US Shelf-Stable Packaging

Demand for shelf-stable food packaging is forecast to increase 2.4%annually to $9.6 billion in 2026. The food market is challenging for packagingsuppliers due to the vast number of applications where packaging must not onlymeet specific performance criteria but also be cost effective and in line withchanging sustainability goals and consumer preferences. This especially appliesto shelf-stable packaging because it tends to be more costly, the type ofprocessing and packaging used depends on the application, and consumers’ viewsregarding the nutrition of shelf-stable food remain in flux. Trends in theshelf-stable food packaging market include:

• Flexible packaging continues to gradually take market share from rigid types based on cost and sustainability advantages.
• Paperboard will remain the fastest growing material for shelf-stable packaging due to growing use of aseptic and retort carton packaging.
• Despite innovations in the field of shelf-stable food and packaging, frozen and especially fresh foods continue to see faster growth as consumers increasingly prefer minimally processed, preservative-free foods due to both taste and nutrition concerns.

Aseptic Processing Continues to TakeShare from Retort Cans & Hot Fill

Aseptic processing affordsmultiple benefits over more traditional thermal processing methods such asretort cans and hot fill containers. The most important advantage of asepticprocessing is shorter heating times, which minimize the impact of thermalprocessing on flavor, texture, and nutrition. Aseptic processing is not onlyimportant for organic foods and items such as baby formula and protein shakes,it can boost the perception of preserved foods overall. Pouches will see thefastest growth among aseptic packaging formats due to their lower weight andmaterial usage, as well as the popularity of aseptically processed condiments.

Paperboard Cartons Remain the Fastest Growing Shelf-Stable PackagingFormat

Aseptic and retort cartons have superior barrier propertiesand offer a lightweight, resealable way to package shelf-stable food. Soups,juices, and milk are established markets used with cartons; however, cartons areincreasingly used with a variety of shelf-stable liquid applications – such asprocessed vegetables and sauces. This is due to their premium and sustainableimage, bolstered by their large billboard space, simple shape, and consumers’perceived image of paperboard as more environmentally friendly than plastic.

Sustainability Concerns Continue to Drive Innovation

Sustainability is an issue for all food packaging, but especially forshelf-stable packaging products such as pouches and cartons, which are oftenmade of composite materials and can be difficult to recycle. These issues aredriving the development of improved barrier materials that are more easilyrecycled. Food waste also remains a primary concern among consumers andproducers, leading to the increasing usage of high evacuation rate shelf-stableformats such as pouches and bag-in-box, as well as resealable options ­– such asbottles and cartons – as opposed to traditional cans.