Thermoformed Medical Packaging Market Research Report Information By Material (PETG, APET, PP, PS, PVC, Others), By Packaging Type (Primary Packaging (Blister Packs, Clamshells, Trays & Lids, Pouches, Vials & Bottles, Others), Secondary Packaging (Cartons, Boxes, Wraps, Others)), By Application (Medical Devices & Instruments (Surgical Instruments, Catheters, Diagnostic Equipment, Others), Pharmaceuticals & Drug Delivery (Injectables, Tablets & Capsules), Implants & Prosthetics (Orthopedic Implants, Cardiovascular Implants, Others), Surgical

Global Thermoformed Medical Packaging Market Overview

The Thermoformed Medical Packaging Market was valued at USD 22.34 Billion in 2024. The Thermoformed Medical Packaging Market industry is projected to grow from USD 23.39 Billion in 2025 to USD 37.48 Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 4.8% during the forecast period (2025-2035).

The increasing demand for sterile and safe packaging and advancements in material technology and sustainability trends and drivers impact analysis are driving the growth of the Thermoformed Medical Packaging Market.

As per the Analyst at MRFR, Thermoformed Medical Packaging Market is an important component of the healthcare supply chain, and it provides safe, sterile, and good packaging solutions for medical devices, pharmaceuticals, diagnostic kits, and other healthcare products. 

Since demand for single-use and disposable medical products continues to increase, high-quality, cost-effective packaging is required to ensure product reliability and patient safety. Thermoformed packaging designs provide major benefits such as flexibility, mild construction, durability, and compliance with stringent regulatory standards such as ISO 11607 and FDA guidelines. These factors make it a favourite option among manufacturers in the medical industry.

 FIGURE 1: THERMOFORMED MEDICAL PACKAGING MARKET VALUE (2019-2035) USD BILLION

 Source: Secondary Research, Primary Research, MRFR Database, and Analyst Review

Thermoformed Medical Packaging Market Opportunity

GROWING DEMAND FOR SUSTAINABLE AND ECO-FRIENDLY PACKAGING SOLUTIONS

Global shift toward sustainability is significantly reshaping the thermoformed medical packaging market. With the rise in awareness about environmental issues and increasing regulatory pressure on plastic waste management, both the healthcare and packaging industries are actively looking for the eco-friendly alternatives if we compare it to the traditional petroleum-based plastics. This growing emphasis on sustainability has led to an increase in the demand for bio-based, recycled and compostable materials that can effectively replace conventional plastics such as polyvinyl chloride (PVC) and polyethylene terephthalate glycol (PETG) — without compromising critical attributes such as sterility, durability, and performance. 

Polymers like polylactic acid (PLA), polyhydroxyalkanoates (PHA), and recycled PET (rPET) are becoming more popular as they have a low carbon footprint, break down naturally, and can meet strict medical packaging standards. Manufacturers are choosing these materials to help with the sustainability goals while sticking to regulations like ISO 13485, FDA rules, and EU Medical Device Regulations (MDR). Governments are stepping in, by creating policies that restrict single-use plastics and encourage a more circular economy. Laws around extended producer responsibility (EPR) and eco-design are pushing companies to come up with packaging that can be reused, recycled, or composted. 

Companies are investing a lot of money into research and development so that they can improve the strength, usability, and cost of eco-friendly materials, while also cutting back on fossil fuels. A lot of healthcare providers and consumers want to buy from the brands that are concern about the environment. This change is making manufacturers look for greener packaging, not only to follow rules but also to improve their image and stay competitive. There are challenges like the high material costs and limits on what can be done with the materials, especially in tough conditions. Still, the benefits of sustainable packaging—like less harm to the environment and a better company image—are pushing it into the medical packaging field. As technology gets better and recycling systems improve worldwide, sustainable thermoformed packaging is all set to become the go-to option, opening up new growth chances for businesses in the industry.

Thermoformed Medical Packaging Market Segment Insights

Thermoformed Medical Packaging by Material Insights

Based on material, we have covered the following segments: PETG, APET, PP, PS, PVC, and Others. The PETG segment dominated the global market in 2024, while the APET segment is projected to be the fastest–growing segment during the forecast period. PETG, another version of PET with glycol modifications, improves durability, impact resistance, and clarity. PETG is commonly used in medical packaging due to its thermoforming characteristics and structural integrity during sterilization (gamma radiation and ethylene oxide [EtO]). In addition to its good chemical resistance and BPA-free, PETG is great for sensitive medical applications. PETG is a clear packaging solution in materials such as clamshells, trays, or blister packaging, requiring a clearer aspect and multiple handling. PETG has good formability properties at lower temperatures, providing energy savings in its production. 

