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US Thermoformed Plastics Market

ID: MRFR/CnM/15419-HCR
111 Pages
Chitranshi Jaiswal
October 2025

US Thermoformed Plastics Market Research Report By Product (Polyethylene Terephthalate (PET), Polymethyl, Methacrylate (PMMA), Polyethylene (PE), Polypropylene (PP), Polystyrene (PS), Acrylonitrile Butadiene Styrene (ABS), Polyvinyl Chloride (PVC), High Impact Polystyrene (HIPS), Biodegradable Polymer), By Process (Vacuum Forming, Pressure Forming, Mechanical Forming) and By Application (Packaging, Construction, Electrical & Electronics, Automotive Packaging, Consumer Goods) - Forecast to 2035.

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US Thermoformed Plastics Market Summary

As per Market Research Future analysis, the US thermoformed plastics market size was estimated at 10.5 USD Billion in 2024.. The US thermoformed plastics market is projected to grow from 10.98 USD Billion in 2025 to 17.1 USD Billion by 2035, exhibiting a compound annual growth rate (CAGR) of 4.5% during the forecast period 2025 - 2035

Key Market Trends & Highlights

The US thermoformed plastics market is experiencing a robust shift towards sustainability and innovation.

  • Sustainability initiatives are driving the adoption of eco-friendly materials across various applications.
  • Technological advancements in manufacturing processes are enhancing efficiency and product quality in the thermoformed plastics sector.
  • the food and beverage segment remains the largest application, while the e-commerce packaging segment is emerging as the fastest-growing.
  • Rising demand for eco-friendly packaging and the expansion of e-commerce are key drivers propelling market growth.

Market Size & Forecast

2024 Market Size 10.5 (USD Billion)
2035 Market Size 17.1 (USD Billion)
CAGR (2025 - 2035) 4.53%

Major Players

Sonoco Products Company (US), Placon Corporation (US), Pactiv Evergreen Inc. (US), Greiner Packaging International (AT), Berry Global Inc. (US), Sealed Air Corporation (US), Amcor plc (AU), Novolex Holdings, LLC (US), Dart Container Corporation (US)

US Thermoformed Plastics Market Trends

The thermoformed plastics market is experiencing notable growth, driven by increasing demand across various sectors such as packaging, automotive, and consumer goods. This growth is largely attributed to the material's versatility, lightweight nature, and cost-effectiveness. As industries seek sustainable solutions, thermoformed plastics are becoming increasingly popular due to their recyclability and ability to reduce waste. Furthermore, advancements in manufacturing technologies are enhancing production efficiency, which may lead to lower costs and improved product quality. In addition, the regulatory landscape is evolving, with stricter guidelines promoting the use of eco-friendly materials. This shift is likely to encourage manufacturers to innovate and adopt sustainable practices. The market appears poised for expansion, as companies invest in research and development to create new applications for thermoformed plastics. Overall, the current trends suggest a dynamic environment where adaptability and sustainability are crucial for success in the thermoformed plastics market.

Sustainability Initiatives

There is a growing emphasis on sustainability within the thermoformed plastics market. Companies are increasingly adopting eco-friendly materials and processes to meet consumer demand for environmentally responsible products. This trend is likely to influence product development and manufacturing practices, as businesses strive to reduce their carbon footprint.

Technological Advancements

Innovations in manufacturing technologies are transforming the thermoformed plastics market. Enhanced production techniques, such as automation and improved molding processes, are leading to greater efficiency and reduced waste. These advancements may enable manufacturers to produce higher-quality products at lower costs.

Diverse Applications

The versatility of thermoformed plastics is driving their adoption across various industries. From packaging solutions to automotive components, the range of applications is expanding. This trend suggests that as industries evolve, the demand for customized thermoformed products will likely increase, presenting new opportunities for manufacturers.

