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Flexible Packaging


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The $17-billion U.S. flexible packaging industry is increasingly relying on single-web plastic coated, single-web co-extruded film products, and plastic bags to outpace domestic packaging materials shipments. This Specialists in Business Information market profile covers plastic, paper, and foil flexible packaging materials and converted packaging. The profile includes analysis of the competitive situation, end-use markets, retail distribution, brand preferences, cost structure, profitability, and much more.


Section 1: U.S. Flexible Packaging Industry Trends

    Executive Summary
    Overall Industry Growth Analysis
    Strong Growing Product Lines
    Important End-Use Markets
    Global Sales Opportunities
    Competitive Environment and Industry Profitability
    Outlook
    • Table 1-1 Value of U.S. Flexible Packaging Material and Converted Product Shipments: 1972-2003 (dollars)
    • Table 1-2 Flexible Packaging Materials and Converted Products' Share of U.S. Packaging Materials Dollar Shipments: 1982-2003 (dollars): Total Packaging Materials Shipments, Percent GDP, and Flexible Packaging Materials Percent Total
    • Table 1-3 Growth Analysis for U.S. Flexible Packaging Industry Product Sectors: 1992-1998 (Dollars and Tons): Single-Web Paper and Film; Multiweb and Laminated; and Uncoated Products
    • Table 1-4 Growth of Total U.S. Production Compared to Food and Beverage Processors and Chemicals and Chemical Product Manufacturers: 1992-1998 (index)
    • Table 1-5 Comparison of Gross Profit Margins for the U.S. Flexible Packaging Industry and Total U.S. Manufacturing Plants: 1987-1998 (percent)
    Scope and Methodology

Section 2: U.S. Shipments of Flexible Packaging Materials

    Summary of Major Findings
    Overall Shipment Trends
    Single-Web Coated Paper
    Single-Web Film
    Laminated Aluminum Foil
    Other Multiweb Laminated Products
    • Table 2-1 Value of U.S. Flexible Packaging Material Shipments: 1972-2003 (dollars)
    • Table 2-2 Value of U.S. Flexible Packaging Material Shipments by Product Sector: 1972-2003 (dollars): Single-Web Paper, Single-Web Film, Paper/Paper Multiweb Laminated, Laminated Aluminum Foil, and Other Multiweb Laminations
    • Table 2-3 Percent Distribution of U.S. Dollar Flexible Packaging Materials Shipments by Product Sector: 1972-2003 (percent): Single-Web Paper, Single-Web Film, Paper/Paper Multiweb Laminated, Laminated Aluminum Foil, and Other Multiweb Laminations
    • Table 2-4 Value of U.S. Single-Web Coated Paper Shipments for Packaging Purposes by Type: 1972-1998 (dollars): Plastic-Coated and Other Types
    • Table 2-5 U.S. Quantity Shipments of Single-Web Coated Paper for Packaging Purposes by Type: 1977-1998 (Tons): Plastic-Coated and Other Types
    • Table 2-6 Value of U.S. Single-Web Film Shipments for Packaging Purposes by Type: 1972-1998 (dollars): Coated Single-Web Film and Coextruded Film
    • Table 2-7 U.S. Quantity Shipments of Single-Web Film for Packaging Purposes by Type: 1987-1998 (Tons): Coated Single-Web Film and Coextruded Film
    • Table 2-8 Value of U.S. Paper/Paper Multiweb Lamination Shipments for Packaging Purposes by Type: 1982-1998 (dollars): Polyethylene Laminations and Other Laminations
    • Table 2-9 U.S. Quantity Shipments of Paper/Paper Multiweb Laminations for Packaging Purposes by Type: 1982-1998 (Tons): Polyethylene Laminations and Other Laminations
    • Table 2-10 Value of U.S. Laminated Aluminum Foil Roll and Sheet Shipments for Flexible Packaging Purposes by Type: 1972-1998 (dollars): Film/Foil Without Paper, Foil Paper, Foil/Film/Paper Combinations, and Gift Wrap
    • Table 2-11 U.S. Quantity Shipments of Laminated Aluminum Foil Rolls and Sheets for Packaging Purposes by Type: 1982-1998 (pounds): Film/Foil Without Paper, Foil Paper, Foil/Film/Paper Combinations, and Gift Wrap
    • Table 2-12 U.S. Shipments of Foil/Paper Laminated Rolls and Sheets for Flexible Packaging Purposes by Type: 1982-1998 (pounds and dollars): Extrusion Laminated Combinations and Adhesive or Wax Laminated Combinations
    • Table 2-13 Value of Other U.S. Multiweb Laminated Roll and Sheet Shipments by Type: 1982-1998 (dollars): Film/Paper Multiweb Laminations and Film/Film Multiweb Laminations
    • Table 2-14 U.S. Quantity Shipments of Other Multiweb Laminated Rolls and Sheets by Type: 1982-1998 (Tons): Film/Paper Laminations and Film/Film Multiweb Laminations
    • Table 2-15 U.S. Shipments of Film/Film Multiweb Laminations by Type: 1982-1998 (Tons and Dollars): Polypropylene/ Polypropylene, Metalized Film/Film Laminates, Cellophane/Other Film, and Other Film/Film Laminates
    • Table 2-16 U.S. Average Value per Pound of Flexible Packaging Materials Shipped by Market Sector and Product Line: 1982-1998 (dollars): Single-Web Paper, Single-Web Film, Paper/Paper Multiweb Laminated, Laminated Aluminum Foil, and Other Multiweb Laminations
    • Table 2-17 U.S. Producer Price Trends for Flexible Packaging Materials by Product Sector: 1988-1998 (index): Single-Web Paper, Single-Web Film, Paper/Paper Multiweb Laminated, Laminated Aluminum Foil, and Other Multiweb Laminations