PETG has good sealing capabilities that are important to sterile barrier systems. PETG also further supports sustainability initiatives for healthcare packaging, as it has recycled content and is regulated through the principles of the FDA and EU. PETG is much more expensive than standard PET and not as heat resistant as other products. However, regardless of all negatives of PETG, the market demand for high-performance, clear, and safe packaging solutions in diagnostics, surgical, and pharmaceutical market areas will help continue to grow the PETG segment globally.

Thermoformed Medical Packaging by Packaging Type Insights

Based on packaging type, we have covered the following segments: Primary Packaging, and Secondary Packaging. The Primary Packaging segment is divided into Blister Packs, Clamshells, Trays & Lids, Pouches, Vials & Bottles, Others. The Secondary Packaging segment is divided into Cartons, Boxes, Wraps, Others. The Primary Packaging segment dominated the global market in 2024, while the Secondary Packaging segment is projected to be the fastest–growing segment during the forecast period. Primary packaging refers to the first level of packaging that encases medical products directly. It has a crucial role in preserving product sterility, safety and integrity. Primary packaging in the medical field includes blister packs, clamshells, trays, pouches, lids, vials, bottles and some other containers which all contact pharmaceuticals or medical devices directly.

Primary packaging must meet extensive regulatory criteria regarding material composition, sterility, and labelling. Thermoformed primary packaging is particularly attractive as it can result in custom-fitted containers that protect devices' integrity during handling, transportation and storage. It generally includes transparent materials to allow easy inspection, can be sealed to demonstrate tampering, and must support sterilization, via gamma irradiation, ethylene oxide, or steam autoclaving.

FIGURE 2: THERMOFORMED MEDICAL PACKAGING MARKET SHARE BY PACKAGING TYPE 2024 AND 2035 (USD BILLION)

Source: Secondary Research, Primary Research, MRFR Database and Analyst Review

Thermoformed Medical Packaging by Application Insights

By application, market is segmented into: Medical Devices & Instruments, Pharmaceuticals & Drug Delivery, Implants & Prosthetics, Surgical & Wound Care Products, and Others. The Medical Devices & Instruments segment is divided into Surgical Instruments, Catheters, Diagnostic Equipment, Others. The Pharmaceuticals & Drug Delivery segment is divided into Injectables, Tablets & Capsules. The Implants & Prosthetics segment is divided into Orthopedic Implants, Cardiovascular Implants, Others. The Surgical & Wound Care Product segment is divided into Sutures & Dressings, Surgical Kits, Others. The End-User segment is divided into Pharmaceutical & Biotechnology Companies and Medical Device Manufacturers. 

The Pharmaceuticals & Drug Delivery segment dominated the global market in 2024, while the Surgical & Wound Care Products segment is projected to be the fastest–growing segment during the forecast period. Pharmaceuticals & drug delivery includes the thermoform or flexible packaging for pharmaceutical products whereby containment of the drug, accuracy of dosage dispensing and protection from moisture, light, air etc., are key considerations. Injectables include those in solid dosage form (e.g., capsules, tablets) as well as parenterals (e.g., injectables). Thermoformed blister packs and trays are popular for both oral and injectable drugs. Solutions must comply with health authority regulations on materials, labeling, and child resistance. Packaging is usually intended for either single-use or unit-doses to limit dosing errors and provide sterile doses.

Thermoformed Medical Packaging by End-User Insights

By end-user, the market is segmented into: Pharmaceutical & Biotechnology Companies, and Medical Device Manufacturers. The Pharmaceutical & Biotechnology Companies segment dominated the global market in 2024, while the Medical Device Manufacturers segment is projected to be the fastest–growing segment during the forecast period. Pharmaceutical and biotechnology companies are another significant end user of thermoformed packaging, especially for drug products, vaccines, and diagnostic reagents. Pharmaceutical companies begin with raw materials (sap, resin, botanical) and need packaging that protects sensitive pharmaceutical formulations from moisture, light and contamination, while ensuring the product is stable and sterile.

