Polypropylene is gaining traction, especially in boards and panels.
Packaging is a critical component of a product’s journey from production to utilization, ensuring safety and integrity throughout the process. Effective packaging materials must be lightweight, sturdy, and durable enough to withstand weight, weather conditions, and other environmental factors.
Various materials, including paper, paperboard, plastics, and metals, are used globally for packaging. While paper and paperboard hold a significant share of the global packaging materials market—valued at over US$1 trillion—plastics come in second. Among them, polypropylene (PP), a thermoplastic polymer known for its versatility, is gaining traction, particularly in boards and panels.
Polypropylene Boards and Their Types
Polypropylene (PP) boards are lightweight yet durable, offering the necessary strength for various applications. A key advantage of plastic over paper is its lightweight nature. Paper bags and boxes can be 6–10 times heavier than lightweight plastic carrier bags, leading to higher transportation costs and environmental impact.
In packaging, PP boards come in various forms, including corrugated sheets and PP panels (often available as honeycomb or bubble-wrap sheets). In 2023, the global PP board market for packaging was valued at USD 600 million, with corrugated PP sheets accounting for over 90% of the share, while PP panels made up the remainder.
The corrugated structure provides enhanced cushioning and strength, making these sheets suitable for packaging as well as signage, promotional displays, and other industrial applications. Available in various thicknesses—≤5 mm, 6–8 mm, and >8 mm—each type offers different strength characteristics. The 5 mm sheets are particularly popular due to their lightweight nature, making them the most widely used option.
Why Choose PP in Packaging?
Businesses consider several key factors when selecting packaging materials, including:
- The type of product being packaged
- The intended use of the packaging
- The cost of materials
- The environmental impact of materials
Regardless of the product type, PP materials provide support and protection while meeting all these criteria. The choice of PP sheets depends on the application. For fragile or perishable items, high-density PP sheets offer necessary protection, while flexible PP sheets are suitable for wrapping. For products like glass containers, chemicals, ceramics, and other fragile goods, rigid PP sheets provide enhanced safety. As a result, PP trays, containers, and boxes are widely used across industries.
Polypropylene Packaging Market Outlook
The rise of e-commerce has dramatically increased the demand for packaging, particularly for food and grocery items. The COVID-19 pandemic further accelerated this trend, driving the demand for contactless deliveries and protective packaging solutions.
At the same time, sustainability concerns are pushing the industry toward biodegradable packaging solutions. While traditional PP materials are recyclable, they have been criticized for their environmental impact due to their non-biodegradable nature, taking over 100 years to degrade. This has led companies to innovate biodegradable PP alternatives. For instance, Mitsui Chemicals, Inc., has developed bio-PP using non-edible biomass fermentation. Other companies, including LyondellBasell, Borealis, and SABIC, are also investing in sustainable PP production.
Europe currently leads the demand for packaging materials due to its developed market and growing preference for convenience-oriented products. The food packaging market in Europe is projected to reach approximately 41.7 million tonnes by 2031. Following Europe, North America and the Asia-Pacific region are experiencing rapid growth in packaging demand, with APAC emerging as the fastest-growing market due to its rising population and economic expansion. The global PP board market is expected to grow from USD 1.2 billion in 2023 to USD 1.5 billion by 2030, with packaging materials accounting for approximately 50% of this share.
Resources
- Environmental Impact of Plastic vs. Paper
- Mitsui Chemicals Bio-PP Development
- Ceresana Food Packaging Market Report – Europe
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Rick LeBlanc, EMBA, is the founder and editor of Reusable Packaging News (subscribe to the free newsletter) and editor of Western Pallet Magazine. A supply chain journalist with more than 30 years of experience, he specializes in pallets, reusable packaging, material handling and related operations. Rick is co-author of Pallets: A North American Perspective and Pallets & Progress: A Collected History of Pallets and Palletized Handling 1922–1945. He is also an advisory board member of the Virginia Tech Center for Packaging and Unit Load Design. Read Rick’s full bio.
