Form-Fill-Seal (FFS) Packaging Machine Market

Market Overview

The global form-fill-seal (FFS) packaging machine market size was valued at USD 8.84 billion in 2022. It is estimated to reach USD 13.59 billion by 2031, growing at a CAGR of 4.90% during the forecast period (2023–2031). The global form-fill-seal (FFS) packaging is primarily driven by the growing demand for per-food packaging, driven by a growing number of pet adoptions. The growing aseptic packaging industry creates opportunities for the growth of the form-fill-seal (FFS) packaging market due to the potential of packaging to cater to the need for extended shelf life of products and higher nutrient retention.

Form Fill Seal Equipment is multi-purpose equipment that simultaneously forms, fills, and seals the packaging. Form-fill-seal (FFS) equipment relies on computer-automated technology to produce flexible to rigid packages and minimize contamination risks during production. Online film printing has low operational costs and provides readable bar codes and other product information. Therefore, it is widely used in the food and beverage (F&B) industry for packaging beverages, granulates, extruded snack foods, spices, and seasonings. It is also employed in producing ointments, syrup, tablets, sutures, lancets, syringes, bandages, gauze pads, test strips, and denture adhesive strips. Manufacturers are adopting advanced computer interfaces and control networks to increase the speed and versatility of FFS equipment.

Market Dynamics

Market Drivers

Rising Demand for Pet Food Packaging

The global pet food packaging market expansion is anticipated to be driven by packaging innovation. The market's development can be attributed to factors such as people's growing interest in adopting pets and their willingness to pay more for more convenient pets. The market is expected to grow over the forecast period due to an increase in adopting more sustainable packaging to comply with government regulations and consumer preferences.

For example, ProAmpac's PRO-EVP multiwall bags are constructed from fiber-based renewable resources and paper/poly hybrid materials and are utilized for sustainable pet food packaging. PRO-DURA is a woven polypropylene bag series from the company that offers flexibility and durability. In addition, the global pet food packaging market is being driven by rising income levels, simple and convenient food and packaging, and changing lifestyles. All these factors are increasing the demand for FFS packaging equipment, which will be the only packaging for this product.

Growing Demand for Customized Packaging

In recent years, there has been an increase in demand for customized and individualized packaging solutions that cater to the preferences of individual consumers and promote brand differentiation. FFS machines adapt to this trend by offering enhanced customization and personalization capabilities. Advanced FFS machines can accommodate a variety of packaging formats, sizes, and designs, enabling manufacturers to meet a wide range of product specifications.

In addition, digital printing and intelligent labeling are being incorporated into FFS machines to enable on-demand printing and variable data personalization. This trend enables companies to create targeted marketing campaigns, increase consumer engagement, and streamline packaging processes. All these factors boost the market growth.

Market Restraints

Uneconomical for Low-Density Products

Packing low-density items such as wheat flour, talcum powder, and whey powder at medium speeds is uneconomical and costs far too much. FFS packaging has a hurdle with this form of packaging. Several firms have introduced FFS packaging machines for low-density items. For example, J.M. Huber Corp., a worldwide engineered materials firm, was the first to package precipitated amorphous silica in polyethylene bags rather than paper bags using a sophisticated de-aeration procedure. The new compact box stacks better, resulting in more stable pallet loads. It also saves money on packaging and is recyclable.

Nevertheless, the exceptional characteristics of FFS (Form-Fill-Seal) packaging have generated a need for its utilization in low-density items. Consequently, an additional safeguarding measure is required to ensure the safety of the packaged product. On the other hand, low-density product makers find it difficult to embrace it early due to the high cost of packing. Thus, all these factors hamper market growth.

Market Opportunities

Growing Demand for the Aseptic Packaging Industry

Aseptic packing is often regarded as a viable alternative to canning and preservatives for extending shelf life. Consumer requirements for more hygienic and safe packaging of ready-to-eat food items drive the demand for aseptically packaged products. Rising milk production in Asia-Pacific, particularly in India, is expected to increase dairy product output and, as a result, lead to a surge in product demand in the region. These factors are anticipated to contribute to a surge in demand for form-fill-seal packaging equipment. Ready-to-eat meals have become a new trend that may drive machine sales in the future.

Aseptic packaging's increased use in the pharmaceutical business is expected to support industry growth. Glass is the most common medical packaging material, followed by plastic and metals. Filling pharmaceutical items using prefilled syringes, vials, and ampoules protects them from contamination until they are used. Aside from that, the rising demand for safe long-distance transportation of drugs, medical specimens, and reactive liquids, combined with the rising popularity of self-administered injectable medicines and biotechnology-based drugs, is creating opportunities for market expansion.

Regional Analysis

Based on region, the global form-fill-seal (FFS) packaging machine market is bifurcated into North America, Europe, Asia-Pacific, Latin America, and the Middle East and Africa. 

Asia-Pacific FFS Packaging machine industry size is projected to exhibit a CAGR of 5.69% during the forecast period. The form-fill-seal (FFS) packaging machine market is the most populated and expanding quickly in Asia-Pacific. The two biggest players are India and China. China's expanding population, rising disposable income, and expanding food and beverage industry contribute to market expansion. Changing lifestyles and emerging multinational food stores in the region also expand the bag market, resulting in a greater demand for form-fill-seal machines. The rising need for quality water and health-conscious drinking habits are also expected to increase the consumption of bottled water, which is likely to directly influence the packaging industry in the region.

India is one of the world's most populous nations, ranking second after China. According to the IMF, the country's population in 2021 was approximately 1391.99 million and is projected to increase to 1455.82 million by 2026. This country's large population makes it a significant consumer of all types of goods. Therefore, India offers a substantial market for FFS packaging machinery.

