The world of flexible packaging
An analysis of the production, economic and application landscape of a strategic segment for the packaging industry, based on 2024 data processed in July 2025
Barbara Iascone
Flexible packaging is divided into two main categories: on one side, flexible converter packaging and, on the other, plastic flexible packaging.
The former includes thin, formable containers produced through lamination, co-extrusion or coupling of films (plastic, paper, aluminium). These are designed to contain both food and non-food products, providing protection, design versatility and sustainability through the use of specific materials and multilayer structures.
The latter refers to flexible plastic packaging that is also thin and formable, but made from a single material, without lamination with others.
This analysis examines the market performance of both types of packaging separately, following the classification used by the Italian Institute of Packaging in its “Packaging in Figures” report.
Converter flexible packaging
Converter flexible packaging represents one of the newest and most innovative packaging solutions currently on the market.
These packages can be produced using a wide range of materials – such as plastic films, paper, or aluminium – and are particularly valued for their ability to reduce the overall packaging weight while offering a high degree of customisation to meet diverse application requirements.
Within this category is multilayer converter laminated packaging, obtained through coupling, extrusion or lamination processes. Depending on the number and type of materials used, they are classified as monomaterial or multi-material laminates. Each layer performs a specific function: some help preserve the product's aroma, others extend shelf life, while others enhance print colour quality or ensure an effective protective barrier. Due to these characteristics, laminated flexible packaging is regarded as a complex structure.
As for plastic films, the most commonly used materials are polyethylene (PE) and polypropylene (PP). In recent years, there has been a growing adoption of recycled and biodegradable polymers, in line with the industry’s environmental sustainability requirements. Paper and aluminium are also widely employed: notably, the lamination between paper and biodegradable plastic is enabling the introduction of paper into sectors where its direct contact with food was once unthinkable – dairy products, frozen foods and ice cream.
Thanks to their innovative and functional properties, flexible packaging is a constantly growing segment today. In Italy, over the past 17 years, production has recorded an average annual growth rate of 2%, confirming the strategic role of flexible packaging in the ongoing evolution of the packaging industry.
A mixed economic picture. Following a slowdown in 2023, the converter flexible packaging sector returned to growth. In 2024, production reached around 422,000 tonnes, marking a 4% increase compared over the previous year – a positive signal that restores confidence in a strategic segment of the Italian packaging industry.
Out of total national packaging production, flexible packaging accounts for 2.4% by volume and 7.2% of turnover, figures that remain substantially stable compared to 2023.
Despite this recovery in production, the economic picture shows both strengths and weaknesses. Exports, which cover 51% of production, recorded a 1.8% decline, while imports – traditionally marginal, at around 3,000 tonnes – remained stable. The domestic market, on the other hand, showed a 10% increase in apparent consumption, driven by the drop in exports and by more dynamic internal demand.
The main concern, however, remains turnover, which continues to suffer from price pressure: following a -1.5% decrease in 2023, 2024 also closed with a further 1.5% drop in turnover. This misalignment between production volume and economic value reflects a broader trend across the entire packaging sector, where margin compression continues to pose a structural challenge.
From a materials perspective, production confirms the predominance of plastic-based flexible packaging, which accounts for 73% of total output, followed by paper-based packaging (25%), and aluminium-based packaging (2%).
In summary, 2024 closes as a year of renewed production momentum but cautious economic outlook, as the industry awaits to see whether 2025 will mark a return to growth in value as well as in volume.
Application sectors. The converter flexible packaging segment continues to find its primary field of application in the food industry, which in 2024 accounted for as much as 94.2% of total production. However, the non-food segment has begun to gain ground, driven mainly by the cosmetics sector, where flexible packaging is finding new areas of application, particularly as refill pouches for soaps, shower gels and shampoos – a trend reflecting the growing focus on sustainability and the reduction of single-use plastics.
Looking more closely, demand from the food sector shows a structure that is well established yet still evolving. Fruit and vegetable products, especially fourth, fifth and sixth range, remain in first place, accounting for 28.4% of total demand in 2024. They are followed by cheese products (21.9%), and by bakery and pasta products, which together account for an further 21.5% of the market.
Smaller, but still significant, are the of sweets, confectionery and chocolate (5%), cured meats (4.7%), coffee (3.9%) and pet food, which stood at 0.8% in 2024. The category of “other food categories” – encompassing sauces, yogurt, vegetables in oil or vinegar, olives, baby food and beverages – represents the remaining 5.6%.
The non-food segment accounts overall for 5.8% of the market overall, with an almost exclusive presence in the cosmetics/pharmaceutical and household cleaning sectors. In both cases, laminated flexible packaging with resealable closures has established itself as the ideal solution for refillable products: lightweight, practical and self-standing thanks to their distinctive structure, they are also perfectly suited to storage and logistics requirements.
Key strengths. Among the main strengths of this type of packaging are its lightness and ease of handling, which help reduce bulk and optimise transport efficiency. This is complemented by an increasing focus on sustainability: many converters are investing in recycled or biodegradable materials, in line with new European directives and the environmental awareness of consumers.
As environmental consciousness continues to rise, the flexible packaging industry is accelerating its transition towards a more circular and innovative future, with ongoing investment in recyclable solutions, waste reduction, and material optimisation.
Flexible plastic packaging
The flexible plastic packaging sector remained a stable and strategic segment within the packaging industry in 2024. This category encompasses a wide range of products, including sacks and bags (such as those for waste collection), industrial sacks, stretch films for wrapping and packaging, shrink and stretch films for transport, and protective materials such as bubble wrap.
The latest data indicate largely stable production, with a slight increase of 0.3%, reaching approximately 1,120,000 tonnes. This reflects a steady demand from sectors such as logistics, transport, and storage, where flexible plastic finds broader applications compared with primary packaging.
On the international front, the sector shows encouraging signs: imports increased by 19% and exports by 13%, highlighting the growing interest of foreign markets in Italian solutions, often valued for their strength, versatility, and reliability.
Flexible plastic packaging accounts for approximately 45% of the total flexible packaging sector, making it more widespread in terms of volume than converter packaging. This predominance is mainly linked to its extensive use in logistics and transport, rather than in primary packaging, where other flexible materials have a stronger presence.
Market considerations. Although the sector remains stable, there are several dynamics to monitor closely. The growth in exports signals an increased competitiveness of Italian products internationally, while the slight expansion of domestic production also points to a balanced national demand. At the same time, evolving regulations on sustainability and plastic recycling could stimulate innovation, encouraging companies to adopt more environmentally friendly materials without compromising product durability or functionality.
Looking ahead, the sector appears poised to maintain a central role in logistics and transport, while the adoption of more sustainable solutions and expansion into foreign markets represent strategic levers to support future growth.
