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Published by: BCC Research
Published: May. 1, 2003 - 321 Pages
Table of Contents
Introduction
Study Goals And Objectives
Reasons For Doing The Study
Contributions Of The Study And For Whom
Scope And Format
Methodology And Information Sources
Analysts Credentials
Related Bcc Work Credentials
Reports
Monthly Newsletter
Bcc On-Line Services
Disclaimer
Summary
Summary Table:
The Overall U.S. Flexible Plastic Packaging Market By Volume, Through 2007 (Million Lbs.)
Summary Figure:
The Overall U.S. Flexible Plastic Packaging Market By Volume, 2002 And 2007 (Million Lbs.)
Industry And Products Introduction And Overview
Flexible Plastic Packaging Definition
Historical Background
Post World War Ii Developments
Materials Used To Make Flexible Plastic Packaging
Plastic Resins
Polymers And Beyond
Bulk Resin Manufacture
Plastic Resin Fabrication
Commodity Vs. Specialty Resins
Commodity Plastics
Specialty Plastics
Metallization And Other Means Of Improving Flexible Plastic Packaging
Film Thickness Units
Types Of Flexible Plastic Packaging
Types Of Flexible Pouches
Types Of Flexible Pouches (Continued)
Flexible Plastic Packaging Markets By Type/Materials
Introduction
Growth Rates And Technology
Mls
Overall Market Analysis And Forecast
Table 1 The Overall U.S. Flexible Plastic Packaging Market By Material Volumes, Through 2007 (Million Lbs.)
Table 2 The Overall U.S. Flexible Packaging Market By Materials And Film Area, Through 2007 (Million Msi)
Commodity Flexible Packaging Film Resins
Polyethylenes (Pes)
Types Of Polyethylene (Continued)
Pe Density
Market Analysis
Table 3 U.S. Flexible Packaging Volume For Polyethylene Resins Through 2007 (Million Lbs.)
Table 4 The U.S. Flexible Packaging Market By Film Area, Polyethlyene Films, Through 2007 (Million Msi)
Figure 1 The U.S. Flexible Packaging Market By Film Area, Polyethlyene Films, 2002 And 2007 (Million Msi)
Properties Of Packaging Film Polyethylenes
Table 5 Properties And Applications Of Common Grades Of Polyethylene
Table 6 Typical Properties Of Polyethylene Films
Conventional Low-Density Pe (Ldpe) Films
Market Analysis
Table 7 U.S. Flexible Packaging Volume For Ldpe/Copolymer Resins Through 2007 (Million Lbs.)
Table 8 The U.S. Flexible Packaging Market By Film Area, Ldpe/Copolymer Films, Through 2007 (Million Msi)
Figure 2 The U.S. Flexible Packaging Market By Film Area, Ldpe/Copolymer Films, 2002 And 2007 (Million Msi)
Linear Low-Density Pe (Lldpe) Films
Market Analysis
Table 9 U.S. Flexible Packaging Volume For Lldpe Resins Through 2007 (Million Lbs.)
Table 9 (Continued)
Table 10 The U.S. Flexible Packaging Market By Film Area, Lldpe Films, Through 2007 (Million Msi)
Figure 3 The U.S. Flexible Packaging Market By Film Area, Lldpe Films, 2002 And 2007 (Million Msi)
Disadvantages Of Lldpe
High Density Polyethylene (Hdpe) Films
Market Analysis
Table 11 U.S. Flexible Packaging Volume For Hdpe Resins Through 2007 (Million Lbs.)
Table 12 The U.S. Flexible Packaging Market By Film Area, Hdpe Films, Through 2007 (Million Msi)
Figure 4 The U.S. Flexible Packaging Market By Film Area, Hdpe Films, 2002 And 2007 (Million Msi)
Extrusion Coated Polyethylene Films
Metallocene/Single-Site Catalyzed Polyethylene Films
Polypropylene (Pp) And Oriented Pp (Opp And Bopp)
A Switch To Regular Cast Pp
Market Analysis
Table 13 U.S. Flexible Packaging Volume For Polypropylene Resins Through 2007 (Million Lbs.)
Table 14 The U.S. Flexible Packaging Market By Film Area, Polypropylene Films, Through 2007 (Million Msi)
Figure 5 The U.S. Flexible Packaging Market By Film Area, Polypropylene Films, 2002 And 2007 (Million Msi)
Competition For Pp Packaging Films
Properties Of Packaging Film Polypropylenes
Table 15 Typical Properties Of Polypropylene Films
Metallocene Polypropylene
Thermoplastic Polyesters (Pet)
Market Analysis
Table 16 U.S. Flexible Packaging Volume For Polyester Resins Through 2007 (Million Lbs.)
Table 17 The U.S Flexible Packaging Market By Film Area, Polyester Films, Through 2007 (Million Msi)
Figure 6 The U.S Flexible Packaging Market By Film Area, Polyester Films, 2002 And 2007 (Million Msi)
Pet Prices
Table 18 Typical Properties Of Polyester (Pet) Films
Table 19 Some Advantages Of Pet Films
Modified Pet Resins
Polystyrene/Oriented Polystyrene And Polystyrene Copolymers
Market Analysis
Table 20 U.S. Flexible Packaging Volume For Polystyrene And Copolymer Resins, Through 2007 (Million Lbs.)
Table 21 The U.S Flexible Packaging Market By Film Area, Polystyrene And Copolymer Films, Through 2007 (Million Msi)
Figure 7 The U.S Flexible Packaging Market By Film Area, Polystyrene And Copolymer Fi, 2002 And 2007 (Million Msi)
Properties Of Polystyrene Films
Table 22 Typical Properties Of Polystyrene Films
Polyvinyl Chloride (Pvc)
Pvc And Perception Problems
Market Analysis
Table 23 U.S. Flexible Packaging Volume For Polyvinyl Chloride Resins, Through 2007 (Million Lbs.)