Europe is estimated to exhibit a CAGR of 4.83% over the forecast period. In Europe, the presence of key countries like Germany, the UK, France, Spain, and Italy, among others, is driving the global market. Germany is the leading revenue contributor in the region. Germany is an indispensable nation for adopting bio-based and environmentally friendly practices. The Bio-based Industries Consortium (BIC), Europe's leading industry association putting circularity, advancement, and sustainability at the center of the European economy, has partnered with the European Committee of Regions (CoR) to create a new partnering platform to connect bio-based industries and European region, especially Germany. In addition, the government of Germany introduced several stringent regulations for the plastics packaging industry in Germany. The German packaging law requires packaging design for recycling, recyclability, and recyclable and renewable materials. The government aims to recycle 63% of plastic packaging by 2022, up from 40% in 2018. Such measures are expected to impact the market in the forecasted period.

North American market is driven by the presence of developed nations like the U.S. and Canada. The rise in demand for FFS packaging in the country will be fueled by flexible packaging. In addition, several cosmetic businesses have been focusing on introducing their goods in the region using sustainable paper-based packaging, which is expected to enhance the demand for sustainable packaging. For instance, the EcoPak Push allows Chicago Paper Tube and Can company to boost its container capacity. Oil-based solids, such as shea butter, balms, gels, and perfume sticks, are directly housed in this all-paperboard, eco-friendly dispenser.

In addition, Canada is one of the significant markets for global flexible packaging vendors because of the high investments in advanced and innovative packaging across the various end-user industries and the company's growing focus on lightweight, portable, flexible, and environmentally friendly packaging. Similarly, the Canadian pet food market is booming, with more pet stores catering to more than 16 million pet cats and dogs. All these factors and increased packaging demand will increase demand for FFS machines in the North American region.

The Middle East and Africa Packaging sector is rapidly transforming with increasing demand in various end-user industries. Within the Middle East and Africa, a rapid expansion of the middle-class population is further expected to play a pivotal role in the growth of the packaging sector. The increased product demand motivates many businesses to pursue industrial efficiencies and technological advances. In addition, the need for FFS packaging machines is expected to increase over the forecast period. The soaring demand for packaged food and beverages provides a significant market share for regional producers. Most food companies are working to engage consumers with updated packaging. Manufacturers keep upgrading their products to the latest trends as packaging automation in this region is expected to grow tremendously. Such factors drive the regional market growth.

Segmental Analysis

The global form-fill-seal (FFS) packaging machine market is segmented by equipment type.

Based on equipment type, the global form-fill-seal (FFS) packaging machine market is bifurcated into vertical form-fill-seal (VFFS) and horizontal form-fill-seal (HFFS) machines. 

The horizontal form fill seal (HFFS) machines segment dominates the global market and is expected to exhibit a CAGR of 5.20% over the forecast period. A piece of machinery known as a horizontal form-fill-seal generates pouches from roll stock film, spout, and cap assemblies and fills them all at once. The machine is referred to as "horizontal" because the film or laminate passes through it in a horizontal direction. This process includes all steps in creating a complete pouch product, including unwinding the film, shaping the pouch, filling it, and sealing it. In addition, HFFS has the advantage of reducing the total cost of ownership and enhancing production flexibility for sizes and forms. It also gives the manufacturer complete control over the packaging procedure. The versatility of the HFFS machine makes it suitable for use in various end-use fields such as food and beverage, pharmaceutical, personal care, and industrial sectors.

Additionally, the machine can be operated in a confined space and used in a contamination-free environment. The flourishing demand for various consumer products due to the shift from cans and the fast-growing flexible packaging industry is also driving the growth of the HFFS machine market. Also, increasing demand for retort packaging with a longer shelf life favors market growth. In pharmaceutical packaging, this technology is useful for I.V. infusion bottles. Steps such as the container's formation, filling the container with content, and sealing the container are carried out consistently, consecutively, and automatically in a closed sterile chamber of the machine.

A vertical form-fill-seal machine is a type of automated assembly-line packaging system commonly used in the food packaging industry, as well as for various other products. In 1936, while working for the Henry Heide Candy Company, Walter Zwoyer, the inventor of the technology, patented his concept for the VFFS machine. The machine creates plastic bags and stand-up pouches from a flat roll of film while simultaneously filling and sealing the bags with the product. This packaging technology enables the containment of both solid and liquid substances within bags. Like HFFS machines, VFFS machines are also used in food and beverage, pharmaceutical industries, personal care and industrial sectors, and other end-users.

The VFFS machine can process various packaging materials. However, each product has its packaging requirements, such as salty foods and snacks, which should be left crispy for as long as possible, and the aroma of coffee should not be lost. Moreover, in single-layer used in packaging materials, it is necessary to use a laminate and each package layer with specific features tailored to the product. Another common factor that helps VFFS machines improve operations is low packaging costs. These machines increase packaging speed and increase throughput per hour of operation. If well-maintained and fine-tuned, they can last a lifetime. In addition, the labeler and the printer are attached to the VFFS machine (combined or individually). Printers often print the expiration date of important information about fresh foods and certain products. On the other hand, labelers are often used to label products, which are pre-printed by automated labelers within a vertical flow wrapper.

Recent Developments

• July 2023- Berry Global updated its patent-protected NorDiVent form-fill-seal (FFS) film for powdered products to incorporate up to 50 percent recycled plastic and satisfy consumer and customer demand for more recycled content.
• May 2023- TotalEnergies Corbion collaborated with COEXPAN to create a bio-based cup made from recycled PLA; the design has been fully validated for line rates and output using form-fill-seal technology.