Section 3: U.S. Shipments and Imports of Converted Flexible Packaging

    Summary of Major Findings
    Overall Shipment Trends
    Plastic Laminated and Coated Bags
    Polyethylene Bags and Liners
    Paper Bags
    Paper Shipping Sacks and Multiwall Bags
    Converted Unmounted Aluminum Foil Packaging Products
    Imports of Paper and Plastic Bags
    • Table 3-1 Value of U.S. Converted Flexible Packaging Product Shipments by Sector: 1972-2003 (dollars): Plastic, Laminated, and Coated Bags and Liners; Uncoated Paper and Multiwall Bags; and Converted Unmounted Aluminum Foil Packaging Products
    • Table 3-2 Percent Distribution of Dollar U.S. Converted Flexible Packaging Product Shipments by Sector: 1972-2003 (percent): Plastic, Laminated, and Coated Bags and Liners; Uncoated Paper and Multiwall Bags; and Converted Unmounted Aluminum Foil Packaging Products
    • Table 3-3 U.S. Shipments of Plastic, Laminated, and Coated Bags and Liners by Product Sector: 1982-2003 (dollars): Single-Web Paper, Single-Web Film, and Multiweb Laminations and Foil
    • Table 3-4 U.S. Shipments of Single-Web Film Bags and Liners by Material: 1982-1998 (Dollars and Tons): Polyethylene, Coextruded Film, and Other Film
    • Table 3-5 U.S. Shipments of Polyethylene Single-Web Film Bags and Liners by Product Type: 1982-1998 (Dollars and Tons): Grocery and Variety, Refuse, Produce, Textile and Clothing, Drum and Box Liners, Shipping Sacks, Household Food Storage, and Other
    • Table 3-6 U.S. Shipments of Multiweb Lamination and Foil Bags and Liners by Material: 1987-1998 (Dollars and Tons): Paper Combinations, Foil and Foil Combinations, and Other Multiweb Laminations
    • Table 3-7 U.S. Average Value per Pound Shipped of Plastic, Laminated, and Coated Bags and Liners by Product Line: 1982-1998 (dollars): Single-Web Film and Multiweb Laminations and Foil
    • Table 3-8 Value of U.S. Uncoated Paper Bag and Shipping Sack and Multiwall Bag Shipments: 1982-2003 (dollars)
    • Table 3-9 Value of U.S. Uncoated Paper Bag Shipments by Product Type: 1982-1998 (dollars): Grocers' Bags and Sacks, Variety Bags, Shopping Bags, and Other Uncoated Paper Bags
    • Table 3-10 U.S. Grocery and Variety Bag Shipments by Material: 1982-1998 (Dollars and Tons): Paper and Polyethylene
    • Table 3-11 U.S. Shipments of Shipping and Multiwall Bags by Type: 1982-1998 (dollars): Single and Double Wall and Multiwall
    • Table 3-12 U.S. Producer Price Trends for Twenty-Five Product Lines of Plastic, Foil, and Coated Bags and Liners; Uncoated Paper and Multiwall Bags: 1992-1998 (index)
    • Table 3-13 U.S. Shipments of Converted Unmounted Aluminum Foil Packaging Products by Type: 1982-1998 (Dollars and Pounds): Household, Institutional, and Freezer Foil; Other Unmounted Foil Flexible Packaging Products
    • Table 3-14 Value of U.S. Paper and Plastic Bag Imports and Share of the U.S. Supply: 1989-1998 (dollars)
    • Table 3-15 Value of U.S. Plastic Bag Imports for the Top Twenty Countries of Origin: 1992-1997 (dollars)
    • Table 3-16 Value of U.S. Paper Bag Imports for the Top Ten Countries of Origin: 1992-1997 (dollars)