Pharmaceutical packaging uses blister packs for tablets and capsules, thermoformed trays for injectables and vials, and clamshells for protective packaging for diagnostic devices. More importantly, thermoformed packaging is also used to ensure compliance. Pharmaceutical products must comply with strict regulatory guidelines from the FDA, EMA and many others for labeling, traceability, tamper evident, and child resistance. In the world of biotech, where products are ultimately very high-value biologics or personalized medicines, packaging must provide optimal barrier protection and support cold chain logistics.  Custom inserts and compartmented trays keep gene therapies, cell cultures, and test kits safe during transport.

Thermoformed Medical Packaging Regional Insights

The report on the Thermoformed Medical Packaging Market has been segmented on the basis of region as: North America, Europe, Asia Pacific, Middle East & Africa, and South America. The Asia-Pacific dominated the global market in 2024, while the Asia Pacific is projected to be the fastest–growing segment during the forecast period. Major demand factors driving the Asia-Pacific market are Asia Pacific is both the largest and fastest growing region of the industrial construction market, driven by rapid urbanization, growing middle-class populations, and strong government initiatives. 

China is the largest and most active Asian industrial construction market, supported with a strong emphasis on self-reliant high-tech manufacturing, the Belt and Road Initiative, and massive direct investment. India is gaining momentum, with "Make in India" attracting defense, electronics, and pharmaceutical manufacturing. Southeast Asia is also gaining traction with relocations to lower-cost areas and to diversify trade away from trade risk with China, with countries such as Vietnam, Thailand, and Indonesia.

FIGURE 3: THERMOFORMED MEDICAL PACKAGING MARKET VALUE BY REGION 2024 AND 2035 (USD BILLION)

Source: Secondary Research, Primary Research, MRFR Database, and Analyst Review

Further, the countries considered in the scope of the Application Tracking System Market are the US, Canada, Mexico, Germany, France, the UK, Russia, Spain, Italy, Rest of Europe, China, India, Japan, South Korea, Malaysia, Thailand, Rest of Asia-Pacific, GCC Countries, South Africa, Rest of MEA, Brazil, Argentina, Rest of South America and others.

Global Thermoformed Medical Packaging Key Market Players & Competitive Insights

Many global, regional, and local vendors characterize the Thermoformed Medical Packaging Market. The market is highly competitive, with all the players competing to gain market share. Intense competition, rapid advances in technology, frequent changes in government policies, and environmental regulations are key factors that confront market growth. The vendors compete based on cost, product quality, reliability, and government regulations. Vendors must provide cost-efficient, high-quality products to survive and succeed in an intensely competitive market.

The major competitors in the market are Amcor Plc, Toppan Holdings Inc, WINPAK Ltd, PLACON Corporation, DORDAN Manufacturing Company, Incorporated, Prent Corporation, T.O. Plastics, Inc, Brentwood Industries, Inc, Tekni-Plex, Inc, NELIPAK are among others. The Thermoformed Medical Packaging Market is a consolidated market due to increasing competition, acquisitions, mergers and other strategic market developments and decisions to improve operational effectiveness.

Key Companies in the Thermoformed Medical Packaging Market include

• Amcor Plc


• Toppan Holdings Inc


• WINPAK Ltd


• PLACON Corporation


• DORDAN Manufacturing Company, Incorporated


• Prent Corporation


• O. Plastics, Inc


• Brentwood Industries, Inc


• Tekni-Plex, Inc


• NELIPAK

Thermoformed Medical Packaging Market Industry Developments

April 2025: TOPPAN Holdings Inc acquired Sonoco Products Company (Sonoco) Thermoformed & Flexibles Packaging business for approximately $1.8 billion. This acquisition is a significant milestone for TOPPAN, greatly expanding its capabilities and global reach in thermoformed packaging, including for medical applications.

January 2024: Amcor announced a significant expansion of its North American thermoforming capabilities specifically to meet the growing needs of healthcare customers. This expansion centers on the installation of advanced, automated thermoforming equipment at Amcor’s healthcare manufacturing plant in Oshkosh, Wisconsin. The new equipment will be located within a Class 7 cleanroom operating under the ISO 13485 quality system.

December 2024: Placon announced a significant expansion of its production capacity at its medical manufacturing facility in Plymouth, MN, and at its Madison, WI headquarters. This move is designed to meet the growing demand for custom thermoformed packaging solutions for the medical and healthcare industries. The expansion includes investments in new thermoforming equipment, additional cleanroom manufacturing space, and increased warehouse capacity.

