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Plastics for Barrier Packaging

Published By :

BCC Research

Published Date : Nov 2017

Category :

Plastics

No. of Pages : N/A

The U.S. barrier resins market should reach 8.5 billion pounds in 2017 and 9.6 billion pounds in 2022, with a CAGR of 2.5%. The U.S. permeable films market should reach 700 million pounds in 2017 and 784 million pounds in 2022, with a CAGR of 2.3%.

Report Includes

  • 20 data tables and 15 additional tables
  • An overview of the global markets for plastics used in barrier packaging
  • Analyses of global market trends, with data estimates for 2017 and projections of compound annual growth rates (CAGRs) through 2022
  • Information on barrier polymers and their applications, their technology, competing barrier materials, and future trends
  • Analysis of the market's drivers and opportunities
  • In-depth analysis of the market's restrictions, specifically including susceptibility to contamination or degradation, disposability and recyclability issues, challenges compared to competing materials, and costs
  • Profiles of major players in the industry

Report Scope

This BCC Research study provides in-depth coverage of many of the most important technological, economic, political, and environmental considerations in the U.S. barrier packaging polymer industry. It is primarily a study of U.S. markets. However, because of the increasingly global nature of polymer and packaging chemistry, it touches on some noteworthy international activities, primarily those having an impact on the U.S. market, such as imports/exports and foreign firms operating in this country.

We analyze and forecast market estimates for barrier packaging plastic resins in volume and pounds. Our base market estimate year is 2017, and we forecast market growth for a five-year period to 2022. All market estimates are rounded to the nearest million pounds and all growth rates are compounded and signified as compound annual growth rates or CAGRs. Because of this rounding, some growth rates may not agree exactly with figures in the market tables; this is especially so with small volumes and their differences. All market volumes are at the manufacturer or producer level.

This report is segmented into nine chapters and an appendix, of which this Introduction is the first.

The Summary, Chapter 2, encapsulates our findings and conclusions, and includes a Summary Table, which summarizes the major barrier packaging resins. It is the place where busy executives can find key elements of the study in summary format.

An Overview follows in Chapter 3, starting with an introduction to the petrochemical industry, the source of all these barrier packaging polymers. Then we discuss the plastic resin industries and focus on barrier packaging. We conclude with a discussion of barrier packaging materials and structures, with emphasis on plastic barrier resins. Our intent is to introduce readers to the field of polymers, barrier packaging, and barrier packaging resins.

Next is Chapter 4, the first of two devoted to market analysis. Here, we discuss, estimate, and forecast markets for barrier packaging plastics by major resin type or class. This discussion includes some major commodity resins, such as polyolefins, that find use as structural packaging resins. However, since these are not primarily barrier resins, and thus outside our scope, we do not attempt to estimate their wide and diffuse markets. We start this chapter with an overall market estimate and forecast for the major types of barrier packaging resins for base year 2017 and forecast to 2022. Then in each subsequent section, we describe individual barrier resin types in more detail, discuss their important applications in barrier packaging, and estimate and forecast their markets in more detail. The types of barrier resins that are coverd and forecast include EVOH, PCTFE fluoropolymer, polyamides (nylons), thermoplastic polyesters, (primarily PET), PVdC, other newer and smaller volume barrier resins like cyclic olefin copolymers (COCs) and liquid crystal polymers (LCPs), tie-layer resins, and vapor-permeable films.

Our discussion and market analysis of vapor-permeable barrier resins and systems is included as an interesting sidelight to barrier resin chemistry, since the very term “vapor-permeable barrier” sounds like an oxymoron. These structures are designed for selective permeation, meaning some gases should pass through the structure but others should not. These markets are growing and very fluid and are more difficult to estimate, giving much rougher market estimates. We include them for interest.

In Chapter 5, we discuss and forecast markets by barrier resin applications. We have placed applications into three specific major groups: food (by far the largest segment), chemical and industrial products, and healthcare products packaging.