Section 4: U.S. Flexible Packaging Industry End-Use Market Analysis

    Summary of Major Findings
    Product Packaging
    Retailers and Wholesalers
    Households
    Export Shipments
    • Table 4-1 U.S. Flexible Packaging Industry Shipments by End-Use Market Sector: 1998 (dollars)
    • Table 4-2 U.S. Flexible Packaging Material and Converted Product Purchases for Twelve Major Intermediate End-Use
    • Markets: 1987-1998 (dollars)
    • Table 4-3 U.S. Food Industry Packaging Cost Analysis: 1972-1997 (Dollars, Percent, and Index): Food and Beverage Processor Packaging Material Costs, Percent Consumer Food and Beverage Spending, Percent Food Industry Marketing Bill, and Price Index for Packaging and Containers
    • Table 4-4 Production Trends for the U.S. Food Industry and Key Food Processor End-Use Markets: 1993-1998 (index): Total Food Industry, Meat Products, Dairy Products, Canned and Frozen Food, Grain Mill Products, Bakery Products, Sugar and Confectionery, and Coffee and Miscellaneous
    • Table 4-5 Production Trends for the U.S. Chemical Industry and Key Chemical Product End-Use Markets: 1993-1998 (index): Total Chemical Industry, Basic Chemicals, Plastic Materials, Industrial Organic Chemicals, Drugs and Medicines, and Soaps and Toiletries
    • Table 4-6 Number of U.S. Plants by State for Key Food Processor End-Use Markets: 1995 (number): Meat Products, Bakery Products, Grain Mill Products, Dairy Products, Sugar and Confectionery Products, and Snack Chips
    • Table 4-7 U.S. Commercial Printer Revenues From Wrapper Printing by Type of Material: 1977-1997 (dollars): Flexographic, Lithographic Offset, Gravure, and Other Commercial Printing; Paper and Other Single and Multiweb Structures in Rolls and Sheets for Packaging Purposes
    • Table 4-8 U.S. Retailer and Wholesaler Flexible Packaging Material Purchases by Type: 1987-1997 (dollars): Paper Coating and Glazing, Bags, and Metal Foil and Leaf
    • Table 4-9 Value of U.S. Retail Foil and Wrap and Food and Trash Bag Sales by Type of Outlet: 1994-1996 (dollars)
    • Table 4-10 Value of U.S. Retail Foil and Wrap and Food and Trash Bag Sales by Type of Product and Outlet: 1994-1996 (dollars): Aluminum Foil, Plastic Wrap, Waxed Paper, Garbage/Trash Bags, Lawn and Leaf Bags, Paper Bags, and Sandwich/Freezer/Food Storage Bags; Food Stores, Mass Merchandisers, and Drug Stores
    • Table 4-11 Share of U.S. Retail Foil and Wrap and Food and Trash Bag Sales by Major Competitor and by Product: 1994-1996 (percent): Aluminum Foil, Plastic Wrap, Waxed Paper, Garbage/Trash Bags, Lawn and Leaf Bags, Paper Bags, and Sandwich/Freezer/Food Storage Bags
    • Table 4-12 Value of U.S. Paper and Plastic Bags Exports and Share of U.S. Shipments: 1982-1998 (dollars)
    • Table 4-13 Value of U.S. Plastic Bag Exports for the Top Twenty-Five Countries of Destination: 1992-1997 (dollars)
    • Table 4-14 Value of U.S. Paper Bag Exports for the Top Eighteen Countries of Destination: 1992-1997 (dollars)

