Flow Wrap Packaging: A Cutting-Edge Technology for Food and Pharmaceutical Industries

Key takeaways:

• Introduction
• Rise in demand for flow wrap packaging in various sectors
• Product launches in the market

Flow wrap packaging is a flexible packaging method wherein the product is placed on a continuous polypropylene or polyethylene foil and then sealed on three sides, thus forming a protective and airtight barrier. Also called Horizontal Form-Fill-Seal (HFFS) packaging, this technique is widely used in various end-use industries such as food & beverages, pharmaceuticals, consumer goods, and confectionery items. It is a continuous process wherein products are moved horizontally by placing them on a conveyor belt and are then packaged automatically using a sealing film. In the next stage, the edges are sealed by applying heat or pressure, and the film is cut to complete the packaging process.

Rise in adoption of flow wrap packaging driving positive industry outlook

The growth of the flow wrap packaging industry is attributed to the increase in applicability of this packaging technique in various sectors. The market accounted for $26.9 billion in 2023 and is anticipated to gather a revenue share of $44.7 billion by 2033, rising at a CAGR of 5.3% during 2024-2033. Rise in use of this sealing methodology is attributed to the versatility and flexibility it offers to companies in packaging various products.

The ability of this technology to wrap items of different shapes and sizes makes it ideal for consumer goods companies. This packaging technique has played a huge role in expanding the food & beverage and healthcare industries by providing a viable solution for wrapping various products, ranging from medical devices to baked eatables. Moreover, compared to conventional methodologies, the speed offered by flow wrap technology is several times higher. This aids businesses in increasing their efficiency and productivity, thus boosting their profit share in the long run. Once the product to be packaged is placed on the conveyor belt, almost all the other tasks are automated, which reduces human intervention and brings down the chances of error. Moreover, since this process generates minimal raw material waste, the overall operational cost is much lower compared to other techniques.

Innovations by private players opening new avenues for growth in the sector

Over the years, several private companies have invested heavily in flow wrap packaging technologies, thus expanding the scope of the industry. For instance, in July 2024, Innovia Films, a packaging and labeling company, announced the launch of a new white ‘ultra-low density’ film. Designed specifically for flow wrap packaging of ice creams, this new product remains unaffected even at high temperatures, helping store ice creams more efficiently. As per the press release issued by the company, the film can be stored for about six months without any risk of deterioration, thereby making it one of the most durable solutions in the industry. The product launch is anticipated to boost the revenue share of Innovia Films substantially in the coming years.

In April 2025, Syntegon, a packaging firm, released a press statement reporting the launch of Pack 103, a state-of-the-art flow wrapping machine. The company stated that the new equipment has been developed to cater to the needs of small and medium-scale enterprises. Furthermore, the machine, with an output of up to 175 packs per minute, is used to package food, non-food, and medical products.

In conclusion, the growth of the flow wrap packaging industry is attributed to the rise in demand for innovative solutions from various sectors such as food & beverages, pharmaceuticals, and consumer goods. Moreover, huge investments by major multinational corporations in the sector are expected to create numerous growth opportunities for the industry in the coming years.

For more information on the leading growth drivers and investment opportunities in the landscape, contact our experts here!

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