Table 24 The U.S. Flexible Packaging Market By Film Area, Polyvinyl Chloride Films, Through 2007 (Million Msi)
Figure 8 The U.S. Flexible Packaging Market By Film Area, Polyvinyl Chloride Films, Through 2007 (Million Msi)
Properties Of Pvc Films
Table 25 Typical Properties Of Polyvinyl Chloride Films
Pvc In Food Packaging And Health Care
Specialty Flexible Packaging Film Resins
Summary Film Area Market Analysis For Specialty Packaging Film Resins
Table 26 The U.S. Flexible Packaging Market For Specialty Film Resins, By Film Area, Through 2007 (Million Msi)
Biodegradable Polymers
Market Analysis
Biodegradable Polymers And Compost Bags
Table 27 U.S. Flexible Packaging Volume For Biodegradable Film Packaging Resins, Through 2007 (Million Lbs.)
Types Of Biodegradable Polymers
Types Of Biodegradable Polymers (Continued)
Ethylene Vinyl Alcohol (Evoh)
Market Analysis
Table 28 U.S. Flexible Packaging Volume For Evoh Barrier Resins, Through 2007 (Million Lbs.)
Figure 9 U.S. Flexible Packaging Volume For Evoh Barrier Resins, Through 2007 (Million Lbs.)
Properties And Advantages Of Evoh
Table 29 Typical Properties Of Evoh
Table 30 Processes, Advantages, And Limitations Of Evoh
Nitrile Resins
Market Analysis
Table 31 U.S. Flexible Packaging Volume For Nitrile Resins, Through 2007 (Million Lbs.)
Figure 10 U.S. Flexible Packaging Volume For Nitrile Resins, 2002 And 2007 (Million Lbs.)
Properties Of Nitrile Resins
Table 32 Typical Properties Of Nitrile (An-Ma) Copolymers
Polyamides (Nylons)
Market Analysis
Table 33 U.S. Flexible Packaging Volume For Nylon Resins, Through 2007 (Million Lbs.)
Figure 11 U.S. Flexible Packaging Volume For Nylon Resins, 2002 And 2007 (Million Lbs.)
Nylons And Food Packaging
Properties Of Packaging Nylons
Table 34 Typical Properties Of Unoriented Nylons
Table 35 Typical Properties Of Oriented Nylon 6
Nylon Permeabilities
Amorphous Nylons
Table 36 Processing, Advantages, And Limitations Of Amorphous Nylon
Table 37 Typical Properties Of Selar® Pa Amorphous Nylons
Mitsubishi Gas Chemical's Mxd6
Specialty Film Packaging Polyesters
Market Analysis
Table 38 U.S. Flexible Packaging Volume For Specialty Polyester Resins, Through 2007 (Million Lbs.)
Polyethylene Naphthalate (Pen)
Table 39 Typical Properties Of Pet And Pen Resins
Polytrimethylene Terephthalate (Ptt)
Liquid Crystal Polymers (Lcps)
Polyarylates
Polyvinylidene Chloride (Pvdc)
Market Analysis
Table 40 U.S. Flexible Packaging Volume For Pvdc Resins, Through 2007 (Million Lbs.)
Figure 12 U.S. Flexible Packaging Volume For Pvdc Resins, 2002 And 2007 (Million Lbs.)
Pvdc Properties, Advantages, And Limitations
Table 41 Typical Properties Of Polvinylidene Chloride
Pvdc Properties, Advantages, And Limitations (Continued)
Table 42 Processes, Advantages, And Limitations Of Pvdc
Pvdc Properties, Advantages, And Limitations (Continued)
Pvdc Coatings
Pvdc-Coated Films
Tie Layer Resins
Market Analysis
Table 43 U.S. Flexible Packaging Volume For Tie Layer Resins, Through 2007 (Million Lbs.)
Figure 13 U.S. Flexible Packaging Volume For Tie Layer Resins, 2002 And 2007 (Million Lbs.)
Characteristics And Properties Of Tie Layer Resins
Table 44 Typical Properties Of Tie Layer Ethylene-Vinyl Acetate And Ionomer Film Resins
Ethylene-Vinyl Acetate (Eva)
Ionomers
Other Tie Layer Resins
Specialty Vapor Permeable Films
Market Analysis
Table 45 U.S. Flexible Packaging Volume For Specialty Vapor Permeable Resins, Through 2007 (Million Lbs.)
Figure 14 U.S. Flexible Packaging Volume For Specialty Vapor Permeable Resins, 2002 And 2007 (Million Lbs.)
Cap/Map Film Specifics
Table 46 Optimum Headspace Packaging Atmospheres For Produce
Table 46 (Continued)
Tyvek® Brand Spun-Bonded Polyolefin
Others
Table 47 U.S. Flexible Packaging Volume For Other Specialty Film Packaging Resins, Through 2007 (Million Lbs.)
Flexible Packaging Markets By Applications
Overall Market Analysis And Forecast
Table 48 U.S. Overall Flexible Plastic Packaging Market By Applications, Through 2007 (Million Lbs.)
Food/Beverage Packaging
Flexible Pouches
Food Wraps
Market Analysis
Table 49 U.S. Flexible Plastic Packaging Applications: Foods And Beverages, 2002 And 2007 (Million Lbs.)
Bakery Products
Cereal Products
Confectionery
Dairy Products
Frozen Foods
Meats And Seafood
Fresh Produce
Snacks
Complexity Of Mls Snack Bags
Beverages And Other Food Products
Some Typical Flexible Food Plastic Packaging Structures
Table 50 Some Typical Flexible Food Plastic Packaging Structures
Table 50 (Continued)
Non-Food Packaging Bags And Sacks
Market Analysis
Table 51 U.S. Flexible Plastic Packaging Applications: Non-Food Packaging Bags And Sacks, Through 2007 (Million Lbs.)