Chapter 6 is devoted to technology, starting with some basic plastic resin chemistry, manufacture, and properties of plastics used in barrier packaging. Next, we go to polymerization technology. We then cover other essential aspects of polymer technology including fabrication of rigid and flexible structures, polymer orientation, barrier technology, some competing barrier materials, food processing and packaging and additional new developments in barrier packaging. One of the most important more recent developments has been work on ways to increase the barrier properties of PET, primarily the attempt to develop a really good PET-based barrier plastic beer bottle.

Chapter 7 covers the barrier-packaging resin industry structure, with emphasis on major domestic producers and suppliers, horizontal and vertical integration, market and product entry and differentiation factors, and other topics. Compounders, converters, and molders are crucial links in the plastics production chain. We briefly discuss and analyze some international aspects of the barrier resin business including its global nature, major foreign-owned supplier companies which operate in the U.S., and imports and exports.

Next is Chapter 8, devoted to some environmental, regulatory, and public policy issues that affect barrier plastic packaging. These include waste disposal and recycling, federal laws and regulations, and the all-important public perceptions of plastics and plastic packaging.

Our last narrative chapter, Chapter 9, consists of profiles of many supplier companies that BCC Research considers to be among the most important or best representatives of this business.

We end with an appendix, a glossary of some relevant terms, abbreviations, and acronyms used in the chemical, polymer, and packaging industries.

We note again that some topics and materials covered in the text of this report are not included in our market estimate and forecast tables. We include these topics and materials for completeness. However, they either are really outside the market scope of this study (such as natural film, cellophane and some oxygen scavengers), too new to have yet developed a measurable commercial market, or whose markets are too large and diffuse to forecast the barrier segment with any certainty (such as the use of polyolefins in barrier packaging as structural and secondary barriers). We include these materials and concepts to give the reader as complete coverage as possible, not only of new developments in barrier packaging plastics, but also other materials that can extend shelf life or otherwise affect markets for barrier resins.

For consistency in style and format, registered trade names are usually indicated by capitalizing the initial letter of the name, and generic names are in lower case. Because many chemical names are long and complicated, we often use abbreviations, acronyms, or chemical formulae. Many of these, such as HDPE, PVC, PVdC, PCTFE, and etc. represent common polymers.

All chemical elements and compounds can be designated by chemical symbols and formulas. After introducing the element or compound, we often use symbols such as HCl for hydrochloric acid or hydrogen chloride. Our glossary in the Appendix at the end of this report contains definitions and explanations of many of the most important abbreviations and acronyms.

