Secondary Packaging Market Size is USD 54.81 Bn in 2025 Driven by E-commerce and Sustainability

The global secondary packaging market size accounted for USD 52.18 billion in 2024 and is predicted to touch around USD 92.53 billion by 2034, growing at a CAGR of 5.89% from 2025 to 2034. The secondary packaging market is experiencing growth driven by local considerations, including e-commerce growth, sustainability, and technological advancements. The key sectors include pharmaceutical, food & beverage, and global logistics. Smart packaging, automation, and personalization ensure that packages remain safe and secure from production to delivery.

Highlights of the Secondary Packaging Market

• North America dominated the global market in 2024.
• Asia Pacific is anticipated to grow at the fastest rate in the market during the forecast period.
• By packaging type insight, the shrink wrap segment held a dominant presence in the market in 2024 and is expected to grow at the fastest rate in the market during the forecast period of 2025 to 2034.
• By packaging type insight, the corrugated boxes segment is expected to grow at a considerable rate during the forecast period.
• By material insight, the paper & paperboard segment dominated the market in 2024.
• By end-use insight, the healthcare segment led the market in 2024.
• By end-use insight, the xx segment is expected to grow at the fastest rate during the forecast period.
• By product insight, the folding cartons segment led the secondary packaging market.

Secondary Packaging Market Statical Scope

Secondary packaging is the real shield for the product, plus it is further consolidated when logistics and retailing stand on the other side of the aisle. It encompasses all the outer-packaging types, from cartons, trays, shrink films, and the like, that cluster the primary package for safer handling, transportation, and storage. It offers shelf appeal, branding, and visibility in a competitive retail environment. Trends in the secondary packaging market are veering towards intelligent packaging that incorporates tracking and marketing functions. With the modernization of the industry through automation, processes are expediting with better consistency. Minimal designs are preferred for the sake of sustainability and consumer backlash against too much clutter. New-age features such as easy-open seals and ergonomic designs augment the end-user experience, thereby cementing with importance of secondary packaging in today's supply chains and aiding in the growth of the market.

Secondary Packaging Market: Stats and Figures

• About 2,000 businesses are currently active within the corrugated box industry in the United States.
• Deufol SE is a global provider of end-to-end supply chain solutions, offering services like packaging, logistics, and IT solutions. In 2024, the company saw a 5.1% increase in revenue, reaching approximately 309 million euros, despite a volatile market.
• Mondi Group is a global leader in packaging and paper, producing and distributing a wide range of packaging and paper products. In 2024, Mondi reported a group revenue of €7,416 million, a slight increase from €7,330 million in 2023.
• Owens-Illinois, Inc. (O-I Glass) is a global manufacturer of glass containers, operating 77 plants in 23 countries. In Q1 2025, the company reported $1.6 billion in revenue.

How AI Has Benefited The Secondary Packaging Market

Using AI, secondary packaging enters an era of refinement: more efficient, less costly, and sustainable. In sectors such as pharmaceuticals, many AI-vision systems are defect detectors. Sustainability is reached when the packaging design considers lowering material consumption while providing sufficient protection to the product. AI thus optimizes shipping container space, cutting emissions and transportation expenses. Automation enhances production speed, lessening manual intervention and errors. Hence, cost savings are realized through reduced use of materials, reduced waste, predictive maintenance, etc. AI strengthens supply chain management through demand forecasting and production schedule optimization. It also looks into customer behavior and product data to create personalized packaging. Conclusively, AI for secondary packaging ensures product quality, efficiency, and enhanced customer engagement.

Secondary Packaging Market Dynamics

What Are the Major Market Drivers in The Secondary Packaging Market?

The major market drivers in the secondary packaging market are the booming e-commerce sector, rising environmental concerns, and advancements in packaging technology.