Section 5: Canadian Plastic and Paper Bag Industry Trends

    Summary of Major Findings
    Market Sales
    Plant Shipments
    Plant Operating Data
    Canadian Imports
    Canadian Exports
    • Table 5-1 Value of Canadian Plastic and Paper Bag and Sack Market Sales: 1992-1997 (dollars)
    • Table 5-2 Value of Canadian Plastic and Paper Bag and Sack Shipments: 1987-1995 (Canadian dollars): Refuse, Grocery, Food Packaging, Shopping, Multiwall, and Other Bags
    • Table 5-3 Canadian Quantity Plastic Bag and Sack Shipments of Ethylene Polymers and Average Value per Pound Shipped for Select Products: 1992-1995 (Tons and Canadian Dollars): Refuse, Grocery, Single- and Multilayer Film Food Packaging, Agricultural Bags, Shopping Bags, and Other Types
    • Table 5-4 Canadian Plastic and Paper Bag and Sack Industry Cost Structure: 1990-1995 (Number, Canadian Dollars, and Percent): Number of Plants, Plant Revenues, Payroll and Material Costs Percent Revenues, Total Employees, Wages, and Weekly Hours
    • Table 5-5 Canadian Imports of Plastic and Paper Bags and Sacks by Product Type and Major Country of Origin: 1992-1997 (Canadian dollars): Ethylene and Bags and Sacks of Other Plastics; Paper Bags and Sacks Having a Base of a Width of 40 Cm or More; and Other Paper Bags
    • Table 5-6 Canadian Exports of Plastic and Paper Bags and Sacks by Product Type and Percent Shipped to the U.S.: 1992-1997 (Pounds, Canadian Dollars, and Percent): Ethylene and Bags and Sacks of Other Plastics; Paper Bags and Sacks Having a Base of a Width of 40 Cm or More; and Other Paper Bags

Section 6: Competitive Environment and the Cost Structure of U.S. Flexible Packaging Industry Plants