Market Segment Insights

By Product: Polyethylene Terephthalate (PET) (Largest) vs. Polypropylene (PP) (Fastest-Growing)

In the US thermoformed plastics market, the product segment exhibits a diverse distribution of market shares among its constituents. Polyethylene Terephthalate (PET) holds a significant share, representing the largest portion of the market. Following close behind are Polypropylene (PP) and Polystyrene (PS), which are rapidly gaining traction. Other notable players include Acrylonitrile Butadiene Styrene (ABS) and Polyvinyl Chloride (PVC), which contribute to a competitive landscape as they cater to various application needs. Looking ahead, the growth trends within this segment are primarily driven by the increasing demand for sustainable and innovative packaging solutions. Polypropylene (PP) is recognized as the fastest-growing variant due to its lightweight properties and recyclability, appealing to manufacturers focusing on eco-friendly practices. Concurrently, the market for PET remains robust, supported by its versatility and widespread use in beverage packaging, thus maintaining its dominant presence.

Polyethylene Terephthalate (PET): Dominant vs. Polypropylene (PP): Emerging

Polyethylene Terephthalate (PET) is the dominant force in the product segment of the US thermoformed plastics market. Renowned for its excellent clarity, strength, and recyclability, PET is extensively utilized in packaging applications, particularly for food and beverages. Its versatility allows it to be molded into various shapes and sizes, making it a preferred choice among manufacturers. On the other hand, Polypropylene (PP) is an emerging player characterized by its lightweight nature and superior resistance to impact and chemicals. As sustainability becomes a critical focus for industries, PP's growing adoption in applications such as containers and automotive parts presents significant opportunities for market expansion.

By Process: Vacuum Forming (Largest) vs. Pressure Forming (Fastest-Growing)

In the US thermoformed plastics market, Vacuum Forming currently holds the largest market share among the various processes employed in thermoforming. This method is prevalent across multiple sectors due to its versatility and cost-effectiveness, making it the go-to choice for many manufacturers. Conversely, Pressure Forming is rapidly gaining traction, attracting attention for its ability to produce high-quality parts with minimal material waste, thereby appealing to environmentally conscious companies. The growth trends in this segment are influenced by advancements in technology and increasing demand for customized packaging solutions. Vacuum Forming remains a dominant process due to its established infrastructure and widespread use. However, Pressure Forming is projected to witness significant growth driven by innovations that enhance its efficiency and applications in the automotive and consumer goods industries, making it a preferred option for emerging markets.

Vacuum Forming (Dominant) vs. Pressure Forming (Emerging)

Vacuum Forming stands out as a dominant force in the US thermoformed plastics market, characterized by its ability to create large-scale, cost-efficient products. It is widely utilized in industries such as packaging and food service, where speed and volume are critical. The process involves heating a plastic sheet until malleable, then forming it over a mold using vacuum pressure. On the other hand, Pressure Forming is emerging as a strong contender, known for its superior detail and strength in the finished products. This method applies pressure to the heated plastic sheet, enabling it to take on complex shapes. Both processes offer unique advantages, catering to different market needs, with Vacuum Forming leading in market share while Pressure Forming capitalizes on innovation and quality.

By Application: Packaging (Largest) vs. Consumer Goods (Fastest-Growing)

In the US thermoformed plastics market, the application segment shows a significant distribution of market share among various values. Packaging dominates this sector owing to the increasing demand for lightweight and durable materials in food preservation and shipping. Construction and electrical & electronics follow as substantial contributors, driven by infrastructural growth and electronic gadget proliferation, respectively. Growth trends indicate a surge in sustainable packaging solutions, placing the consumer goods category on an upward trajectory. Factors supporting this growth include the rising consumer awareness regarding eco-friendly products and the transition towards more sustainable materials. Additionally, the automotive packaging segment is benefiting from advancements in vehicle design that favor lightweight materials, enhancing vehicular efficiency.

Packaging (Dominant) vs. Construction (Emerging)

Packaging stands as the dominant application in the US thermoformed plastics market, attributed to its versatility and critical role in ensuring product safety during transportation and storage. The attributes of thermoformed plastics, such as lightweight nature and barrier properties, make it the preferred choice in various industries. On the other hand, the construction sector is emerging, fast adapting to innovative applications of thermoformed plastics in building materials and insulation solutions. This transition is propelled by the need for energy-efficient structures and sustainable building practices, positioning construction as a significant growth area that complements the established packaging domain.