February 2023: Winpak has accelerated the commercialization of its recycle-ready thermoforming films, ReForm (forming film) and ReLam (non-forming film), which are part of its ReFresh™ product portfolio. These films are over 95% polyolefin, suitable for polyethylene mono-material recycling streams, and can include post-consumer resin content certified by ISCC PLUS

Thermoformed Medical Packaging Market Segmentation

Thermoformed Medical Packaging by Material Outlook

• PETG


• APET


• PP


• PS


• PVC


• Others

Thermoformed Medical Packaging by Packaging Type Outlook

• Primary Packaging
  
  
  
  • Blister Packs
  
  
  • Clamshells
  
  
  • Trays & Lids
  
  
  • Pouches
  
  
  • Vials & Bottles
  
  
  • Others
  
  
  
  


• Secondary Packaging
  
  
  
  • Cartons
  
  
  • Boxes
  
  
  • Wraps
  
  
  • Others
  
  
  
  

Thermoformed Medical Packaging by Application Outlook

• Medical Devices & Instruments
  
  
  
  • Surgical Instruments
  
  
  • Catheters
  
  
  • Diagnostic Equipment
  
  
  • Others
  
  
  
  


• Pharmaceuticals & Drug Delivery
  
  
  
  • Injectables
  
  
  • Tablets & Capsules
  
  
  
  


• Implants & Prosthetics
  
  
  
  • Orthopedic Implants
  
  
  • Cardiovascular Implants
  
  
  • Others
  
  
  
  


• Surgical & Wound Care Products
  
  
  
  • Sutures & Dressings
  
  
  • Surgical Kits
  
  
  • Others
  
  
  
  


• Others

Thermoformed Medical Packaging by End-User Outlook

• Pharmaceutical & Biotechnology Companies


• Medical Device Manufacturers

Thermoformed Medical Packaging Regional Outlook

• North America
  
  
  
  • US
  
  
  • Canada
  
  
  • Mexico
  
  
  
  


• Europe
  
  
  
  • Germany
  
  
  • UK
  
  
  • France
  
  
  • Russia
  
  
  • Italy
  
  
  • Spain
  
  
  • Rest of Europe
  
  
  
  


• Asia-Pacific
  
  
  
  • China
  
  
  • India
  
  
  • Japan
  
  
  • South Korea
  
  
  • Malaysia
  
  
  • Thailand
  
  
  • Rest of Asia-Pacific
  
  
  
  


• South America
  
  
  
  • Brazil
  
  
  • Argentina
  
  
  • Rest of South America
  
  
  
  


• Middle East & Africa
  
  
  
  • GCC Countries
  
  
  • South Africa
  
  
  • Rest of MEA
  
  
  
  

Report Attribute/Metric	Details
Market Size 2024	USD 22.34 Billion
Market Size 2025	USD 23.39 Billion
Market Size 2035	USD 37.48 Billion
Compound Annual Growth Rate (CAGR)	4.8% (2025-2035)
Base Year	2024
Forecast Period	2025-2035
Historical Data	2019-2023
Forecast Units	Value, Volume (USD Billion, Million Units)
Report Coverage	Revenue Forecast, Competitive Landscape, Growth Factors, and Trends
Segments Covered	By Material, By Packaging Type, By Application, By End-User
Geographies Covered	North America, Europe, Asia Pacific, South America, Middle East & Africa
Countries Covered	The US, Canada, Mexico, Germany, France, the UK, Russia, Spain, Italy, Rest of Europe, China, India, Japan, South Korea, Malaysia, Thailand, Rest of Asia-Pacific, GCC Countries, South Africa, Rest of MEA, Brazil, Argentina, Rest of South America
Key Companies Profiled	Amcor Plc, Toppan Holdings Inc, WINPAK Ltd, PLACON Corporation, DORDAN Manufacturing Company, Incorporated, Prent Corporation, T.O. Plastics, Inc, Brentwood Industries, Inc, Tekni-Plex, Inc, NELIPAK
Key Market Opportunities	·         Growing Demand for Sustainable and Eco-Friendly Packaging Solutions
Key Market Dynamics	·         Increasing Demand for Sterile and Safe Packaging ·         Advancements in Material Technology and Sustainability Trends