• E-commerce Boom: E-commerce growth has immensely impacted the secondary packaging market, creating a need for packaging strong enough to protect the product until it reaches the consumer. Secondary packaging comprising corrugated cartons, shrink-wraps, and protective inserts is vital for shipping and logistics: it is also a branding medium, as the unboxing experience should augment brand identity. Companies are now focusing on the customization of packages to ensure greater product excitement, satisfaction, and loyalty among customers. Under the sustainability banner, alternatives of recycling and biodegradability have been proposed for e-commerce shipping. Being the ever-increasing online sales, these secondary packaging concerns are anticipated to be greatly influenced. And this will ultimately contribute to the market expansion.
• Pharmaceutical Industry Growth: The pharmaceutical industry constitutes a major segment within the secondary packaging realm due to its stringent regulation and demand for high standards of product integrity. Secondary packaging is designed for several purposes: tamper-evidence, sterility, traceability, and safety to be considered from manufacturing through the end consumers. Some products require secondary packaging to ensure they are not contaminated, broken, or mislabelled-given vials, blister packs, and prefilled syringes. Above all else, the packaging must comply with regulatory bodies such as the FDA, EMA, and WHO. Also, smart packaging technologies, including RFID tags and QR codes, have increased the monitoring of products and testified to their authenticity. The rise in popularity for personalized medication, biologics, and home-care drug delivery has simultaneously complicated pharmaceutical packaging, making the pharmaceutical industry's role more pertinent in boosting the secondary packaging market.

What Are the Major Market Restraints in The Secondary Packaging Market?

The growth of the secondary packaging market is restrained by factors such as fluctuating raw material prices, environmental regulations, supply chain disruptions, and intense competition.

• Fluctuating Raw Material Prices: The second packaging market experiences stagnancy, growth, and stability issues owing to the price fluctuations of raw materials. Materials such as paperboard, corrugated fiberboard, plastic films, adhesives, and inks changed due to the worldwide economic situation, geopolitical tensions, energy prices, and supply-demand imbalances. Packaging manufacturers' margins offered the strongest resistance to changes in price, more so for the smaller companies that have less capacity to absorb the increase in costs. They may compromise the quality of materials and reduce transport charges or simply ask the end user to pay more, which lowers competitiveness. Planning for the long term and investments in sustainable innovations are made very difficult by this volatility, which prevents the creation of a reliable budget forecast. Procurement incurred delays and disruptions, especially during global crises and trade disputes. This uncertainty creates a hindrance for market expansion and pushes the search for substitute raw materials that are cheap, sustainable, and reliable.
• Environmental Regulations: A tightening of environmental regulations across the world poses adverse challenges for the secondary packaging market. These regulations emphasize the reduction of environmental impact by prohibiting single-use plastics, mandating recyclable materials, and restricting packaging waste. Manufacturers and retailers are mandated to abide by the stringent requirements, and this would often require heavy investments in R&D. These changes are sometimes costly, not only in terms of investment but specialized costs of machinery related to their new options that can include anything but paperboard, bioplastics, or even compostables. Should anyone believe to have violated the law, he/she might have to shoulder enormous penalties, lose their business, or face negative repercussions on their brand name in the business. Small and medium-sized companies see a rise in operating costs, changes to their supply chains, and an ongoing need for innovation just to stay compliant and competitive.

What Are the Market Opportunities in the Secondary Packaging Market?

The opportunities in the secondary packaging market are associated with sustainability concerns and advancements in packaging technology.

Sustainability Focus:

Sustainability is gaining prominence in secondary packaging because of environmental consciousness and regulatory requirements. Paperboard made from recycled materials, molded fiber, biodegradable films, and compostable plastic are just some of the greener options companies are now opting for to reduce carbon footprints and landfill waste. Such a transition in packaging increases brand positioning and consumer acceptability; green packaging companies already have a stigma for good. Major retailers and e-commerce platforms have also come up with packaging guidelines to promote sustainable practices that foster new opportunities for suppliers. The companies that prioritize sustainability will lead the market as well as have access to green financing.