Table 52 U.S. Flexible Packaging Market For Bags And Sacks, By Film Area, Through 2007 (Million Msi)
Bag Categories
Grocery Sacks
Carry-Out And Other Light Duty Bags
Trash And Lawn Bags And Can Liners
Heavy Duty Sacks
Llpe And Hdpe Bags
Shrink And Stretch Wrap Films
Market Analysis
Table 53 U.S. Flexible Plastic Packaging Applications: Shrink And Stretch Wrap Films, Through 2007 (Million Lbs.)
Table 54 U.S. Flexible Packaging Market For Shrink And Stretch Wrap Films, By Film Area, Through 2007 (Million Msi)
Consumer Products Packaging
Table 55 U.S. Flexible Plastic Packaging Applications: Consumer Goods Packaging, Through 2007 (Million Lbs.)
Healthcare (Medical/Pharmaceutical) Packaging
Market Analysis
Table 56 U.S. Flexible Plastic Packaging Applications: Healthcare Products Packaging, Through 2007 (Million Lbs.)
Table 57 Typical Flexible Film Constructions For Medical Packaging
Fluid Administration And Collection Bags
Alternatives To Pvc In Health Care
Unit Dose Bags
Dupont's Tyvek® Brand Spunbonded Polyolefin
Pouches And Other Applications
Industrial Products Packaging
Market Analysis
Table 58 U.S. Flexible Plastic Packaging Applications: Industrial Products Packaging, Through 2007 (Million Lbs.)
Envelopes, Magazine Overwrap, Etc.
Other Industrial Product Packaging
Other Industrial Product Packaging (Continued)
Technology
Production Of Polyethylenes
Low-Density Polyethylene (Ldpe)
High Density Polyethylene (Hdpe)
Linear Low-Density Polyethylene (Lldpe)
Other Important Film Packaging Polyethylenes
Production Of Polypropylene
Production Of Thermoplastic Polyesters
Production Of Polystyrene
Production Of Polyvinyl Chloride
Production Of Other Flexible Packaging Resins
Ethylene Vinyl Alcohol (Evoh)
Nitrile Polymers (Polyacrylonitrile And Copolymers)
Polyamides (Nylons)
Specialty Film Packaging Polyesters
Polyvinylidene Chloride (Pvdc)
Tie Layer Resins And Ionomers
Newer Flexible Packaging Polymer Polymerization Processes
Gas Phase Processes
Liquid Phase Processes
Metallocene/Single-Site Catalyzed Polyolefins
Property Improvements With Metallocene/Single-Site Films
Metallocene/Single-Site Developments
Metallocene/Single-Site Developments (Continued)
Downside To Metallocenes
Flexible Plastic Film Fabrication Technology
Roll Goods Manufacture
Film Extrusion
The Film Extruder
Polymer Drying
Melt Film Fabrication
Film Casting
The Casting Process
Solvent Casting
Thickness Downgauging
Blown Films
Blown Film Vs. Cast Film
Calendering
Form/Fill/Seal (Ffs) Packaging
Polymer And Film Orientation
Biaxial Orientation-The Tenter Frame
Barrier Technology
Gas Permeabilities And Transmission Rates
Permeability And Oxygen And Water Vapor Transmission Rates
Barrier Properties Of Flexible Plastic Packaging Resins
Table 59 Vapor Permeabilities Of Packaging Resins
Table 59 (Continued)
Other Gases
Light (Visible And Ultraviolet)
Odors, Aromas, Solvent Vapors, And Others
Organic Permeation Detection Systems
Metallization And Inorganic Barrier Film Coatings
Film Metallization
Inorganic Barrier Coatings
Siox Films
Oxygen Scavenging
Nanocomposites
Selective/Semipermeable Barriers
Cap Packaging
Cap Packaging (Continued)
Cap Packaging (Continued)
Multilayer Film Structures
Monolayer Vs Multilayer
Lamination/Coating
Coextrusion
Feed Block Coextrusion
Multimanifold Die Coextrusion
Coextrusion Versus Lamination
Source Reduction/Downgauging/Lightweighting
Forces Behind Downgauging
Forces Behind Downgauging (Continued)
Industry Structure And Competitive Factors
Plastic Resin Suppliers-The Major Players
Plastic Resin Suppliers-The Major Players (Continued)
Flexible Packaging Converters/Compounders And Distributors
End-User Companies
Marketing And Competitive Factors
Materials Competition
Competition Among Different Flexible Plastic Packaging Films
Competition With Other Materials
Competition With Rigid Packaging
Life-Cycle Assessment
Company Competition
Market Entry Factors
Factors Affecting Market Size And Growth
Factors Affecting Market Size And Growth
Factors Affecting Market Size And Growth (Continued)
End-User Flexible Plastic Packaging Selection Criteria
Industry Consolidation And Restructuring
Mergers And Acquisitions Of Flexible Plastic Packaging Suppliers
Mergers And Acquisitions Of Flexible Plastic Packaging Suppliers (Continued)
Mergers And Acquisitions Of Flexible Plastic Packaging Suppliers (Continued)
Trends In The Flexible Plastic Packaging Business
Trends In The Flexible Plastic Packaging Business (Continued)
A Growth Industry
Some International Aspects
Major Foreign Players
Imports And Exports
Imports And Exports (Continued)
Public/Environmental/Regulatory Factors And Issues
Federal Regulations For Use Of Flexible Packaging
The Food And Drug Administration (Fda)