Get more detailed insights about US Thermoformed Plastics Market

Key Players and Competitive Insights

The thermoformed plastics market is currently characterized by a dynamic competitive landscape, driven by increasing demand for lightweight, durable packaging solutions across various sectors, including food and beverage, healthcare, and consumer goods. Key players such as Sonoco Products Company (US), Berry Global Inc. (US), and Pactiv Evergreen Inc. (US) are strategically positioned to leverage innovation and sustainability in their operations. Sonoco Products Company (US) focuses on enhancing its product offerings through advanced technology and sustainable practices, while Berry Global Inc. (US) emphasizes its commitment to circular economy principles, aiming to reduce plastic waste. Pactiv Evergreen Inc. (US) is also investing in expanding its product lines to meet the growing consumer preference for eco-friendly packaging solutions. Collectively, these strategies contribute to a competitive environment that prioritizes sustainability and innovation.

In terms of business tactics, companies are increasingly localizing manufacturing to reduce lead times and enhance supply chain efficiency. This approach appears to be a response to the growing demand for customized solutions and the need for agility in production. The market structure is moderately fragmented, with several key players holding significant market shares, yet leaving room for smaller companies to innovate and capture niche segments. The collective influence of these major players shapes market dynamics, as they compete not only on price but also on quality and sustainability.

In October 2025, Sonoco Products Company (US) announced the launch of a new line of biodegradable thermoformed packaging solutions aimed at the food service industry. This strategic move underscores the company's commitment to sustainability and positions it favorably in a market increasingly driven by eco-conscious consumer behavior. By introducing biodegradable options, Sonoco is likely to attract environmentally aware customers, thereby enhancing its market share.

In September 2025, Berry Global Inc. (US) expanded its production capabilities by investing in a new manufacturing facility in Texas, specifically designed for producing sustainable thermoformed products. This expansion not only increases Berry's production capacity but also aligns with its strategic focus on sustainability, allowing the company to meet the rising demand for eco-friendly packaging solutions. The facility is expected to enhance operational efficiency and reduce carbon emissions, further solidifying Berry's position as a leader in sustainable packaging.

In August 2025, Pactiv Evergreen Inc. (US) entered into a partnership with a leading technology firm to develop smart packaging solutions that integrate AI for enhanced supply chain management. This collaboration aims to optimize inventory management and reduce waste, reflecting a broader trend towards digital transformation in the industry. By leveraging AI, Pactiv Evergreen is likely to improve operational efficiency and respond more effectively to market demands.

As of November 2025, the competitive trends in the thermoformed plastics market are increasingly defined by digitalization, sustainability, and technological integration. Strategic alliances are becoming more prevalent, as companies seek to enhance their capabilities and market reach. The shift from price-based competition to a focus on innovation, technology, and supply chain reliability is evident, suggesting that future competitive differentiation will hinge on the ability to adapt to evolving consumer preferences and regulatory pressures.

Key Companies in the US Thermoformed Plastics Market market include

Industry Developments

The US Thermoformed Plastics Market has witnessed significant developments recently, driven by evolving consumer demands and sustainability concerns. In September 2023, Sonoco Products Company announced the expansion of its production capabilities to meet the increasing demand for eco-friendly packaging solutions. Meanwhile, Pactiv Evergreen has been investing in advanced technologies to enhance the recycling processes within their operations, aligning with industry trends towards sustainability. The market has also seen notable growth in valuation; Berry Global Group reported a 15% increase in revenue, reflecting the rising applications of thermoformed plastics across sectors like food packaging and medical supplies.

In terms of mergers and acquisitions, WestRock Company acquired a leading thermoform packaging provider in August 2023, a strategic move aimed at enhancing their product offerings. Exactech continues to expand, showcasing thermoformed solutions in orthopedic implants. Over the past two years, companies like Plastipak Holdings have focused on sustainable innovations and process redesigns. These trends reflect a broader shift within the US Thermoformed Plastics Market towards sustainability and innovation, driven by both consumer preferences and regulatory pressures.

