medical device suppliers are increasingly focusing on choosing recyclable cartons and bio-alternative secondary packaging components to practically reduce their carbon footprint.
Cost Complexity and Supply Chain Challenge
Fluctuating raw material prices and disruptions in the supply chain are some of the key challenges that the medical devices and secondary packaging market have been witnessing. The adoption of advanced track-and-trace technologies also increases packaging costs. Yet automation and smart packaging innovations should improve efficiency and lower ongoing costs.
Tier 1 Companies
This includes existing dominant players with a high share around the globe, offering various types of secondary packaging solutions along with a manufacturing edge. They are recognised for their strong position across several geographies while providing advanced technology and solutions to the medical devices industry.
Generally, Tier 1 companies are known to operate within stringent regulatory compliances and implement good quality controls over manufacturing. Tier 1, which includes industry leaders such as Amcor, Sealed Air Corporation, Berry Global, WestRock, Sonoco, DuPont and Mitsubishi Chemical Holdings. Targeted for enormous scale and featuring products for variable materials (e.g. plastic movies, rigid containers, pouches) and drug security, security, and healthcare compliance.
Tier 2 Companies
Companies that are regional players with specialised capabilities in medical devices secondary packaging. They usually hedge a particular market or region but still provide consistent and low-cost solutions with the highest regulatory compliance. However, these companies have the advantage of customising their packaging solutions to target niche markets or specific categories of medical devices.
Some manufacturers of Tier 2 include Innova Packaging, Advanced Protective Packaging, Cleancorp, Prism Medical Packaging, FlexPak, ProAmpac, and Makro Plastics. While they may not be as widespread as Tier 1, they possess significant power in their specific industries due to their specialisations.
Tier 3 Companies
These are generally small players that are active regionally or locally and specialise in catering to a specific demand in the medical devices industry. They usually serve very narrow markets and highly specialised forms of medical packaging, like packaging for small medical devices that are not widely used or custom packaging for local health care providers. They also tend to operate in less formalised market structures and have more localised geographies.
Tier 3 companies in the medical device secondary packaging market comprise small-scale manufacturers, converters, and regional players providing economical, simple packaging solutions or packaging formats aimed at very specific demands.
| Countries | Value CAGR (2025 to 2035) |
|---|---|
| United States | 5.8% |
| India | 7.5% |
| Germany | 4.0% |
| China | 6.2% |
| Brazil | 3.6% |
| United Kingdom | 4.3% |
| Canada | 4.0% |
The growth of e-commerce and the healthcare industry in the USA is increasing the need for strong and resilient secondary packaging solutions in the medical device sector. With growing numbers of medical products being delivered directly to consumers, healthcare providers, and pharmacies, the demand for packaging that can absorb shock and protect sensitive medical devices in transit has increased.
The demand is across the spectrum of healthcare products, from pharmaceuticals to diagnostic equipment to surgical devices. Increasing adoption of moulded pulp packaging on the back of its lightweight, economical, and protective nature. Moulded pulp packaging is becoming a viable alternative for USA companies searching for sustainable packaging over plastic-based solutions.
Germany has been leading the way in the introduction of sustainable and environmentally friendly packaging for medical devices. Germany has strict regulations surrounding waste management and recyclability of packaging and is moving toward more sustainable alternative packaging methods, such as moulded fibre pulp, for secondary packaging.
The country is at the forefront of environmental concerns, and consumers are demanding green products, Japan is a vital market for the uptake of sustainable packaging in the medical device industry. This is especially true in the pharmaceutical and medical device industries, where regulations are tight, and there's a growing need for greener alternatives.
The players of this industry are coming up with new product development and launch, customised solutions using innovative materials to meet specialised requirements for medical device packaging. They are working with healthcare providers and packaging material suppliers to grow their business. Businesses are also making a push towards sustainability through eco-friendly practices and technologies that decrease product damage while minimising their environmental footprint.
The market is expected to grow at a CAGR of 4.9% from 2025 to 2035.
The global market stood at USD 13.7 billion in 2024.
The market is anticipated to reach USD 23.1 billion by 2035.
Asia Pacific is projected to show the highest growth with a CAGR of 6.1%.
Key players include Amcor, Sealed Air, AptarGroup, Berry Global, Smurfit Kappa, WestRock, and Tekni-Plex.
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Medical Devices Secondary Packaging Market
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