Food Additive Rules And Categories
Regulation Of Packaging Materials
Code Of Federal Regulations (Cfr)
Code Of Federal Regulations (Cfr) (Continued)
Simulant Testing To Detect Chemical Migration
The Food And Drug Administration Modernization Act (Fdama) And New Premarket Notification Procedures
Pending New Gras Affirmation Process
The U.S. Department Of Agriculture (Usda)
The U.S. Environmental Protection Agency (Epa)
Other Federal Agencies
State And Local Regulations
Environmental Considerations
Disposal Problems
Biodegradable/Compostable Bags
Flexible Plastic Recycling
Public Perceptions
Public Perceptions (Continued)
Supplier Company Profiles
Introduction
Suppliers
Aep Industries Inc.-South Hackensack, Nj
Aep Industries Inc.-South Hackensack, Nj (Continued)
Aet Films (Or Aet Packaging Films)-See Applied Extrusion Technology
Alcan Inc.-Montreal, Canada
Alcan Packaging-Baie D'urfe, Canada
Lawson Mardon Usa-Northbrook, Il
Alliedsignal Inc.-See Honeywell
Aluminum Company Of America (Alcoa)-Pittsburgh, Pa
Alcoa Packaging And Consumer Business-Richmond, Va
Alcoa Flexible Packaging-Richmond, Va
Alcoa Kama-Hazleton, Pa
Presto Products Company-Appleton, Wi
American National Can-See Pechiney Group
Applied Extrusion Technologies Inc.-New Castle, De
Aet Films-New Castle, De
At Plastics Inc.-Brampton, Ontario
Atlantis Plastics-Atlanta, Ga
Bemis Company Inc.-Minneapolis, Mn
Banner Packaging, Inc.-Oshkosh, Wi
Bemis Industrial Products Division-Oshkosh, Wi
Bemis Polyethylene Packaging Division-Terre Haute, In
Curwood, Inc.-Oshkosh, Wi
Milprint Incorporated-Oshkosh, Wi
Perfecseal-Oshkosh, Wi
Blessings Corporation-See Pliant Corporation
Bp Chemicals-Cleveland, Oh
Bryce Corporation-Memphis, Tn
Carlisle Plastics-See Tyco International
Celanese Ag-Kronburg Im Taunus (Frankfurt), Germany
Clopay Plastic Products Company-Cincinnati, Oh
The Chlorox Company-Oakland, Ca
First Brands Corporation-Danbury, Ct
Cortec Corporation-White Bear Lake, Mn
Courtaulds Performance Films-Martinsville, Va
Cryovac-See Sealed Air
Deerfield Plastics-See Pliant Corporation
Delta Plastics Corp-See Flex Sol Holding Corporation
The Dow Chemical Company-Midland, Mi
E.I. Du Pont De Nemours And Company-Wilmington, De
Dupont Teijin Films U.S. Limited Partnership-Wilmington, De
Dupont Teijin Films U.S. Limited Partnership-Wilmington, De (Continued)
Dupont Teijin Films U.S. Limited Partnership-Wilmington, De (Continued)
Eastman Chemical Company-Kingsport, Tn
Voridian Company-Kingsport, Tn
Ems-Chemie Ag- Domat/Ems, Switzerland
Ems-Chemie (North America) Inc.-Sumter, Sc
Ems-Grivory-Sumter, Sc
Epsilon Opti Films-See Sealed Air Corporation
Equistar Chemicals Lp-Houston, Tx
Essex Plastics Inc.-See Flex Sol Holding Corporation
Eval Company Of America-See Kuraray Co., Ltd.
Exopack Llc-Spartanburg, Sc
Exxon Mobil Corporation-Irving, Tx
Exxon Mobil Chemical Company Films Business-Macedon, Ny
First Brands Corporation-See The Chlorox Company
Flexo Transparent-Buffalo, Ny
Flex Sol Holding Corporation-Pompano Beach, Fl
Delta Plastics Corporation-Newark, Nj
Essex Plastics Inc.-Pompano Beach, Fl
Flex Tech Packaging Ltd.-Cincinnati, Oh
Formosa Plastics Corporation Usa-Livingston, Nj
Inteplast Group, Ltd.-Livingston, Nj
Nan Ya Plastics Corporation Usa- Livingston, Nj
Heritage Bag Co.-Carrollton, Tx
Heritage Bag Co.-Carrollton, Tx
Himolene Incorporated-Danbury, Ct
Himac Inc.-See Scholle Corporation
Himolene Incorporated-See Heritage Bag Co.
The Hood Group Of Companies-Burlington, Ontario, Canada
Hood Packaging Corporation-Burlington, Ontario, Canada
Southern Bag Company-Yazoo City, Ms
Honeywell, Inc-Morristown, Nj
Honeywell Specialty Films-Morristown, Nj
Alliedsignal Inc-Morristown, Nj
Huhtamaki Van Leer Oyj-Espoo, Finland
Huhtamaki Americas-De Soto, Ks
Huntsman Packaging Corporation-See Pliant Corporation
Illinois Tool Works-Glenview, Il
Itw Mima-Glenview, Il
Inteplast Corporation-See Formosa Plastics
Intertape Polymer Group, Inc.-Montreal, Quebec, Canada
Ivex Packaging Corporation And Kama Corporation-See Alcoa
S.C. Johnson & Son Inc.-Racine, Wi
Kuraray Co., Ltd-Osaka, Japan
Eval Company Of America-Lisle, Il
Lawson Mardon-See Alcan Packaging
Mitsubishi Gas Chemical America-New York, Ny
Mitsubishi Polyester Film Llc-Greer, Sc
Mobil Corporation And Mobil Chemical Company-See Exxon Mobil Corporation
Nan Ya Plastics-See Formosa Plastics
New England Extrusion Inc.-Turners Falls, Ma
Noltex L.L.C.-La Porte, Tx
Nippon Gohsei Co. Ltd.-Osaka, Japan
Mitsubishi Chemical America Inc.-New York, Ny
Outlook Group Corporation-Menasha, Wi
Pactiv Corporation-Lake Forest, Il
Paragon Films, Inc.-Broken Arrow, Ok
Paramount Packaging-See Bemis Company
Pcl Packaging Corporation-Barrie, Ontario, Canada
Pechiney Group-Paris, France
Pechiney Plastic Packaging Inc.-Chicago, Il
