The USA and Canada molded fiber pulp packaging industry is projected to be grown from USD 2.1 billion in 2025 to USD 3.5 billion by 2035, at a CAGR of 5.2%. In 2024, USD 1.9 billion in sales was recorded, showing a consistent upward trajectory in demand driven by sustainability mandates and consumer preferences for eco-friendly packaging.
Metric | Value |
---|---|
Market Size (2025) | USD 2.1 Billion |
Market Size (2035) | USD 3.5 Billion |
CAGR (2025 to 2035) | 5.2% |
This growth has been attributed to increasing regulations against single-use plastics and rising awareness regarding biodegradable and compostable materials. Strong traction has been gained by the molded fiber segment across foodservice, retail, and industrial applications due to its recyclability and minimal environmental footprint.
In 2025, Huhtamaki announced an acquisition to strengthen its molded fiber packaging capabilities in response to shifting legislation in North America. “This acquisition is attractive for us as legislation in North America continues to shift packaging choices in the egg industry toward more renewable and recyclable options, such as molded fiber.
It supports our aspiration to be a leader in this category, delivers installed capacity to strengthen our manufacturing footprint, and helps grow our excellent customer relationships, including advancements in double-coated fiber packaging,” said Ann O’Hara, President, Huhtamaki North America.
Significant investments are being made by manufacturers in the region in automation, high-precision molds, and hybrid fiber technologies to scale production and meet evolving performance standards. Acceleration in market penetration is being driven by government support for sustainable materials and pressure from retail brands to meet ESG targets. A key role is being played by strategic collaborations, acquisitions, and infrastructure expansions in boosting capacity and innovation.
Looking ahead, an upward trend is expected to be continued in the molded fiber pulp packaging market in the USA and Canada, driven by regulatory momentum and rising demand from eco-conscious consumers. A competitive edge is likely to be gained by companies focusing on the development of lightweight, cost-effective, and functionally advanced molded fiber solutions. As shifts are made by the industry toward closed-loop systems and circular packaging models, a critical role is expected to be played by molded fiber in North America's sustainable packaging future
Segmentation of the market is done based on molded pulp type, product type, application, end use, and region. By molded pulp type, thick wall, transfer molded, thermoformed fiber, and refined molded pulp are included. In terms of product type, trays, drink carriers (2-cup holders, 4-cup holders, 6-cup holders, more than 8-cup holders), boxes, end caps, plates, bowls, cups, and clamshell containers are categorized.
By application, the market is comprised of primary packaging, secondary packaging, and edge protectors. By end use, consumer durables, food and beverage, cosmetics, healthcare, automotive, and logistics are included. Regionally, the market is analyzed across the USA and Canada.
Thermoformed fiber has been projected to account for 41.1% of the molded fiber packaging market in 2025 due to its superior precision and surface finish compared to traditional molded pulp. High-definition tooling and advanced drying techniques have enabled the production of intricate designs suitable for premium packaging. Adoption has surged in applications demanding exact fit, aesthetic appeal, and stack ability, especially in electronics, cosmetics, and foodservice trays. Its compatibility with post-consumer recycled fiber aligns with sustainability mandates while maintaining structural strength.
The ability to integrate water and oil-resistant coatings within thermoformed designs has allowed broader use in packaging perishable items. Innovations in tooling speed and automation have further driven its scalability across regions. Global brands have adopted thermoformed fiber packaging to meet plastic reduction targets without compromising branding or user experience. The technology’s capacity for detailed embossing and printability has positioned it as a viable alternative to vacuum-formed plastics.
Food and beverage has been estimated to hold a 48.9% market share in the molded fiber packaging sector by 2025, driven by growing consumer and regulatory pressures to reduce plastic waste. Egg cartons, cup carriers, produce trays, and foodservice containers have rapidly transitioned to fiber-based alternatives. Shelf-ready molded trays and pulp containers offer composability, while maintaining protection for fresh, frozen, and ready-to-eat foods. The sector benefits from molded fiber's cushioning and breathability, particularly for produce and dairy applications.
Restaurants and QSRs have scaled adoption of molded pulp clamshells and bowls, supported by bans on EPS and single-use plastics in North America and Europe. Demand is further supported by increased takeout and delivery trends post-pandemic. Leading beverage brands have introduced molded fiber secondary packaging for multipacks and bottle protection. Fiber-based solutions have been favored for their branding potential and ease of integration into curbside recycling systems.
Rapid Shift toward Eco-friendly Packaging to Spur Demand for Custom Molded Fiber Packaging
Molded pulp is a sustainable material that is projected to witness a significant growth rate in the field of secure packaging. In early days, expanded polystyrene packaging was used for maintaining various products from external shocks and damage. However, government agencies in numerous countries such as the USA banned the use of single-use plastic material for making take-out containers for food, as well as in several other end-use industries.
Increasing shift toward eco-friendly packaging, including molded fiber pulp packaging as it bears the same properties as expanded polystyrene is likely to drive sales. However, it is difficult to recycle expanded polystyrene unlike molded fiber pulp, which is obtained from recycled paper. Hence, molded pulp material is durable and bears shock-bearing properties.
