The versatility and flexibility of flexibles

One of the fastest-growing materials segments for packaging has been flexibles, as in films, papers and foils. It is flexible's versatility that has helped to make it such a popular choice for packaging. Indeed, the 28 winning packages in the Flexible Packaging Association (www.flexpack.org) awards exemplify the wonderful things that can be achieved with a flexible substrate (see our coverage of the top winners, starting on page 24.

Converted flexible packaging demand in the U.S. is forecast to grow at 2.4 percent per year, reaching a value of $14 billion by 2008, according to The Freedonia Group (www.freedoniagroup.com). The study attributes some of that growth to technological advances such as breathable films and resealable standup pouches, as well as manufacturers' needs for higher-performance packaging with enhanced graphics capabilities. Plastic films will continue to make inroads against paper and foil, with particularly good growth for polypropylene film. Further research and development for flexible films will focus on improving strength, sealing and barrier properties, as well as graphics capabilities.

Demand for flexible film, specifically, will increase 2.8 percent yearly through 2008. Polyethylene will keep its position as the film leader, but polypropylene continues to demonstrate its opportunities. Ethylene vinyl alcohol films will record the fastest advances because of their barrier capabilities, especially important for foods. According to Freedonia, paper packaging will exhibit only marginal growth but still remain an important player in the packaging market because of its low cost and environmental compatibility, and its use in laminations. Foils will find niche applications where light, moisture and other barrier properties are mandated, as well as where the aesthetics of high gloss and shine are desired.

A very fast-growing segment of flexible packaging is pouches, which are projected to grow 7 percent per year through 2008 to $5.2 billion. In fact, 16 of the FPA award winners this year are pouches. Standup pouches, in particular, continue to find new uses and new markets. Now, also, retort pouches have entered the scene. Says Freedonia, the incorporation of such value-added feaures as resealability, spouts, and retort and aseptic properties will stimulate advances for all pouch varieties. Faster line speeds have also led to increased interest in pouches as the package of choice.

Even though it seems as if all conceivable uses for standup pouches have already been introduced, the standup pouch category is growing at a robust, above-average rate of 15 percent. The fastest-growing markets for standups will be cheese, snack foods, processed foods and lawn and garden consumables. However, flat pouches remain dominant, projected to reach a value of $3.9 billion by 2008. Three- and four-side-seal pouches find new popularity with the addition of zippers. Flat pouches with retort properties are expected to rapidly replace cans in the mature petfood and processed food markets because of added consumer convenience and fresher taste. The best markets for flat pouches will be cheese, pudding and yogurt, and consumer products such as wipes.