Plassein International-Willington, Ct
Pliant Corporation-Schaumburg, Il
Huntsman Packaging Corporation-Schaumburg, Il
Blessings Corporation-Newport News, Va
Deerfield Plastics Company-Deerfield Ma
Huntsman Packaging Corporation-Schaumburg, Il (Continued)
Poly-America L.P.-Grand Prairie, Tx
Poly-Pak Industries-Melville, Ny
Presto Products Company-See Aluminum Company Of America
Printpack Inc.-Atlanta, Ga
Rexam Plc-London, England
Rexam Flexibles-Mundelein, Il
Rollprint Packaging Products, Inc.-Addison, Il
Scholle Corporation-Irvine, Ca
Himac Inc.-Atlanta, Ga
Vacumat Corporation-Wayne, Nj
Sealed Air Corporation-Saddle Brook, Nj
Cryovac Films Division-Duncan, Sc
Cypress Packaging-Rochester, Ny
Epsilon Opti Films Corporation-South Plainfield, Nj
Sigma Plastics Group-Lyndhurst, Nj
Smurfit-Stone Container Corporation-Chicago, Il
Smurfit-Stone Flexible Bag Group-Schaumburg, Il
Sonoco Products Company-Hartsville, Sc
Flexible Packaging Division-Hartsville, Sc
Sonoco High Density Film Products-Hartsville, Sc
Southern Film Extruders Inc.-High Point, Nc
Spartech Corporation-Clayton, Mo
Spartech Plastics-Cape Girardeau, Mo
Sunkyong Group-Seoul, South Korea
Skc America, Inc.-Mt. Olive, Nj
Skc Films Ltd.-Covington, Ga
Terphane, Inc.-Bloomfield, Ny
Toray Industries Inc.-Tokyo, Japan And New York, Ny
Toray Plastics (America)-North Kingstown, Ri
Transilwrap Co., Inc.-Franklin Park, Il
Tredegar Industries-Richmond, Va
Tredegar Film Products-Richmond, Va
Tyco International Ltd.-Exeter, Nh
Tyco Plastics And Adhesives Group-Nantucket, Ma
Armin Plastics-Jersey City, Nj
Carlisle Plastics-Phoenix, Az
Vacumat Corporation-See Scholle Corporation
Vanguard Plastics, Inc.-St. Louis, Mo
Vibac Finanziara/Vibac Group-Allessandria And Ticineto, Italy
Vifan Canada Inc./Vifan Usa-Montreal, Quebec
Voridian Company-See Eastman Chemical Company
Winpak Ltd.-Winnepeg, Manitoba, Canada
Appendix: Glossary Of Important Terms, Abbreviations, Acronyms, Etc.
List Of Tables
Summary Table:
The Overall U.S. Flexible Plastic Packaging Market By Volume, Through 2007 (Million Lbs.)
Table 1 The Overall U.S. Flexible Plastic Packaging Market By Material Volumes, Through 2007 (Million Lbs.)
Table 2 The Overall U.S. Flexible Packaging Market By Materials And Film Area, Through 2007 (Million Msi)
Table 3 U.S. Flexible Packaging Volume For Polyethylene Resins Through 2007 (Million Lbs.)
Table 4 The U.S. Flexible Packaging Market By Film Area, Polyethlyene Films, Through 2007 (Million Msi)
Table 5 Properties And Applications Of Common Grades Of Polyethylene
Table 6 Typical Properties Of Polyethylene Films
Table 7 U.S. Flexible Packaging Volume For Ldpe/Copolymer Resins Through 2007 (Million Lbs.)
Table 8 The U.S. Flexible Packaging Market By Film Area, Ldpe/Copolymer Films, Through 2007 (Million Msi)
Table 9 U.S. Flexible Packaging Volume For Lldpe Resins Through 2007 (Million Lbs.)
Table 10 The U.S. Flexible Packaging Market By Film Area, Lldpe Films, Through 2007 (Million Msi)
Table 11 U.S. Flexible Packaging Volume For Hdpe Resins Through 2007 (Million Lbs.)
Table 12 The U.S. Flexible Packaging Market By Film Area, Hdpe Films, 2002 And 2007 (Million Msi)
Table 13 U.S. Flexible Packaging Volume For Polypropylene Resins Through 2007 (Million Lbs.)
Table 14 The U.S. Flexible Packaging Market By Film Area, Polypropylene Films, Through 2007 (Million Msi)
Table 15 Typical Properties Of Polypropylene Films
Table 16 U.S. Flexible Packaging Volume For Polyester Resins Through 2007 (Million Lbs.)
Table 17 The U.S Flexible Packaging Market By Film Area, Polyester Films, Through 2007 (Million Msi)
Table 18 Typical Properties Of Polyester (Pet) Films
Table 19 Some Advantages Of Pet Films
Table 20 U.S. Flexible Packaging Volume For Polystyrene And Copolymer Resins, Through 2007 (Million Lbs.)
Table 21 The U.S Flexible Packaging Market By Film Area, Polystyrene And Copolymer Films, 2002 And 2007 (Million Msi)
Table 22 Typical Properties Of Polystyrene Films
Table 23 U.S. Flexible Packaging Volume For Polyvinyl Chloride Resins, Through 2007 (Million Lbs.)
Table 24 The U.S. Flexible Packaging Market By Film Area, Polyvinyl Chloride Films, Through 2007 (Million Msi)
Table 25 Typical Properties Of Polyvinyl Chloride Films
Table 26 The U.S. Flexible Packaging Market For Specialty Film Resins, By Film Area, Through 2007 (Million Msi)
Table 27 U.S. Flexible Packaging Volume For Biodegradable Film Packaging Resins, Through 2007 (Million Lbs.)
Table 28 U.S. Flexible Packaging Volume For Evoh Barrier Resins, Through 2007 (Million Lbs.)
Table 29 Typical Properties Of Evoh
Table 30 Processes, Advantages, And Limitations Of Evoh
Table 31 U.S. Flexible Packaging Volume For Nitrile Resins, Through 2007 (Million Lbs.)