    Summary of Major Findings
    Competitive Environment
    Industry Profit Margins
    Material Inputs
    Labor Inputs
    Sales and Profit Trends of Leading Competitors
    • Table 6-1 Number of U.S. Flexible Packaging Material and Converted Product Manufacturers and Plants by Product Specialization: 1987-1998 (number and dollars): Paper Coated and Laminated Packaging Materials, Metal Foil and Leaf, Plastic Bags, and Uncoated Paper and Multiwall Bags
    • Table 6-2 U.S. Flexible Packaging Material and Converted Product Plant Operating Ratios and Profit Margins by Plant Product Specialization: 1987-1998 (percent): Paper Coated and Laminated Packaging Materials, Metal Foil and Leaf, Plastic Bags, and Uncoated Paper and Multiwall Bags; Payroll, Other Labor Costs, Material Costs, and Gross Profit Margins Percent Plant Shipments
    • Table 6-3 Materials Purchased by U.S. Flexible Packaging Materials Plants by Product Specialization and Kind of Material: 1987-1997 (dollars): Paper, Plastic Resins and Products, Aluminum Foil and Other Shapes, Glues and Adhesives, Printing Ink, and Paperboard Containers
    • Table 6-4 Material Purchases by U.S. Bag Plants by Product Specialization and Kind of Material: 1987-1997 (dollars): Paper, Plastic Resins and Products, Aluminum Foil, Glues and Adhesives, Printing Inks, and Paperboard Containers
    • Table 6-5 U.S. Thermoplastic Resin Usage for Flexible Packaging by Type of Resin: 1989-1998 (pounds)
    • Table 6-6 U.S. Ldpe and Lldpe Resin Used to Manufacture Packaging Film by End-Use: 1990-1996 (pounds)
    • Table 6-7 U.S. Low Density Polyethylene Resin Used to Manufacture Packaging Film by End-Use: 1990-1996 (pounds)
    • Table 6-8 U.S. Linear Low Density Polyethylene Resin Used to Manufacture Packaging Film by End-Use: 1990-1996 (pounds)
    • Table 6-9 U.S. Producer Price Trends for Major Material Inputs: 1992-1998 (index): Packaging Papers, Film and Sheeting Films, Unsupported Plastic Film and Sheet, Plain Aluminum Foil, Adhesives and Sealants, and Printing Ink
    • Table 6-10 Plant Labor Situation for U.S. Flexible Packaging Material and Converted Product Manufacturers: 1987-1998 (number, dollars, and percent): Total Employees, Shipments per Employee, Production Workers Percent Total Employees, Average Hourly Wages, and Average Weekly Hours
    • Table 6-11 Plant Labor Situation for U.S. Flexible Packaging Material and Converted Product Manufacturers by Product Specialization: 1987-1998 (number, dollars, and percent): Paper Coated and Laminated Packaging Materials, Metal Foil and Leaf, Plastics Bags, and Uncoated Paper and Multiwall Bags; Total Employees, Shipments per Employee, Average Hourly Wages, and Average Weekly Hours
    • Table 6-12 Capital Expenditures of U.S. Flexible Packaging Material and Converted Product Plants by Product Specialization: 1987-1996 (dollars and percent): Paper Coated and Laminated Packaging Materials, Metal Foil and Leaf, Plastics Bags, and Uncoated Paper and Multiwall Bags; New Capital Expenditures and Percent Value Added
    • Table 6-13 Number of U.S. Plants Specializing in Packaging Paper and Plastic Film, Coated and Laminated by State and by Number of Employees: 1987-1995 (number)
    • Table 6-14 Number of U.S. Plastic Bag Plants by State and by Number of Employees: 1993 and 1995 (number): Plastic, Laminated, and Coated Bags and Liners, Uncoated Paper and Multiwall Bags
    • Table 6-15 Number of U.S. Paper Bag Plants by State and by Number of Employees: 1993 and 1995 (number): Plastic, Laminated, and Coated Bags and Liners, Uncoated Paper and Multiwall Bags
    • Table 6-16 Share of U.S. Flexible Packaging Plant Shipments by Industry Sector and by Company Group Category: 1987-1998 (percent): Paper Coated and Laminated Packaging; Plastics, Laminated, and Coated Bags; Uncoated Paper and Multiwall Bags; Metal Foil and Leaf; 4, 8, 20, and 50 Largest Companies
    • Table 6-17 Sales Ranking of Twenty-Three U.S.-Based Flexible Packaging Materials and Converted Product Manufacturers With Sales Over $100 Million Profiled in Section Seven: 1997 (dollars)
    • Table 6-18 Sales and Profit Trends for Eighteen U.S. Manufacturers of Flexible Packaging Materials and Converted Products: 1992-1997 (dollars and percent)
    • Table 6-19 Union Camp's Volume Flexible Packaging Shipments: 1990-1997 (Tons)

Section 7: Competitive Intelligence: Company Profiles and Recent Developments

    Summary of Major Findings
    Consolidation Among Top Competitors
    Investments to Boost Plant Efficiency and Manufacturing Capabilities
    New Product Introductions
    International Expansion
    Methodology, Sources, and Objectives
    ACX Technologies, Inc.
    Advanced Deposition Technologies, Inc
    AEP Industries, Inc.
    A. Ahlstrom OY
    Alltrista Corp.
    Alusuisse-Lonza Holding Ltd.
    Amcor Ltd. American Business Products, Inc.
    Applied Extrusion Technologies, Inc
    Artra Group, Inc.
    Assidomän AB
    Atlantis Plastics, Inc
    Badger Paper Mills, Inc
    Bemis Co. Inc.
    Bpi Packaging Technologies, Inc
    British Polythene Industries PLC
    Clondalkin Group PLC
    Crown Vantage, Inc.
    Envirodyne Industries, Inc
    First Brands Corp.
    Gascogne SA
    Gaylord Container Corp
    Inteplast Corp.
    Intertape Polymer Group, Inc
    Low & Bonar PLC
    Maxco, Inc.
    Mobil Corp.
    Pechiney SA
    Printpack, Inc
    Reynolds Metals Co
    Rollprint Packaging Products, Inc.
    Rubbermaid, Inc.
    S.C. Johnson & Son, Inc
    Sealed Air Corp.
    Sealright Co., Inc.
    Sidlaw Group, PLC.
    Sonoco Products Co
    Southern Bag Corp.
    Stone Container Corp.
    Tenneco, Inc
    Tyco International Ltd.
    Uniflex, Inc.
    Union Camp Corp
    Upm-Kymmene
    Viag AG
    Winpak Ltd.
    W.R. Grace & Co.

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