Chapter 1 Introduction
Study Goals and Objectives
Reasons for Doing This Study
Intended Audience
Scope and Format
Oxygen and Water Vapor Barrier Resins
Methodology and Information Sources
Analyst's Credentials
Related BCC Research Reports
Chapter 2 Summary and Highlights
Chapter 3 Market and Technology Background
U.S. Chemical and Petrochemical Industries
Crude Oil and Natural Gas
Some Industry History
Crude Oil and Natural Gas Prices
U.S. Chemical Industry Information
U.S. Plastic Resin Industry
U.S. Plastic Resin Industry Size and Production
Bulk Resin Manufacture
Plastic Resin Fabrication
Rigid Containers
Flexible Packaging
Resin Modification: Converting and Compounding
Barrier Coatings: Solution/Emulsion
End Users
Plastic Resin Prices
Barrier Packaging
History and Evolution of Barrier Packaging and Barrier Plastics
Food Spoilage
The Need for Barrier Packaging
Terms Used in Barrier Packaging
Gas Permeabilities and Transmission Rates
Materials and Structures
Plastics
Other Materials
Barrier Structures
Chapter 4 Packaging Markets by Barrier Resin Type
Overall Market Estimate and Forecast
Regenerated Cellulose (Cellophane)
Ethylene-Vinyl Alcohol (EVOH) Copolymers
EVOH Barrier Packaging Market Estimate and Forecast
EVOH Properties
EVOH Producers
EVOH Structures, Formats and Applications
Fluoropolymers-PCTFE
PCTFE Barrier Packaging Market Estimate
PCTFE Properties and Applications
Commercial Aclar Brand PCTFE Barrier Resins and Films
Nitrile Polymers (Polyacrylonitrile and Copolymers)
Nitrile Resin Properties
Nitrile Resin Applications
AN-MA Resin Structures and Formats
Barex Replacements
Polyamide (Nylon) Resins
Nylon Barrier Packaging Market Estimate
Properties of Crystalline Nylon Resins
Amorphous Nylons
Nylon Structures and Formats
Polyolefins
Polyolefin Properties
Thermoplastic Polyesters
Polyester Barrier Packaging Market Estimate
Polyethylene Terephthalate (PET)
Polyethylene Naphthalate (PEN)
Polytrimethylene Terephthalate (PTT)
Polyethylene Furanoate (PEF)
Polyvinylidene Chloride (PVdC) and Copolymers
PVdC Barrier Packaging Market Estimate
PVdC Properties
PVdC Packaging Formats and Applications
PVdC Coatings
Other Barrier Materials and Systems
Adhesive Tie Layer Resins
Nonpolymeric Barriers in Plastic Barrier Structures
Liquid Crystal Polymers
Cycloolefin Copolymer (COC)
Polyethylene Furanoate (PEF)
Oxygen and Ethylene Scavenging Systems
Structural Resins
Polyethylenes
Polypropylene
Thermoplastic Polyesters
Polystyrene
Polycarbonate
Other Structural Resins
Vapor Permeable Resins
Vapor Permeable Resin Packaging Market Estimate
Polyvinyl Chloride (PVC)
DuPont Tyvek
Controlled/Modified Atmosphere Packaging (CAP/MAP)
Chapter 5 Packaging Markets by Barrier Resin Applications
Overall Market Estimate and Forecast
Food Packaging
Food Barrier Packaging Market Estimate
Chemical/Industrial Product Packaging
Chemical/Industrial Barrier Packaging Market Estimate
Automotive Fuel Tanks
Healthcare Packaging
Healthcare Barrier Packaging Market Estimate
Chapter 6 Market Breakdown by Technology
Plastic Resin Chemistry, Manufacture and Properties
Commodity Resins
Regenerated Cellulose (Cellophane)
Ethylene-Vinyl Alcohol Copolymers (EVOH)
Fluoropolymers - Barrier PCTFE
Nitrile Polymers (Polyacrylonitrile and Copolymers)
Polyamide (Nylon) Resins
Polyolefins
Thermoplastic Polyesters
Vinyl Polymers
Other Barrier Materials
Other Structural Resins
Newer Polymerization Technologies
Polyolefin Processes
New and Improved Polyester Resin and Processes
Metallocene/Single-Site Catalyst Technology
Polymer Fabrication Technology
Rigid Structures-Plastics Molding
Flexible Structures
Thermoforming Technology
Polymer and Film Orientation
Biaxial Orientation: The Tenter Frame