Table 32 Typical Properties Of Nitrile (An-Ma) Copolymers
Table 33 U.S. Flexible Packaging Volume For Nylon Resins, Through 2007 (Million Lbs.)
Table 34 Typical Properties Of Unoriented Nylons
Table 35 Typical Properties Of Oriented Nylon 6
Table 36 Processing, Advantages, And Limitations Of Amorphous Nylon
Table 37 Typical Properties Of Selar® Pa Amorphous Nylons
Table 38 U.S. Flexible Packaging Volume For Specialty Polyester Resins, Through 2007 (Million Lbs.)
Table 39 Typical Properties Of Pet And Pen Resins
Table 40 U.S. Flexible Packaging Volume For Pvdc Resins, 2002 And 2007 (Million Lbs.)
Table 41 Typical Properties Of Polvinylidene Chloride
Table 42 Processes, Advantages, And Limitations Of Pvdc
Table 43 U.S. Flexible Packaging Volume For Tie Layer Resins, Through 2007 (Million Lbs.)
Table 44 Typical Properties Of Tie Layer Ethylene-Vinyl Acetate And Ionomer Film Resins
Table 45 U.S. Flexible Packaging Volume For Specialty Vapor Permeable Resins, Through 2007 (Million Lbs.)
Table 46 Optimum Headspace Packaging Atmospheres For Produce
Table 47 U.S. Flexible Packaging Volume For Other Specialty Film Packaging Resins, Through 2007 (Million Lbs.)
Table 48 U.S. Overall Flexible Plastic Packaging Market By Applications, Through 2007 (Million Lbs.)
Table 49 U.S. Flexible Plastic Packaging Applications: Foods And Beverages, 2002 And 2007 (Million Lbs.)
Table 50 Some Typical Flexible Food Plastic Packaging Structures
Table 51 U.S. Flexible Plastic Packaging Applications: Non-Food Packaging Bags And Sacks, Through 2007 (Million Lbs.)
Table 52 U.S. Flexible Packaging Market For Bags And Sacks, By Film Area, Through 2007 (Million Msi)
Table 53 U.S. Flexible Plastic Packaging Applications: Shrink And Stretch Wrap Films, 2002 And 2007 (Million Lbs.)
Table 54 U.S. Flexible Packaging Market For Shrink And Stretch Wrap Films, By Film Area, 2002 And 2007 (Million Msi)
Table 55 U.S. Flexible Plastic Packaging Applications: Consumer Goods Packaging, Through 2007 (Million Lbs.)
Table 56 U.S. Flexible Plastic Packaging Applications: Healthcare Products Packaging, Through 2007 (Million Lbs.)
Table 57 Typical Flexible Film Constructions For Medical Packaging
Table 58 U.S. Flexible Plastic Packaging Applications: Industrial Products Packaging, Through 2007 (Million Lbs.)
Table 59 Vapor Permeabilities Of Packaging Resins
List Of Figures
Summary Figure:
The Overall U.S. Flexible Plastic Packaging Market By Volume, 2002 And 2007 (Million Lbs).
Figure 1 The U.S. Flexible Packaging Market By Film Area, Polyethlyene Films, 2002 And 2007 (Million Msi)
Figure 2 The U.S. Flexible Packaging Market By Film Area, Ldpe/Copolymer Films, 2002 And 2007 (Million Msi)
Figure 3 He U.S. Flexible Packaging Market By Film Area, Lldpe Films, 2002 And 2007 (Million Msi)
Figure 4 The U.S. Flexible Packaging Market By Film Area, Hdpe Films, 2002 And 2007 (Million Msi)
Figure 5 The U.S. Flexible Packaging Market By Film Area, Polypropylene Films, 2002 And 2007 (Million Msi)
Figure 6 The U.S Flexible Packaging Market By Film Area, Polyester Films, 2002 And 2007 (Million Msi)
Figure 7 The U.S Flexible Packaging Market By Film Area, Polystyrene And Copolymer Fi (Million Msi)
Figure 8 The U.S. Flexible Packaging Market By Film Area, Polyvinyl Chloride Films, Through 2007 (Million Msi)
Figure 9 U.S. Flexible Packaging Volume For Evoh Barrier Resins, Through 2007 (Million Lbs.)
Figure 10 U.S. Flexible Packaging Volume For Nitrile Resins, Through 2007 (Million Lbs.)
Figure 11 U.S. Flexible Packaging Volume For Nylon Resins, 2002 And 2007 (Million Lbs.)
Figure 12 U.S. Flexible Packaging Volume For Pvdc Resins, 2002 And 2007 (Million Lbs.)
Figure 13 U.S. Flexible Packaging Volume For Tie Layer Resins, Through 2007 (Million Lbs.)
Figure 14 U.S. Flexible Packaging Volume For Specialty Vapor Permeable Resins, 2002 And 2007 (Million Lbs.)
Abstract Flexible packaging, and flexible plastic packaging (FPP) in particular, is a very large, multibillion-dollar business within the $100 billion-plus total U.S. packaging market (the total global packaging market is estimated to be more than $400 billion). A large percentage of the total volume of thermoplastic resins produced and consumed in the United States goes into packaging, estimated by the American Plastics Council to be about 29% of the total in 2001. And flexible packaging of all types constitutes close to 20% of the total packaging market for all materials.
STUDY GOALS AND OBJECTIVES
It is our goal in this report, an update on a 1998 BCC report on this specific subject by the same author, to give the reader a comprehensive update on several aspects of the U.S. flexible plastic packaging industry, including (1) the state of the industry, (2) the plastic materials from which such packaging is made, and (3) where BCC believes it is headed at the beginning of the 21st century. These objectives include:
To describe the flexible plastic packaging industry, its importance to the functioning and quality of life, and its future prospects.
To describe many different types of flexible plastic packaging products and their major end-use markets in the United States. We describe, discuss, and forecast markets for major types of flexible plastic packaging, both by type of plastic resin used, and by several of the important major applications.
