Thin Wall Packaging Market Size - By Product Type, Material Type, Production Process, Application, Growth Forecast, 2025 - 2034

Thin Wall Packaging Market Size

The global thin wall packaging market size was valued at USD 41.2 billion in 2024 and is estimated to grow at a CAGR of 6.5% to reach USD 76.6 billion by 2034 with the volume of 714.2 billion units. The growth of the market is driven by key factors such as surge in demand for convenience and ready-to-eat foods, rise of food delivery and QSR channels, as well as rapid urbanization in emerging economies.
 

The increase in demand for convenience and ready-to-eat (RTE) foods is exhibiting a positive influence on the growth of the thin wall packaging market. In the case of food products, the shift in consumer lifestyles and urbanization leads to the growing need for thin wall packaging due to its light weight, strength, and affordable price. According to the 2024 Statista Global Consumer Survey conducted in the United States, frozen ready-to-cook items and frozen ready-to-eat meals ranked as the most preferred convenience food products.
 

Baby Boomers (born between 1946 and 1964) emerged as the leading consumers, accounting for 63% of purchases in both categories. In contrast, Generation Z (born between 1995 and 2012) demonstrated a comparatively lower reliance on convenience food, indicating generational differences in food consumption behaviour. Thin wall packaging type can be used with automated filling lines for perishable and microwaveable food items due to its exceptional barrier protection.
 

Moreover, it consists of great compatibility with single-serving and portable food formats which is rapidly increasing in demand around urban areas and fast paced retail settings. With consumers increasingly seeking quick, easy-to-use, and portable food solutions due to busy lifestyles, there is growing preference for lightweight, microwaveable, and resealable packaging formats. Thin wall packaging, known for its durability, cost-efficiency, and excellent barrier properties, aligns well with these needs. It enables faster production cycles, reduces material usage, and extends product shelf life making it ideal for packaging dairy, snacks, frozen meals, and other ready-to-eat items.
 

Thin wall packaging manufacturers should focus on developing lightweight, microwaveable, and resealable packaging formats tailored for ready-to-eat and frozen meals, particularly targeting Baby Boomers and urban consumers seeking convenient, durable, and cost-effective food packaging solutions.
 

In addition, the demand for thin wall packaging is accelerating due to increased lifestyle changes, disposable income, and consumption of packaged food and beverages as a result of rapid urbanization in emerging economies. According to the World Bank, there are more than half of the world's population, or 4.4 billion people, reside in urban areas. This trend is predicted to continue, with nearly seven out of ten people living in cities by 2050, when the urban population is predicted to more than double.
 

A growing urban population has distinct food needs which is shifting toward convenience and fast moving ready to eat food items. Such foods are light, take up less space and have low cost packaging. Accordingly, these requirements are align by thin wall packaging and lower material usage. Additionally, lower production cycles strengthens these requirements. Furthermore, modern retailing and e-commerce make vertical centre shift to urban centres increases the need for strong appealing packaging, which is propelling the growth of the market during the estimated period. 
 

Thin wall packaging manufacturers should develop visually appealing, lightweight, and cost-efficient packaging solutions tailored for the growing urban consumer base in emerging economies, with a focus on fast-moving packaged food and beverage products. They should also invest in production technologies that enable faster manufacturing cycles and reduced material usage to meet the rising demand driven by urbanization, modern retailing, and e-commerce expansion.
 

Trump's trade policies have had a profound economic effect on the thin wall packaging market. The tariffs placed on imported materials like polypropylene and polyethylene have driven up the costs for manufacturers. In addition to these challenges, the ongoing disruption in the supply chain creates high complications for businesses struggling with procurement bottlenecks and extended timelines. These factors are especially affecting the small and medium-sized businesses, as they are enduring severe profit losses and uncertain operational control. To remain financially viable, some of these businesses are trying out new sourcing options that include shifting to domestic producers and broadening their list of potential suppliers.
 

Thin Wall Packaging Market Trends

• The rise in adoption of recyclable and bio-based polymers trend in the thin wall packaging industry is a key trend which is being advanced by increasing concern for the environment and global regulations on plastic waste. There is an evident shift by manufacturers from using traditional resins like polystyrene and polypropylene to more sustainable options such as PLA, bio-PET, and post-consumer recycled materials. These new polymers improve carbon emission metrics in addition to EPR and circular economy compliance.
   
• Moreover, various companies are using sustainable packaging to attract green consumers and enhance brand differentiation in the ready meals, personal care, and even in the dairy sectors. The sustainability initiatives are fast-tracking the investment into innovations of thin wall packaging solutions to more eco-friendly and to enhance their functionality, strength, and aesthetic appeal.
   