Barrier Technology
Moisture (Water Vapor) and Oxygen
Other Gases
Light (Visible and Ultraviolet)
Odors, Aromas, Solvent Vapors and Others
Testing Gas Permeability
Nonpolymeric Barrier Surface Films and Coatings
Metallized Films
Silicon and Other Metal Oxide Coatings
Plasma Treatment
Multilayer Lamination and Coextrusion
Lamination
Coextrusion
Food Processing Methods
Thermal Processing
Nonthermal Processing
Food Packaging
Developments in Barrier Packaging
More and Thinner Layers in Multilayer Structures
New Barrier Polymers
Bioplastics
Oxygen Scavengers
Nanocomposite Barriers
New Closure Designs
PET Barrier Methods and Materials
Plastic Beer Bottles
Chapter 7 Industry Structure and Competitive Analysis
Trends in U.S. Barrier Plastic Resins Industry
Barrier Plastic Resin and Packaging Suppliers
Vertical Integration
Industry Concentration and Consolidation
Impact of Large Resin Producers and End Users
Case Study: PET Bottle Resin Producers
Product Differentiation and Substitution
Market Entry Factors
Compounders/Converters/Molders and Distributors
Marketing
Factors Affecting Market Size and Growth
End-User Resin Selection Criteria
International Aspects
Global Use of Barrier Packaging and Resins
Major Foreign Players
Imports and Exports
Chapter 8 Environmental Regulatory and Public Policy Issues
Environmental Considerations
Disposal of Waste Plastics
Materials Substitution
Recycling
Biodegradability and Other Factors
Environmental Laws and Regulations
Federal Laws and Regulatory Processes
Food Safety Modernization Act of 2011
Packaging Law
Code of Federal Regulations (CFR)
The U.S. Food and Drug Administration (FDA)
Department of Agriculture (USDA)
Environmental Protection Agency (EPA)
Other Federal Agencies
State and Local Agencies
Case Study: Polyacrylonitrile Resins
Public Perceptions
Greenwashing
Chapter 9 Company Profiles
Introduction
Supplier Companies
ADVANSIX INC.
AMCOR FLEXIBLES
AET FILMS
ARKEMA INC.
ASCEND PERFORMANCE MATERIALS LLC
BASF CORP.
BEMIS COMPANY INC.
BERRY GLOBAL GROUP INC.
BILCARE RESEARCH INC.
BYK ADDITIVES INC.
CELANESE CORP.
CHARTER NEX FILMS INC.
CHEVRON PHILLIPS CHEMICAL COMPANY
COLORMATRIX CORP.
CONSTAR INTERNATIONAL LLC
COVESTRO LLC
CRYOVAC
DAIKIN AMERICA INC.
DAK AMERICAS LLC
DOW CHEMICAL COMPANY
DSM ENGINEERING PLASTICS
E.I. DUPONT DE NEMOURS AND COMPANY
ELEMENTIS SPECIALTIES INC.
EMS-CHEMIE HOLDING AG
EVAL
EXXONMOBIL CORP.
GRAHAM PACKAGING COMPANY
GRAPHIC PACKAGING HOLDING COMPANY
HONEYWELL, INC.
INDORAMA VENTURES PUBLIC COMPANY LIMITED
INEOS USA
INERGY AUTOMOTIVE SYSTEMS (USA) LLC
JINDAL FILMS AMERICA LLC
KLCKNER-PENTAPLAST OF AMERICA INC.
KOCH INDUSTRIES INC.
KORTEC
KURARAY CO., LTD.
KUREHA CORP./KUREHA AMERICA LLC
LANDEC CORP.
LANXESS CORP.
LYONDELLBASELL INDUSTRIES
MILACRON CO-INJECTION/KORTEC
MITSUBISHI CHEMICAL CORP.
MITSUBISHI GAS CHEMICAL AMERICA INC.
MITSUI CHEMICALS AMERICA INC.
GRUPPO MOSSI & GHISOLFI
MSM POLY LLC
MULTISORB TECHNOLOGIES
NOLTEX LLC/SOARUS LLC/MSI TECHNOLOGY LLC
PERLEN CONVERTING LLC
PLASTIC OMNIUM GROUP/AUTO INERGY DIVISION
PLASTIPAK PACKAGING INC.
POLYONE CORP.
PPG INDUSTRIES INC.
PRETIUM PACKAGING LLC
PRINTPACK INC.
PROAMPAC
ROLLPRINT PACKAGING PRODUCTS INC.
SCHOLLE IPN PACKAGING INC.
SEALED AIR CORP.
SIDEL - see TETRA LAVAL
SKC GROUP LTD.
SOARUS LLC - see NOLTEX LLC
SOLVAY GROUP
SOUTHERN CLAY PRODUCTS INC. - see BYK Additives Inc.
SPARTECH CORP./SPARTECH PLASTICS - see Polyone Corp.
TAGHLEEF INDUSTRIES INC.
TEIJIN-DUPONT FILMS - see DuPont
TIEPET USA/STARPET INC. - See Indorama
TEKNI-FILMS, USA
TETRA LAVAL INTERNATIONAL S.A.
TOPAS ADVANCED POLYMERS INC.
TOPPAN USA INC.
TORAY INDUSTRIES (AMERICA) INC.
WINPAK LTD.
Chapter 10 Appendix: Glossary of Important Terms, Abbreviations, and Acronyms