To analyze industry production and shipments in base year 2002 and forecast growth to 2007 for several of the major flexible plastic packaging materials and applications markets. In addition to forecasts in pounds of bulk resins used to produce plastic films and flexible plastic packaging structures, we also analyze and forecast the larger and more definable markets by area of plastic film consumed, based on average film thicknesses and/or typical thickness ranges.
To describe manufacturing and application methods used to make and apply the important types of flexible plastic packaging materials, both the base resins and important packaging structures.
To identify some of the major suppliers of materials for the flexible plastic packaging industry. Our primary focus is on compounders/converters who produce the flexible plastic packaging rollstock and finished packaging structure. We also include some major suppliers of bulk plastic resins that are also active in some important aspects of flexible plastic packaging, such as production of barrier film resins.
To describe flexible plastic packaging technology and trends. This includes both resin and flexible plastic packaging structure production technology. Our emphasis is on technology to produce flexible plastic packaging structures.
To note and discuss come of the major dynamics in the industry, including supplier strategies; industry changes such as consolidation and mergers/acquisitions; marketing and competitive factors; and some international effects on the U.S. industry, such as activities of foreign firms and imports/exports. Since our first report in 1998 there have been quite a few changes in the chemical, plastics, and packaging industries, and many of the companies profiled then have changed name, owner, or otherwise have become different.
To discuss public, environmental, and governmental regulatory issues and factors that affect the flexible plastic packaging industry. Public perceptions are an important factor in these issues, since packaging is under constant public scrutiny. This is a very dynamic issue, with perceptions and opinions capable of almost instant change in these days of 24/7 media (especially television) coverage.
This study focuses primarily in the United States but also, as noted above in our objectives, has some international observations, given the global nature of business and trade these days, when no nation or region can operate without consideration of the rest of the world. However, given the sheer volume of flexible plastic packaging in the U.S., most of the products covered are American in nature and production.
REASONS FOR DOING THE STUDY
The flexible plastic packaging industry is in actuality a very dynamic industry, despite the rather staid general impression of snack bags and other everyday flexible plastic packaging products. New products and applications are constantly coming on the market, ranging from new packages for new products to new resins and packaging structures. This is a very competitive industry, and a new innovation, such as a thinner let stronger packaging structure or a better barrier, can change packaging (and consumer) choices.
BCC performed this study to provide a comprehensive and updated reference for those interested and/or involved in the flexible plastic packaging industry. This wide and varied group of personnel are involved with the following types of companies: materials, chemical, polymer, mechanical equipment and parts (including original equipment manufacturers [OEM] and for those concerned with maintenance and replacement parts). We have sorted through, organized, and condensed information from large quantities of literature and other reference materials to compile this report.
Major changes have taken place in the past few years and continue to take place today (and probably for the foreseeable future) as both newer and older materials compete for places in the flexible plastic packaging market. The major competitive factors in the market are those between materials and different packaging methods and technologies. Inter-material competition is a way of life in a technologically advancing society, and plastic packaging is no exception. For example, metallocene and other single-site catalysts are producing new polyolefins with enhanced properties such as better strength and clarity; incorporating these new resins in flexible plastic packaging films allows significant downgauging with no loss of properties.
CONTRIBUTIONS OF THE STUDY AND FOR WHOM
Because of the size and diversity of flexible plastic packaging, this report should be of interest to a wide group of organizations and individuals, including:
People who are involved in the development, design, manufacture, sale, and use of flexible plastic packaging and flexible plastic packaging materials, as well as the general public.
BCC feels that this report will be of value to technical and business personnel in the following areas, among others:
Marketing and management personnel in companies which produce, market, and sell all types of flexible plastic packaging, as well as those involved in installing equipment and parts, components, maintenance materials, and chemicals for cleaning and other uses.
Companies that supply, or want to supply equipment and services to flexible plastic packaging materials and equipment supply companies.
Financial institutions that supply money for such facilities and systems, including banks, merchant bankers, venture capitalists, and others.
Personnel in end-user companies, communities, and industries that purchase and use flexible plastic packaging.
Personnel in government, primarily those involved with protection of public health and safety in consumer packaged goods. Local, state, and federal officials are all involved in writing and enforcing standards to ensure and protect public health and safety and the environment. For example, state and local packaging recycling regulations can affect the choice and use of flexible plastic packaging structures.
SCOPE AND FORMAT
This BCC study covers in depth many of the most important economic, technological, political, regulatory, and environmental considerations in U.S. markets for the use of materials in the flexible plastic packaging. Such packaging is made from several different polymer substrates (the base material from which a package is made) for different packaging applications.
Most flexible packaging is produced from commodity polymers, but an increasing percentage of packaging, especially food packaging, is made with sophisticated multilayer structures (MLS), which can include some quite sophisticated combination substrates. These MLS often use specialty resins, usually to add gas and/or moisture barrier to the structure. Thus this study is in large part a review and analysis of materials and structures, not specific packages.
Our focus in this study is discussion and analysis from the viewpoint of the flexible plastic packaging structures produced from plastic materials. In order to cover the subject thoroughly, we discuss and describe some basic thermoplastic resin production technology; this way we can also describe some of the basic characteristics of each resin that make it appropriate for certain types of flexible packaging. However, our primary intent is to cover this from the aspect of the flexible plastic packaging structures that are produced from these plastics. For example, as noted above, an important dynamic in today's flexible plastic packaging industry is the effect of new metallocene/single-site catalyst technologies on production of flexible plastic packaging structures, especially using polyolefins.
Our study includes key technologies (and new technologies), the markets, and key player companies that make up the U.S. flexible plastic packaging industry in all its ramifications. This is primarily a study of activities and markets in the United States, but because of the global nature of most industries these days, it touches on some noteworthy international activities. These are primarily those that can have an impact on the U.S. business and markets, such as the activities of foreign-based companies in U.S. markets.