• Additionally, the growth of e-commerce is also an important factor driving the market. E-commerce demands that packages be lightweight yet strong enough to withstand intricate shipping systems, constant handling, and various environmental conditions.
   
• According to the Ecommerce Tips, in the United States, there are 218.8 million internet shoppers, while there are 2.4 billion worldwide. It is anticipated that global e-commerce sales will increase from $6.9 trillion in 2024 to USD 8.1 trillion in 2026. There are various initiatives to further enhance thin wall containers specifically in the areas of sealing and tamper evidence. These are designed for the expanding marketing channel.
   
• For greater engagement and tracking purposes, some brands are utilizing smart labels and QR codes on the thin wall packages to engage with customers in advanced retail other than the direct sale surfaces. All these are effects of the tendency to streamline and optimize packaging design to minimize volumetric weight which facilitates lower shipping costs, last mile delivery, and overall environmental sustainability.
   

Thin Wall Packaging Market Analysis

Based on the product type, the market is segmented into cups, tubs, trays, jars, lids, and other containers.
 

• The jars segment accounted for USD 9 billion in 2024. Thin wall packaging market jars are widely used in food, personal care and household products as it offers cost effective benefits for a wide range applications. Jars are becoming increasingly popular among consumers for their convenience and reusability, while also preserving freshness of products in particular dairy products, sauces and cosmetic applications.
   
• Increasing on-the-go and ready-to-eat consumption habits has generated the demand for plastic jars with food safe sealing and tamper-evident closure. Furthermore, the use of recyclable polypropylene and bio-based materials by manufacturers for sustainability objectives is likely to propel demand for thin wall jars.
   
• Cups accounted for the fastest growing segment that is likely to reach USD 19.2 billion in 2034. The usage of cups is being spurred by the expanding consumption of single-serve meals, and desserts, in addition to growing consumption of dairy products, especially with the busy urban lifestyle. They are ideal for both hot and cold food applications as they are cost-efficient and possess lightweight structure along with superior barrier properties.
   
• Moreover, the proliferation of quick-service restaurants (QSRs) and the takeaway culture has driven the demand for thin wall plastic cups in the foodservice retail sectors. These are now made with environmentally friendly compostable and recyclable materials which helps manufacturers meet environmental regulations and further reinforces the adoption.
   

Based on the material type, the market is divided into polypropylene (PP), polyethylene (PE), polystyrene (PS), polyethylene terephthalate (PET), polyvinyl chloride (PVC), and others.
 

• Polypropylene (PP) is expected to account for 37.8% of the thin wall packaging market in 2024. The demand for polypropylene (PP) in the market stems from its remarkable balance of strength, the lightness of weight, as well as its cost effectiveness, rendering it suitable for high-speed injection moulding. PP provides excellent moisture resistance, is chemically inert and is clear, an important characteristic in food packaging, particularly for dairy, and ready-to-eat and frozen items. Its recyclable nature also makes it more appealing in the market as environmental and sustainability regulations become more stringent. Furthermore, new PP formulations are improving performance and allowing for the manufacture of thinner but tough packaging, maximizing material usage while reducing total carbon footprint.
   
• Polyethylene Terephthalate (PET) segment accounted for CAGR of 7.8% in 2025-2034. The demand for PET is driven by excellent barrier properties of polyethylene terephthalate (PET), high recyclability credentials, and transparency. Polyethylene terephthalate (PET) is the preferred plastic polymer for packaging because of high visibility, protection against oxygen and moisture, and its use in beverages, personal care products, and dairy. It serves all these industries. Polymers that are rPET compliant can be food-grade, which strengthen consumer spending alongside industrial packaging and sustainability mandates, thereby shifting focus from virgin plastic in a circular economy, accelerating the segment growth in the market.
   

Based on production process, the thin wall packaging market is bifurcated into thermoforming, injection molding, and others.
 

• Injection molding segment dominated the market, accounting for USD 21.6 billion in 2024. The thin wall packaging market is increasing because of the advancement in technology in injection molding processes. This is due to high precision, fast cycle times, and excellent repeatability which optimally serves bulk production of complex shaped lightweight packaging including tubs, lids, and cups in cost efficient manners. The process is further enhanced due to the vast array of polymers that can be used such as Polypropylene (PP) and Polythylene Terephthalate (PET) without compromising the quality of the structure. In addition, new advancements in multi-cavity tooling and the high speed injection machines have minimized the overall production costs and increased efficiency in tandem with the industry requirements for increased production capacity, stable eco-friendly practices, and reduced lead production times.
   