List of Table

Summary Table : U.S. Packaging Barrier Resin Market Volume Estimate, by Type, Through 2022
Table 1 : U.S. Production of Major Thermoplastic Resins, by Type, Through 2016
Table 2 : Prices of Bulk Commodity Thermoplastic Resins, 1992-2016
Table 3 : Vapor Permeabilities of Packaging Resins
Table 4 : U.S. Packaging Barrier Resin Market Volume Estimate, by Type, Through 2022
Table 5 : Typical Properties of Regenerated Cellulose (Cellophane)
Table 6 : U.S. Packaging Volume Estimate for EVOH Barrier Resins, Through 2022
Table 7 : Typical EVOH Properties
Table 8 : Processes, Advantages, and Limitations of EVOH
Table 9 : U.S. Packaging Volume Estimate for PCTFE Barrier Resins, Through 2022
Table 10 : Typical PCTFE Properties
Table 11 : PCTFE Advantages
Table 12 : Typical Properties of Barex Brand Nitrile (AN-MA) Copolymers
Table 13 : U.S. Packaging Volume Estimate for Polyamide (Nylon) Barrier Resins, Through 2022
Table 14 : Typical Properties of Unoriented Nylons
Table 15 : Typical Properties of Oriented Nylon 6
Table 16 : Processing, Advantages, and Limitations of Amorphous Nylons
Table 17 : Typical Properties of Selar PA Amorphous Nylons
Table 18 : Typical Properties of Polyethylene Films
Table 19 : Typical Properties of Polypropylene Films
Table 20 : U.S. Packaging Volume Estimate for Thermoplastic Polyester Barrier Resins, Through 2022
Table 21 : Typical Properties of Polyester (PET) Resins
Table 22 : Some Advantages of PET Barrier Resins
Table 23 : U.S. Packaging Volume Estimate for PVDC Barrier Resins, Through 2022
Table 24 : Typical Properties of Polyvinylidene Chloride
Table 25 : PVdC Processes, Advantages and Limitations
Table 26 : Typical Properties of Ethylene-Vinyl Acetate Copolymer and Ionomer Film Resins
Table 27 : U.S. Packaging Volume Estimate for Barrier Tie Layer Resins, Through 2022
Table 28 : U.S. Packaging Volume Estimate for Vapor Permeable Resins, Through 2022
Table 29 : Typical Properties of Polyvinyl Chloride Films
Table 30 : Optimum Headspace Packaging Atmospheres for Produce
Table 31 : Overall U.S. Market Estimate for Packaging Barrier Resin Volumes, by Application, Through 2022
Table 32 : U.S. Barrier Plastic Food Packaging Market Volume Estimate, Through 2022
Table 33 : U.S. Barrier Plastic Chemical and Industrial Packaging Market Volume Estimate, Through 2022
Table 34 : U.S. Barrier Plastic Healthcare Packaging Market Volume Estimate, Through 2022
Table 35 : International Major Barrier Resin Markets, 2017

List of Chart

Summary Figure : U.S. Packaging Barrier Resin Market Volume Estimate, by Type, 2017 and 2022

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