Future Outlook

US Thermoformed Plastics Market Future Outlook

The thermoformed plastics market is projected to grow at a 4.53% CAGR from 2024 to 2035, driven by increasing demand in packaging, automotive, and consumer goods sectors.

New opportunities lie in:

  • Expansion into biodegradable thermoformed products for eco-conscious consumers.
  • Development of customized packaging solutions for e-commerce businesses.
  • Investment in advanced manufacturing technologies to enhance production efficiency.

By 2035, the thermoformed plastics market is expected to achieve robust growth and increased market share.

Market Segmentation

US Thermoformed Plastics Market Process Outlook

  • Vacuum Forming
  • Pressure Forming
  • Mechanical Forming

US Thermoformed Plastics Market Product Outlook

  • Polyethylene Terephthalate (PET)
  • Polymethyl Methacrylate (PMMA)
  • Polyethylene (PE)
  • Polypropylene (PP)
  • Polystyrene (PS)
  • Acrylonitrile Butadiene Styrene (ABS)
  • Polyvinyl Chloride (PVC)
  • High Impact Polystyrene (HIPS)
  • Biodegradable Polymer
  • Others

US Thermoformed Plastics Market Application Outlook

  • Packaging
  • Construction
  • Electrical & Electronics
  • Automotive Packaging
  • Consumer Goods
  • Others

Report Scope

MARKET SIZE 202410.5(USD Billion)
MARKET SIZE 202510.98(USD Billion)
MARKET SIZE 203517.1(USD Billion)
COMPOUND ANNUAL GROWTH RATE (CAGR)4.53% (2024 - 2035)
REPORT COVERAGERevenue Forecast, Competitive Landscape, Growth Factors, and Trends
BASE YEAR2024
Market Forecast Period2025 - 2035
Historical Data2019 - 2024
Market Forecast UnitsUSD Billion
Key Companies Profiled["Sonoco Products Company (US)", "Placon Corporation (US)", "Pactiv Evergreen Inc. (US)", "Greiner Packaging International (AT)", "Berry Global Inc. (US)", "Sealed Air Corporation (US)", "Amcor plc (AU)", "Novolex Holdings, LLC (US)", "Dart Container Corporation (US)"]
Segments CoveredProduct, Process, Application
Key Market OpportunitiesGrowing demand for sustainable packaging solutions drives innovation in the thermoformed plastics market.
Key Market DynamicsRising demand for sustainable packaging drives innovation and competition in the thermoformed plastics market.
Countries CoveredUS

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FAQs

What is the expected market size of the US Thermoformed Plastics Market by 2024?

The US Thermoformed Plastics Market is expected to be valued at 8.4 billion USD by 2024.

What market growth rate can be anticipated in the US Thermoformed Plastics Market from 2025 to 2035?

The market is projected to witness a compound annual growth rate (CAGR) of 4.753% from 2025 to 2035.

What will be the market size of Polyethylene Terephthalate (PET) in 2035?

The market size for Polyethylene Terephthalate (PET) is expected to reach 3.5 billion USD by 2035.

Which product segment holds the largest market share in the US Thermoformed Plastics Market?

Polyethylene (PE) is projected to hold a significant share of the market with expected revenues of 4.3 billion USD in 2035.

Who are the key players in the US Thermoformed Plastics Market?

Major players in the market include Sonoco Products Company, Sealed Air Corporation, and Pactiv Evergreen among others.

What is the expected market size of the US Thermoformed Plastics Market by 2035?

By 2035, the overall market size is anticipated to be valued at 14.0 billion USD.

How much is the Polymethyl Methacrylate (PMMA) segment expected to grow by 2035?

The PMMA segment is projected to increase to 2.0 billion USD by 2035 from 1.2 billion USD in 2024.

What challenges might affect the growth of the US Thermoformed Plastics Market?

Potential challenges could include fluctuations in raw material prices and environmental regulations impacting production.

What are some key applications of thermoformed plastics in the market?

Thermoformed plastics are widely used in packaging, consumer goods, and automotive components.

What impact does regionality have on the US Thermoformed Plastics Market?

Regional demand varies, with specific applications and growth opportunities present across different US states.

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