• Thermoforming segment is expected to register significant growth during the forecast period, growing at a CAGR of 6.2% for 2025 to 2034. The demand for thermoforming in the thin wall packaging market stipulates from its low-cost production and rapid prototyping capabilities as well as its appropriateness for light-weight shallow container production like trays, clamshells, and lids. Thermoforming is especially advantageous in the food, dairy, and takeaway packaging sectors because of its indirect tooling costs to injection molding for short to medium production runs. Moreover, custom designs and the ability to integrate with high efficiency packaging lines broaden the scope of applicability for the retail market, enhancing the focus on consumer value.
   

Based on the application, the market is segmented into food, beverages, personal care & cosmetics, household products, electrical & electronics, pharmaceuticals & nutraceuticals, and industrial.
 

• Food segment accounted for USD 15.9 billion in 2024. Thin wall packaging requirement in food industry stipulates from lightweight and high-performing packaging that enable fast filling and longer shelf life in the food sector. Growing consumption of on-the-go and ready-to-eat food items, snacking trend and expansion in organized retailing are driving the market growth of thin wall containers which consist of trays, cups, and tubs. Further, the ability of the packaging to provide barrier protection, transparency, and compatibility with microwave and freezer is also in line with changing consumer lifestyles and regulatory focus on food safety and hygiene.
   
• Pharmaceuticals & nutraceuticals accounted for the fastest growing segment that is likely to reach USD 6.9 billion in 2034 due to the growing requirements for hygiene, light weight, and sterility along with tamper evidence and compliance with strict health regulations. To prevent primary and secondary packages from contamination, consumer interest in preventive healthcare and dietary supplements surged causing manufacturers to use thin wall containers due to their precise molding, high barrier protection, and thin plastic cost efficiency which make the products more affordable.
   
• Additionally, the shift toward e-pharmacy and direct-to-consumer healthcare is further accelerating reliance on the packaging due to its efficiency and security for safe transport.
   

In 2024, the U.S. thin wall packaging market accounted for USD 9.2 billion. The demand for thin wall packaging in the United States is supported by the food and beverage industry such as rise in consumption of prepared meals, dessert and snack items, driving demand for low priced, light weight, strong and thin wall packages. Moreover, the growth of online shopping and door to door delivery services require that the packing materials be strong but light in order to protect the item properly while minimizing shipping expenses.
 

Furthermore, growing public awareness and attention to sustainability alongside policies and regulations has resulted in manufacturers using recyclable and lesser materials by reducing packaging weight which is favourable for sustainability, in turn, accelerating the market growth.
 

The Germany thin wall packaging market is expected to grow at a CAGR of 7.7% during the forecast period owing to the region’s heightened focus on sustainability and severe environmental policies. German manufacturers are progressively shifting towards the use of sustainable materials and the application of energy-saving production methods in accordance with these regulations. Furthermore, the market is expanding with the introduction of multi-use high-performance thin wall packaging systems that are more advanced in terms of strength and functional capabilities which serve the German ideals of quality and innovation, further resulting into the growth of the market at a substantial rate.
 

China thin wall packaging market is expected to grow at a CAGR of 8.7% during the forecast period. The growing middle class and rapid urbanization has resulted in heightened consumption of packaged foods like ready-to-eat meals and dairy products which require lightweight and cheap packaging. This is further fuelled by the growth of e-commerce and home delivery which increases the demand for durable and efficient transport packaging.
 

Also, government initiatives toward environmental sustainability, through The Five Year Action Plan for reducing plastic used, aim to bolster recyclable and eco-friendly plastics which increases thin wall packaging. Recent developments in manufacturing technologies such as high-speed injection molding and automation also increase production efficiency, allowing for increased customization to meet the demands of consumers, thus, is leveraging various growth prospects for the market expansion in China at a substantial rate.
 

In 2024, Japan is expected to account for a share of 18% of the thin wall packaging market in Asia Pacific. The growing consumer acceptance of paying for convenience and ready-to-eat food products has increased the demand for light and strong packaging materials. Thin wall packaging is economically and visually appealing due to advances in high-speed injection molding and in-mold labeling technologies in cost-efficient manufacturing.
 

There is also a heightened focus on sustainable reusable and recyclable materials by consumers and deploying them by businesses which further strengthens the market in Japan. The growth of e-commerce coupled with the consumer and business focus on sustainable reusable and recyclable materials is leading to the market growth in Japan.
 

India thin wall packaging market accounted for USD 5.4 billion in 2034. The rapid urbanization, along with the growth of the middle class, has led to a higher consumption of packaged food items, especially ready-to-eat meals and dairy products, which need light weight and economical packages. Additionally, the growth of organized retail stores, as well as the rise of e-commerce, is spurring the demand for thin wall packaging. Thus, these factors are contributing to the market in India.
 