We estimate demand data for our base year of 2002, and forecast for 5 years to 2007. All figures are in constant 2002 U.S. dollars. Markets are all analyzed and projected in volumes, and resin markets and some application markets are also analyzed in terms of the film area (in thousands of square inches or msi, the common term used in the industry) that could be produced from these volumes, assuming an average or typical film thickness. Five-year growth rates are all compounded (signified as average annual growth rates or AAGRs). All market figures are rounded to the nearest million pounds or million msi. Because of this rounding, some growth rates may not agree exactly with figures in the market tables, especially for small market segments where rounding can be significant.
This report is segmented into ten sections, of which this is the first.
The Summary encapsulates our findings and conclusions, and includes summary major market tables. It is the place where the busy executive can find the major findings of the study in summary format.
Next is an Overview of the flexible plastic packaging industry. We start with a historical perspective on packaging and define and describe the major plastic materials used in flexible plastic packaging, both commodity and specialty resins. We then describe different types of flexible plastic packaging, such as plastic bags, pouches, and overwraps.
In the first of our market analysis sections, we describe, discuss, and analyze the U.S. market by flexible plastic resin or packaging type or material. We analyze U.S. markets for commodity and specialty flexible plastic packaging resins, by physical volume in pounds and in area using some typical film wall thicknesses.
The second market analysis section looks at flexible plastic packaging markets by some of the most important applications. These include food packaging; non-food bags/sacks; shrink/stretch film; and consumer, healthcare, and industrial applications. Food packaging and bags/sacks are the largest segments.
The next section is devoted to flexible plastic packaging technology, with special emphasis on production of flexible plastic packaging resins and packaging structures. We cover the basic technologies of producing flexible plastic packaging structures, such as polymer orientation, film formation, barrier technology, and multilayer film structures.
Next we look at the structure and competitive factors and trends in the U.S. flexible plastic packaging industry. We introduce some major suppliers of the plastic resins used in flexible plastic packaging, as well as compounders and converters who turn base resins into flexible plastic packaging structures. We discuss competition among materials, both inter-plastic competition and competition with paper packaging. We note some international aspects that affect the U.S. industry.
The next section is devoted to a discussion of public, environmental, and regulatory issues that affect the flexible plastic packaging industry. These include government regulations for use of plastics and plastic structures in flexible packaging, disposal and recycling of flexible plastic packaging, and public perceptions of packaging.
The last narrative section, Supplier Profiles, is devoted to information about some of the most important major suppliers to this large industry. Our emphasis is on leading suppliers of flexible plastic packaging films and structures rather than manufacturers of plastic resins.
Finally, we include an appendix and a glossary of some important terms, abbreviations, acronyms, etc. used in the FPP industry and related technologies such as important materials, chemicals, and polymers.
This report is devoted primarily to commercial industrial markets for flexible plastic packaging in the United States. Different organizations, publications, and analysts define "packaging" in different ways, especially flexible packaging. For example, The Society of the Plastics Industry (SPI) includes household and institutional refuse bags and film in their definition of flexible plastic packaging, whereas Modern Plastics magazine calls such bags and sacks "non-packaging film."
We agree with SPI and define flexible plastic packaging rather broadly. Thus we include plastic bags and sacks as well as shrink/stretch wraps, etc. However, we do not cover non-packaging applications such as uses of flexible plastic films in agriculture, construction, electronics (except for packaging), medical devices and disposables (that is, the devices themselves as opposed to the packages in which they come), labels (and release films for stationery and labels), graphic arts and wallcoverings, and other such non-packaging industrial and consumer products and applications. We also exclude films used for decorative or protective overlays when their primary purpose is not to package a product; this includes plastic labels. Such non-packaging applications use a great deal of flexible plastic films, upwards of one-third of all plastic films used in the United States.
We also stress that this report is devoted to flexible plastic packaging. "Flexible" means different things to different people, but our definition and scope follow those of most in the industry. Plastic resins can be extruded and blown into flexible web rollstock structures of many different thicknesses. Thinner rollstock is called "film" while thicker is called "sheet." The dividing line between what is called film and what is sheet is arbitrary, and varies with the material and the supplier or analyst. Some put the line as thin as 5 mils, while others generally consider film to any web up to 10 mils thick and anything thicker is sheet. Further confusing the issue The Society of the Plastics Industry, the industry trade association, describes all polyethylene rollstock up to 12-mil thickness as film, but makes the divide for polypropylene at 10 mils.
Softer and more flexible films are considered films at greater thicknesses than others that are basically more rigid and stiff. Thus low-density polyethylenes, ionomer, EVA, and well plasticized PVC resins are inherently flexible and can be formed into thicker films, while nylons, polycarbonate, higher density polyethylenes, nitrile resins, and unplasticized PVC are inherently stiffer. Thus BP Chemicals defines sheet as any thickness of 5 mils or greater for its BarexÒ brand of nitrile resins, while a plasticized PVC hospital bag can be up to 15 mils thick and still be quite flexible and considered to be film.
Despite the fact that these terms are somewhat arbitrary, and different dividing thicknesses are used for different resins and sometimes even for the same resin, in general, flexible packaging is said to use plastic films while more rigid packaging uses sheet webstock. Thus all thermoforming, blister, and skin packaging are considered rigid packaging and are not within the scope of this report. In other words, the final packaging film product must be truly flexible to be included in this study.
Finally, this report is concerned exclusively with synthetic polymer plastic films; we exclude cellophane and other such cellulose-based films, most of which have almost vanished from the U.S. scene in favor of synthetic polymer films.
METHODOLOGY AND INFORMATION SOURCES
Extensive searches were made of the literature and the Internet, including many of the leading trade publications, and well as technical compendia, government publications, and information from trade and other associations. Much product and market information was obtained from the principals involved in the industry. The information for our company profiles was obtained primarily from the companies themselves, especially the larger publicly owned firms. Other sources included directories and articles.
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