Global EPP Foam Market Size Study & Forecast, by Type, Density, Additives, Form, and End-Use Industry and Regional Forecasts 2025-2035

The Global Expanded Polypropylene (EPP) Foam Market is valued at approximately USD 23.4 billion in 2024 and is poised to experience a robust expansion, growing at a CAGR of more than 5.26% over the forecast period from 2025 to 2035. Expanded Polypropylene, known for its excellent energy absorption, light weight, and high thermal resistance, has emerged as a critical material across diverse industrial sectors. Its widespread utilization in automotive bumpers, packaging materials, HVAC components, and even medical devices stems from its impressive versatility and cost-effectiveness. As industries navigate the twin pressures of sustainability and operational efficiency, EPP foam has gained momentum as a recyclable and durable solution that doesn’t compromise on performance.

The growth trajectory of the EPP Foam Market is underpinned by surging applications across automotive and packaging segments. In the automotive space, the transition toward electric vehicles and lightweighting initiatives has driven demand for high-performance materials that offer both crash protection and thermal insulation—criteria where EPP foam excels. On the other hand, the rise of e-commerce and the growing necessity for protective, reusable packaging in fragile goods transportation is boosting demand in the packaging domain. Further, technological innovations have enabled manufacturers to enhance the foam’s structural performance, with the inclusion of fire retardants, antistatic agents, and UV stabilizers—broadening its usability in critical and sensitive applications such as consumer electronics and medical devices.

From a geographical standpoint, North America commands a substantial share of the global EPP Foam Market, attributed to its strong automotive manufacturing base and heightened demand for sustainable packaging alternatives. The region’s well-established logistics and consumer electronics sectors further contribute to consistent uptake. Meanwhile, Asia Pacific is on a trajectory to become the fastest-growing region in the forecast period. China, Japan, and India are fueling this momentum due to their robust automotive supply chains, expanding construction sectors, and government-backed sustainability programs. In Europe, stricter environmental regulations and the proliferation of green building materials are fostering a shift towards eco-friendly and recyclable foam materials, with EPP foam being a frontrunner in this transition.

Major market player included in this report are:
• BASF SE
• JSP Corporation
• Hanwha Solutions
• Knauf Industries
• Woodbridge Foam Corporation
• Kaneka Corporation
• Borealis AG
• DS Smith Plc
• Sonoco Products Company
• Furukawa Electric Co., Ltd.
• ACH Foam Technologies
• Pregis Corporation
• BEWI ASA
• Sealed Air Corporation
• The Ravago Group

Global EPP Foam Market Report Scope:
• Historical Data – 2023, 2024
• Base Year for Estimation – 2024
• Forecast period – 2025-2035
• Report Coverage – Revenue forecast, Company Ranking, Competitive Landscape, Growth factors, and Trends
• Regional Scope – North America; Europe; Asia Pacific; Latin America; Middle East & Africa

The objective of the study is to define market sizes of different segments & countries in recent years and to forecast the values for the coming years. The report is designed to incorporate both qualitative and quantitative aspects of the industry within the countries involved in the study. The report also provides detailed information about crucial aspects, such as driving factors and challenges, which will define the future growth of the market. Additionally, it incorporates potential opportunities in micro-markets for stakeholders to invest, along with a detailed analysis of the competitive landscape and product offerings of key players.

The detailed segments and sub-segments of the market are explained below:

By Type:
• Packaging
• Automotive
• Consumer Electronics
• Construction
• Medical

By Density:
• Low Density (15–20 kg/m³)
• Medium Density (20–40 kg/m³)
• High Density (40–60 kg/m³)

By Additives:
• Fire Retardants
• Antistatic Agents
• Colorants
• UV Stabilizers

By Form:
• Sheets
• Blocks
• Molded Parts

By End-Use Industry:
• Food and Beverage
• Medical and Healthcare
• Electronics
• Automotive
• Building and Construction

By Region:

North America
• U.S.
• Canada

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

Asia Pacific
• China
• India
• Japan
• Australia
• South Korea
• Rest of Asia Pacific

Latin America
• Brazil
• Mexico

Middle East & Africa
• UAE
• Saudi Arabia
• South Africa
• Rest of Middle East & Africa

Key Takeaways:
• Market Estimates & Forecast for 10 years from 2025 to 2035.
• Annualized revenues and regional level analysis for each market segment.
• Detailed analysis of geographical landscape with country-level analysis of major regions.
• Competitive landscape with information on major players in the market.
• Analysis of key business strategies and recommendations on future market approach.
• Analysis of competitive structure of the market.
• Demand side and supply side analysis of the market.

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