Thin Wall Packaging Market Share

The market for thin wall packaging is fragmented and intensely competitive containing several major companies at different levels of the value chain. Companies like Berry Global Inc., Amcor plc, Greiner Packaging International GmbH, Paccor GmbH, and ILIP S.r.l. have a considerable presence in the market and are holding market shares of nearly 31.2%. These companies have increased their focus on augmenting production capacity, fostering strategic alliances, and investing in R&D to strengthen thier positions in the market and diversify supply chain risks. Adopted policies are aimed at meeting consumer demand, legal regulations, and compliance standards.
 

The market for thin wall packaging is continuously developing with new product innovations that are tailored to meet sustainability. For instance, in October 2023, Netstal unveiled the introduction of 100% polypropylene thin-wall dairy cups using injection compression molding at Fakuma. The cup has a 200g filling capacity, a 5.4g part weight, and a 0.3mm wall thickness. When paired with product optimization, injection compression molding, or ICM it reduces the weight of the cup by 34% and the volume of packaging by 27%.
 

Thin Wall Packaging Market Companies

Leading companies in the thin wall packaging industry comprise:

• Berry Global Inc.
• Greiner Packaging International GmbH
• Amcor plc
• Paccor GmbH
• ILIP S.r.l.
   

Berry Global Inc. is considered one of the leaders of the thin wall packaging market and provides a plethora of services pertaining to packaging solutions in food, beverages, pharmaceuticals and even industrial sectors. It is well-known that the ice cream, pastries, and yogurt packaging, is lightweight and also robust and recyclable. Berry Global maintains a competitive edge by prioritizing innovation and sustainability in all aspects of product development and diversification.
 

Greiner Packaging International GmbH is the producer of rigid plastic packaging. The company has a special attention given to thin-wall packaging solutions. The company focuses on the development of thin-wall packaging solutions. It possesses an extensive catalog of packaging solutions for various industry sectors while incorporating environmentally consciousness and modern designs. The food and beverage industries prefer thin-wall packaging because of its strength and light weight. These fall into the category of walls less than 0.8mm thick.
 

Thin Wall Packaging Industry News

• In March 2025, LyondellBasell announced the introduction of Pro-fax EP649U, a novel polypropylene impact copolymer intended for the rigid packaging market. This cutting-edge product is suitable for food packaging applications because it is specially made for thin-walled injection molding. Because of its high flow characteristics and quick crystallization, Pro-fax EP649U facilitates to produce thin-walled containers quickly and effectively, improving output and product quality. Pro-fax EP649U's additive package makes it easier to release mold, lowers static, and enhances downstream handling on high-speed filling lines.
   
• In May 2021, SABIC and KraussMaffei HighPerformance AG have announced their partnership at the partner's newly enlarged Thin-Wall Packaging Application Center in Näfels, Switzerland. This location is establishment to KraussMaffei's Swiss subsidiary and netsal brand manufacturer of high-performance injection molding systems. Through greater cooperation throughout the segment's whole value chain, the enlarged Application Center by representatives from both businesses, will facilitate novel application, material, and processing solutions in the thin-wall packaging sector.
   

This thin wall packaging market research report includes in-depth coverage of the industry with estimates & forecasts in terms of revenue (USD Million) and volume (Units) from 2021 to 2034, for the following segments:

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Market, By Product Type

• Cups
• Tubs
• Trays
• Jars
• Lids
• Other containers

Market, By Material Type

• Polypropylene (PP)
• Polyethylene (PE)
  • High-density polyethylene (HDPE)
  • Low-density polyethylene (LDPE)
• Polystyrene (PS)
• Polyethylene terephthalate (PET)
• Polyvinyl chloride (PVC)
• Others

Market, By Production Process

• Thermoforming
• Injection molding
• Others 

Market, By Application

• Food
  • Dairy products
  • Ready-to-eat meals
  • Bakery & confectionery
  • Meat, poultry & seafood
• Beverages
• Personal care & cosmetics
• Household products
• Electrical & electronics
• Pharmaceuticals & nutraceuticals
• Industrial

The above information is provided for the following regions and countries:

• North America
  • U.S.
  • Canada
• Europe
  • UK
  • Germany
  • France
  • Italy
  • Spain
  • Russia
• Asia Pacific
  • China
  • India
  • Japan
  • South Korea
  • ANZ 
• Latin America
  • Brazil
  • Mexico
• MEA
  • UAE
  • Saudi Arabia
  • South Africa