US Moulded Fibre Packaging Market Size, Share, Trends and Forecasts 2031

Key Findings

• The US Moulded Fibre Packaging Market is growing as sustainability, biodegradability, and recyclability drive packaging choices across industries.

• Egg cartons, food trays, protective packaging, and cup carriers dominate applications in US, supported by rising consumption of packaged food and beverages.

• Consumer and regulatory pressure to eliminate single-use plastics is accelerating the adoption of moulded fibre alternatives.

• Advanced moulding technologies are improving strength, precision, and aesthetics, enabling broader use beyond traditional categories.

• E-commerce and electronics sectors in US are increasingly adopting moulded fibre for protective packaging solutions.

• Investment in water-resistant coatings and hybrid fibre–plastic designs is enhancing product durability and barrier performance.

• Regional manufacturers in US are scaling up automated production lines to meet growing demand.

• Branding potential through printing and embossing is making moulded fibre attractive for premium sustainable packaging.

US Moulded Fibre Packaging Market Size and Forecast

The US Moulded Fibre Packaging Market is projected to grow from USD 9.8 billion in 2025 to USD 16.5 billion by 2031, at a CAGR of 9.1%. Growth is primarily driven by sustainability mandates, expansion of quick-service restaurants, and increased reliance on e-commerce. Egg packaging remains the largest segment, but foodservice, electronics, and healthcare packaging are gaining strong traction. With regulatory pressure on plastic waste and technological innovation improving moulded fibre quality, the market in US is expected to see widespread adoption across multiple industries.

Introduction

Moulded fibre packaging is manufactured from recycled paper, cardboard, and natural fibres, offering an eco-friendly alternative to plastics. It is widely used for food trays, egg cartons, cup carriers, and protective packaging for electronics and industrial goods. In US, rising demand for sustainable, biodegradable, and compostable solutions has positioned moulded fibre as a key player in the circular economy. Modern production technologies such as thermoformed fibre allow for higher precision and smoother finishes, expanding applications in premium packaging. As consumer and regulatory focus intensifies on plastic waste, moulded fibre is evolving into a mainstream packaging solution.

Future Outlook

By 2031, moulded fibre packaging in US will be widely adopted across retail, foodservice, electronics, and healthcare industries. Advances in moulding technologies will enable high-quality designs suitable for premium products, while water- and grease-resistant coatings will open applications in ready-to-eat meals and frozen foods. As governments implement stricter bans on single-use plastics, moulded fibre will become the default replacement. Branding and design innovations will position it as not only sustainable but also visually appealing packaging. Integration with automated production lines will lower costs, driving competitiveness against plastic and foam alternatives.

US Moulded Fibre Packaging Market Trends

• Transition Away from Single-Use Plastics
  In US, bans and restrictions on single-use plastics are accelerating the shift to fibre-based packaging. Retailers and foodservice operators are phasing out plastic trays, clamshells, and cutlery, replacing them with moulded fibre alternatives. Consumer acceptance of fibre packaging has grown significantly due to increased awareness of its biodegradability and compostability. Manufacturers are responding with expanded product lines tailored to foodservice, takeaway, and retail. This trend is reinforced by corporate sustainability commitments, with global brands pledging to eliminate plastics in their packaging portfolios. As regulations tighten further, moulded fibre will become a default packaging solution across multiple categories.

• Technological Advances in Thermoformed Fibre
  Thermoformed fibre technology is transforming moulded fibre packaging in US by delivering smooth surfaces, thinner walls, and precision shaping. These innovations make fibre packaging suitable for premium applications such as cosmetics, electronics, and healthcare. High-definition embossing and printing capabilities allow for enhanced branding opportunities, improving shelf appeal. Automation in forming and drying processes is increasing production efficiency, reducing costs, and supporting scalability. This technology is bridging the gap between functionality and aesthetics, enabling fibre to compete with plastics even in high-visibility retail environments. Over the next decade, thermoformed fibre is expected to dominate product innovation in US.

• Growth in Foodservice and Quick-Service Restaurants (QSRs)
  The expansion of QSRs, cafes, and delivery platforms in US is driving strong demand for moulded fibre trays, containers, and cup carriers. Consumers are increasingly demanding sustainable packaging for takeaway and home-delivered food. Fibre-based clamshells, trays, and drink carriers are replacing Styrofoam and plastics in many regions. Water- and grease-resistant coatings are expanding fibre’s suitability for hot, greasy, and frozen foods. Partnerships between fibre packaging producers and foodservice giants are scaling adoption quickly. As consumer behavior shifts toward convenience dining, QSRs are expected to be the largest growth sector for moulded fibre packaging in US.

• Adoption in Electronics and E-Commerce Protective Packaging
  E-commerce and electronics industries in US are adopting moulded fibre for protective packaging due to its cushioning, shock absorption, and recyclability. Fibre-based inserts and trays are being used to replace plastic foams like EPS. Rising environmental concerns and regulations on hazardous plastics are accelerating this transition. Moulded fibre packaging provides excellent protection while reducing environmental impact, making it attractive to brands that emphasize sustainability. The growing electronics and e-commerce sectors are fueling demand for customized moulded fibre packaging designed to fit specific products. This trend underscores the expansion of fibre beyond food-related uses.