During transportation or shifting of expensive products, molded fiber pulp packaging is used. Expensive products such as electronic gadgets, wine bottles, and mobile phones are packed in this type of materials to prevent them from vibration and shock. Eventually, need for protective packaging is positively impacting molded fiber pulp packaging demand in the USA and Canada.
Country | USA |
---|---|
Market Share (2025) | 79.6% |
Market Share (2035) | 76.4% |
Basis Points (BPS) Analysis | -320 |
Country | Canada |
---|---|
Market Share (2025) | 20.4% |
Market Share (2035) | 23.6% |
Basis Points (BPS) Analysis | 320 |
Increasing Consumption of Eggs in the USA to Push Sales of Molded Pulp Fiber
The USA is estimated to hold around 79.6% of market share by 2025. The USA is considered to have the world’s largest poultry industry and is the second-largest exporter of poultry eggs and meat. Consumption of poultry meat is higher than beef or any other meat type in the country. According to data provided by the USA Department of Agriculture, in 2021, about 18% of poultry production was exported, and this poultry production consumption will positively impact the USA and Canada molded fiber pulp packaging industry.
Eggs are exported in various regions from the USA and hence require secure packaging to avoid breakage. This factor is projected to impact the molded fiber pulp packaging industry. Trays made of molded fiber pulp are set to be the primary material used for egg packaging. Overall, poultry products will require molded trays and this will surge the market for molded fiber pulp packaging in the USA and Canada.
Presence of Renowned Automotive Companies in Canada to Spur Demand for Molded Fiber Packaging
Canada is considered to be a developing country in the automotive sector. Various automotive parts are manufactured in Canada. According to data provided by the International Trade Administration, by 2021, Canada is set to be the second-largest automotive market among other countries and currently holds about 1/3rd portion of the market through manufacturing of new vehicles. Leading automotive producers are based in Canada, and the five local companies include Toyota, Honda, General Motors, Stellantis N.V. (formerly FCA), and Ford.
Accumulative auto sales and expansion of the automotive market were assessed over USD 19 billion and were stable during 2021. Expansion of the automotive sector is anticipated to flourish the molded fiber pulp packaging industry. Growth is attributed to requirement of primary packaging and edge protectors for storing spare parts. Automotive trays and boxes are available in various dimensions and shapes for transportation or storage purposes in Canada.
Key players operating in the USA and Canada molded fiber pulp packaging market are focusing on expanding their production capacities and trying to improve product quality according to needs of numerous consumers. Leading players are also adopting latest technologies to come up with innovative features for their existing products
One of the recent developments by leading players include:
Report Attributes | Details |
---|---|
Market Size (2025) | USD 2.1 billion |
Projected Market Size (2035) | USD 3.5 billion |
CAGR (2025 to 2035) | 5.2% |
Base Year for Estimation | 2024 |
Historical Period | 2020 to 2024 |
Projections Period | 2025 to 2035 |
Quantitative Units | USD billion for value and kilotons for volume |
Molded Pulp Type Segments Analyzed (Segment 1) | Thick Wall, Transfer Molded, Thermoformed Fiber, Processed Pulp |
Product Type Segments Analyzed (Segment 2) | Trays, Drink Carriers (2 Cups, 4 Cups, 6 Cups, More than 8 cups), Boxes, End Caps, Plates, Bowls, Cups, Clamshell Containers |
Application Segments Analyzed (Segment 3) | Primary Packaging, Secondary Packaging, Edge Protectors |
End Use Segments Analyzed (Segment 4) | Consumer Durables (Mobile Phone, Television, Laptops, Tube Lights and Bulbs, Others (Air Conditioners, Refrigerators)), Food & Beverage (Egg Packaging (4 eggs, 6 eggs, 12 eggs, 24 eggs, More than 30 eggs), Wine Packaging (375 ml, 750 ml, 1.5 liters, More than 3 liters), Fruit Packaging, Others), Cosmetics, Food Services, Healthcare, Automotive, Logistics, Others (Candles, Flower Packaging) |
Regions Covered | North America |
Countries Covered | United States, Canada |
Key Players influencing the Molded Fiber Pulp Packaging Market | FiberCel Packaging LLC, Pactiv LLC, Henry Molded Products, Inc, EnviroPAK Corporation, Michelsen Packaging Company, Western Pulp Products Company, Multipap Industries, ProtoPak Engineering Corporation, Hartmann Canada Inc., Keiding Inc, Atlantic Pulp, MFT-CKF Inc, OrCon Industries Corporation, Cascades Inc., Huhtamaki Oyj, Pacific Pulp Molding, Inc., IB Packaging, Earth Recycle International S. de R. L. de C. V., Interbrands Packaging, YFY Jupiter |
Additional Attributes | Dollar sales by molded pulp type and product type, Adoption trends in sustainable packaging, Rising demand for egg, wine, and fruit packaging formats, Country-level market penetration, Technology upgrades in thermoformed and transfer molded fiber products, Competitive landscape with regional manufacturing footprint and innovation partnerships in North America |
The market is valued at USD 3.5 billion in 2035.
A 45% to 50% share of the value was acquired in 2024
The market witnessed a CAGR of 3.1% from 2020 to 2024.
A sustainable and protective packaging solution to drive sales.
The market holds a 79.6% share in 2025.
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