Technological Advancements:

The secondary packaging market is proliferating massively owing to technological advances. The advent of automation gives companies the ability to speed up processes while cutting labor costs and improving throughput. Smart packaging technologies-short of description-better supply chain management, and customer interaction supply coordination for inventory

accuracy and customer engagement. Personalization is a huge opportunity with actual brands able to design packaging targeted at different groups and tastes, thus transforming the unboxing experience while also forging brand equity. AI and AR are further disrupting packaging design and marketing by aiding data-driven decisions on packaging format, materials usage, and inventory forecasting. These opportunities offer immense growth and are a great lever for differentiation for innovators in packaging firms.

Industry Leader Announcements

• Marcel Martin-Chief Corporate Affairs and Sustainability Officer:

“This is the first-ever packaging solution of its kind for 1.5-litre multipacks of Coca-Cola, Fanta, and Sprite. It’s the result of our entrepreneurial mindset, an absolute belief in collaborating with trusted partners and our focus on reaching net zero emissions by 2040.”

• Patrick Verhelst, President of the FBCA Board :

“Our industry is working tirelessly in designing fully renewable and sustainable packaging solutions that meet the needs of both consumers and the planet. We are excited to expand globally and champion the role of beverage cartons in building a more resilient, low-carbon future.”

Segmental Insights

Packaging Type Insight

The shrink wrap segment dominated the market and is expected to grow at the fastest rate during the forecast period. By their versatility and value for money, coupled with excellent protection, shrink wraps are the fastest-growing segment from the secondary packaging perspective. It finds wide acceptance among the food & beverages, personal care, pharmaceutical, and electronic industries to establish tamper evidence, resistance against moisture, and shelf appeal. Being very thin compared to poly boxes and crates, shrink wraps prove to reduce a lot of shipping costs while maintaining structure. The need for safe packaging and smaller boxes in e-commerce and retail logistics has pushed the adoption of shrink wraps. Biodegradable and recyclable shrink films have emerged as a big platform for sustainability. As more companies now look for packaging that is flexible, protective, and good-looking, it is shrink wraps that come forth as a big opportunity for high growth.

Corrugated boxes are expected to grow at a notable rate during the forecast period. Corrugated boxes are dressed in their greatest glory in the secondary packaging market because of being strong, recycled, and versatile to various industries. They constitute long-distance shipping, warehousing solutions in e-commerce, transportation, Food & Beverage, and pharmaceuticals, etc. Lightweight freight reduces freight as well as high load bearing. Corrugated boxes can be tailored to the needs of branding, printing, and size. The development of e-commerce has further elevated the demand for corrugated boxes as they provide a good deal of structural support and product safety. From a sustainability point of view and on the directives of the laws, corrugated materials are normally recycled from paper. Increased automation of packaging centers further strengthens the integration of corrugated boxes into high-speed operations.

Material Insight

Paper and paperboard materials needed for secondary packaging are favoured due to being eco-friendly. However, supply-oversupply imbalances have crept in. With operational costs rising and regulations impeding expansion and modernization, it is not all that easy. Still, paper-based packaging holds its ground against demand on the grounds of environmental consciousness and further considerations involving a preference toward leaves. To keep viable, all players in the industry are currently making changes to their operational structure, making more investments into process optimization, and paving the way toward new-age, lightweight, and high-performance paper packaging. A correct reflection of market dynamics, global sustainability themes, and consumer expectations of responsible packaging will decide the future of the segment.

Product Insight

Easy folding cartons are secondary packaging for consumer products. This specific type of packaging gives branding and intricate design to the product, visibility, and consumer engagement. The carton structure supports different industries and is being developed for packaging technologies for digital tracking and bulk inventory management. These folding cartons are recyclable or are accepted for biodegradation; hence, they come in handy for any sustainability-conscious company. A flat design aids in optimizing space utilization and least logistics costs for shipping and handling. Folding cartons thus fill that versatile need as more companies go toward usable, green, and attractive packaging solutions.