• Integration of Branding and Design Innovation
  In US, moulded fibre packaging is evolving from plain, utilitarian designs to branded, visually appealing formats. Advanced embossing, custom coloring, and high-resolution printing technologies are enhancing consumer-facing applications. Brands in cosmetics, premium food, and beverages are adopting fibre packaging for its eco-friendly image and unique aesthetic appeal. The ability to combine sustainability with strong branding is turning moulded fibre into a marketing asset. Consumers are associating fibre packaging with authenticity and environmental responsibility, boosting brand loyalty. As this trend grows, moulded fibre will be positioned as a premium as well as sustainable choice.

Market Growth Drivers

• Government Bans on Plastics
  Regulatory bans on single-use plastics in US are a major driver of moulded fibre adoption. Governments are mandating biodegradable and recyclable alternatives, creating strong demand. Compliance is accelerating investment in fibre packaging infrastructure. This driver ensures long-term market momentum.

• Rising Consumer Preference for Sustainable Packaging
  In US, consumers are actively choosing eco-friendly packaging, driving demand for compostable and recyclable solutions. Fibre packaging aligns with this preference, supporting brand loyalty and market differentiation. Growing eco-consciousness is ensuring steady growth for moulded fibre products.

• Expansion of Foodservice and Takeaway Culture
  The booming QSR and food delivery ecosystem in US is fueling demand for trays, containers, and cup carriers. Fibre packaging offers the right mix of functionality and sustainability for this sector. This trend is expected to be a consistent demand driver.

• Growth of E-Commerce and Protective Packaging Needs
  E-commerce growth in US is creating strong demand for fibre-based protective packaging. Fibre inserts and trays are replacing plastics in electronics, cosmetics, and fragile product categories. This driver ensures expansion beyond traditional food-related uses.

• Technological Innovation in Fibre Moulding
  Advances in thermoformed fibre technology are making packaging more precise, lightweight, and appealing. This innovation is opening new premium applications, ensuring broader adoption across industries. Technology is directly fueling growth opportunities in US.

Challenges in the Market

• Moisture and Grease Resistance Limitations
  Fibre packaging struggles in high-moisture and oily food applications without special coatings. In US, this limits its use in hot meals and liquid packaging. Developing water-resistant yet compostable coatings remains a technical challenge. Until solved at scale, fibre adoption will be limited in certain categories.

• High Production and Setup Costs
  Fibre moulding requires specialized equipment and drying processes, making initial investment high. In US, smaller producers face financial barriers to entering the market. Scaling production is necessary to achieve cost competitiveness with plastics. This remains a barrier to broader adoption.

• Competition from Alternative Sustainable Materials
  Bioplastics, compostable films, and paperboard are strong competitors to fibre in US. Each offers sustainability benefits while addressing performance gaps. This competition makes it difficult for fibre to dominate certain applications. Brands often choose based on cost, performance, and availability.

• Supply Chain and Raw Material Dependence
  Fibre packaging relies heavily on recycled paper and natural fibres, which are subject to price fluctuations and availability issues. In US, supply chain disruptions can affect production costs and timelines. Securing consistent raw material supply is a persistent challenge.

• Limited Consumer Awareness and Disposal Confusion
  While eco-friendly, consumers in US may not always understand the compostability and recycling requirements of fibre packaging. Confusion over disposal can lead to contamination in recycling streams. Without proper education, environmental benefits may not be fully realized. This presents a challenge for credibility and adoption.

US Moulded Fibre Packaging Market Segmentation

By Type

• Thick-Wall

• Transfer Moulded

• Thermoformed Fibre

• Processed Fibre

By Application

• Foodservice Packaging

• Egg Cartons & Trays

• Cup Carriers

• Electronics Packaging

• Healthcare Packaging

• Others

By End-User Industry

• Food & Beverage

• Consumer Goods

• Electronics & Appliances

• Healthcare

• E-Commerce & Retail

Leading Key Players

• Huhtamaki Oyj

• UFP Technologies, Inc.

• EnviroPAK Corporation

• Pactiv Evergreen Inc.

• Hartmann

• Stora Enso Oyj

• Celluloses de la Loire

• Keiding, Inc.

• FibreCel Packaging

• Henry Molded Products, Inc.

Recent Developments

• Huhtamaki Oyj expanded moulded fibre production facilities in US with focus on foodservice packaging.

• UFP Technologies, Inc. launched advanced thermoformed fibre packaging for electronics in US.

• Stora Enso Oyj introduced water-resistant fibre packaging solutions for QSRs in US.

• Hartmann partnered with local producers in US to strengthen supply of egg cartons and trays.

• Pactiv Evergreen Inc. invested in automated fibre moulding lines in US to boost output efficiency.

This Market Report Will Answer the Following Questions

1. What is the projected size and CAGR of the US Moulded Fibre Packaging Market by 2031?

2. Which sectors in US are driving the strongest adoption of moulded fibre packaging?

3. How is thermoformed fibre expanding applications into premium and branded packaging?

4. What challenges are limiting moulded fibre adoption in moisture- and grease-heavy applications?

5. Who are the leading companies shaping innovation and scale in moulded fibre packaging in US?