End Use Insight

Secondary packaging is imperative in the healthcare industry for the safety, integrity, and usability of medical products such as drugs, devices, and diagnostics. Secondary packaging conveys treatment information, dosage instructions, storage requirements, and warnings to ensure the correct administration of the medicine by healthcare providers or patients. There are packaging forms widely used for secondary packaging of healthcare products-the folding carton, blister pack, and other special containers-which are dimensioned to accommodate the uniqueness of the healthcare product and ensure sterility or tamper evidence throughout the supply chain. These developments have been enhancing traceability, authentication, and convenience. Secondary packaging is increasingly in demand, further inspired by the patient-centric approach and personalized medicine, which thus becomes one of the critical players in enhancing healthcare and maintaining high industry standards.

Geographical Insights

North America dominated the market in 2024. With its advanced economic bases, infrastructure, and well-established transport networks, North America is the world leader in the secondary packaging area. Unique packaging solutions are provided to protect products, build brand visibility, and accord with local regulations in core sectors such as retail, food and beverage, pharmaceutical, electronics, and automotive industries. By emphasizing consumer consciousness towards sustainability and product innovation, North America poses an increasing demand for environmentally friendly and efficient packaging solutions. Proceedings are ongoing in the region in adopting new materials and hybrid designs that lessen environmental footprints without compromising product safety. In addition, the packaging industry's strategic mergers and acquisitions will surely augment their current capabilities while widening the market outreach.

Asia-Pacific is expected to grow at the fastest rate during the forecast period. The secondary packaging market finds an enticing scope in the Asia-Pacific region, elaborating upon the economic growth and industrial expansion of the area. Countries like China, India, Japan, and South Korea serve as manufacturing centers, fueling the demand for packaging. A very diverse customer base demands efficacious packaging-protection of the product while in transit, shelf appeal, and regulatory requirements. The packaging industry of the region is one where rapid innovation acts as its heartbeat, where companies focus much on sustainability, material optimization, and automation. These changes combine to achieve better protection and presentation of products from an environmental standpoint, thus cementing itself to become the world's key competitor in secondary packaging.

Recent Developments in the Secondary Packaging Market:

• In July 2025, Kenco, a leading logistics provider, launched its Contract Packaging Division, a strategic investment in secondary packaging, aiming to streamline operations and enhance supply chain management.
• In January 2024, the Food and Beverage Carton Alliance (FBCA), formed by ACE and EXTR: ACT, is a platform promoting beverage cartons as sustainable, renewable, and circular packaging solutions.
• In September 2023, Coca-Cola HBC introduces LitePac Top, a revolutionary packaging for 1.5 litre bottles, potentially ending plastic shrink wrap. The 100% recyclable cardboard and paper wrap is easy to carry and recycle.
• In February 2022, GPA Global introduced Eco-Logic, a sustainable, biodegradable secondary packaging made from moulded pulp, water-based glue, soy-based inks, and biodegradable finishes, made from recycled paper or natural fibres.

Competitive Landscape

The market is moderately fragmented with local players like Amcor PLC, Nippon Paper Industries Co Ltd, Berry Plastics, Oji Holdings Corp, Deufol SE, Crown Holdings Inc., International Paper Company, Ball Corporation, SCG Packaging, etc., wishing to take the time to edge their presence through investments, partnerships, acquisitions, and mergers. They also invest in product development and competitive pricing. These strategies will promote market growth and lucrative opportunities for market players

• Company Name: Ball Corporation
• Year of Incorporation: 1880
• Headquarters: Westminster, Colorado

Ball Corporation's most recent twelve-month (TTM) revenue is $12.02 billion, reflecting a 0.53% increase year-over-year. In the first quarter of 2025, the company reported $3.10 billion in sales, a 7.76% increase compared to the same period in the previous year.

• Company Name: Oji Holdings Corp
• Year of Incorporation: 1949
• Headquarters: Chuo-ku, Tokyo, Japan

Oji Holdings Corp's revenue in the fiscal year ending March 31, 2025, was 1.85 trillion JPY, with a 9.02% growth. In the quarter ending March 31, 2025, the company's revenue was 465.53 billion JPY, reflecting a 15.27% increase.

• Company Name: SCG Packaging
• Year of Incorporation: 1975
• Headquarters: Bangkok, Thailand

SCG Packaging (SCGP) reported a revenue of Baht 132,784 million in 2024, a 3% increase compared to the previous year.