United States Extrusion Coatings Market Size
Extrusion coating manufacturers are increasingly offering customized products in terms of thickness, color, and texture for niche applications across different substrate materials including plastics, paper, cartons, aluminum foils, and others. Potential advantages of high-speed application and reduced material waste., ability to create a variety of finishes and colors, improved durability, UV resistance, and barrier properties, and others drive the market outlook. Amidst growing demand in end-user industries including liquid and flexible packaging, medical packaging, Photographic paper, industrial packaging, and others, is encouraging new product launches in extrusion coatings. The development of new polymer materials and additives allows for enhanced performance characteristics in extrusion coatings. The process is used to produce a large range of thin multilayer structures, in particular, Low density polyethylene (LDPE) is widely used for use in the extrusion coating process. On the other hand, the polyethylene coating provides increased tear resistance, and acts as barrier against water and various gases.
United States Extrusion Coatings Market Analysis
The use of advanced materials for the extrusion coating process as protective or decorative layer onto the substrate is extending the applications of extrusion coatings across taurpalins, paper coatings, cable wraps, pharmaceutical packaging, fertilizer packaging, and others. Leading companies are focusing diversification of applications to boost market shares. LyondellBasell offers a wide range of PU resins including Petrothene and Lupolen low-density polyethylene (LDPE), Linear Low-Density Polyethylene (LLDPE), and Alathon high density polyethylene (HDPE), PPG markets coatings with both liquid and power technologies, SABIC offers extrusion coatings for battery components, Kraton specializes in advanced polymers and elastomers, which are used in extrusion coatings for batteries. Strong demand prospects are encouraging smaller firms and startups to develop new technologies and sustainable materials for addition of a thin polymer layer to create versatile, multilayer packaging across industries.
Advancements in extrusion coating technologies including co-extrusion, multi-layer coatings, and others coupled with robust demand for bio-based and eco-friendly coatings set to shape the market outlook. Ability to customize coatings to specific applications, such as varying thicknesses, textures, and colors fuel the market outlook. Co-extrusion involves simultaneously extruding multiple layers of different materials to create a multi-layered coating. In particular, Co-extrusion is used to create multi-layer films with different layers serving specific functions, such as oxygen and moisture barriers, which are crucial for food packaging, Multi-layer coatings are used in automotive parts to provide both aesthetic appeal and functional properties like scratch resistance and UV protection. Borealis AG and Kraton Polymers are focusing developing coatings with tailored properties. In addition, companies such as DuPont Kapton and Nomex, Solvay high-performance polymers are launching advances in polymer chemistry including PET-based extrusion coatings, Polyamide (Nylon) for use in automotive and industrial applications. Self-Cleaning Coatings, Anti-Microbial Coatings, and others drive the market outlook. Development of coatings with enhanced barrier properties such as High-Barrier Films in electronic packaging, Medical Device Coatings with biocompatibility and sterilization resistance are focused by Mitsui Chemicals, Medicoat AG, and other players.
The extrusion coatings market is experiencing significant growth in the packaging industry, driven by the demand for lightweight, durable, and eco-friendly packaging solutions. The shift toward sustainable packaging materials, such as bio-based polymers, is also gaining traction, encouraging innovation in extrusion coatings. In particular, the food and beverage packaging applications with enhanced protection against moisture, oxygen, and other contaminants are gaining strong demand, owing to excellent barrier properties, making them ideal for applications in flexible packaging, cartons, and aseptic packaging. Extruded Aluminum Foil with Polyethylene Coating is used in aseptic packaging for dairy and non-refrigerated beverages. Amcor utilizes extrusion coatings in its AmLite product line, which includes aseptic packaging materials that offer high barrier protection.
Extrusion coatings enhance the protective properties of materials like paper, paperboard, and aluminum, making them suitable for a wide range of packaging applications. Flexible packaging, which includes bags, pouches, and wraps, is a major consumer of extrusion coatings to barrier properties against moisture, oxygen, and light, extending the shelf life of perishable products. Dow Chemical offers a variety of polyethylene resins under its ELITE™ and DOWLEX™ brands. Cartons for beverages like milk, juice, and soups rely heavily on extrusion coatings for protection against leaks and contamination. Extruded Polyolefin Coatings on paperboard are extensively used for liquid packaging. Tetra Pak, a global leader in liquid food packaging, uses high-performance extrusion coatings to create its multi-layered, protective cartons.
Extruded LDPE (Low-Density Polyethylene) Coatings are commonly used in frozen food bags and trays. For instance, Mondi Group offers coated materials for frozen food applications. Extrusion-Coated Metalized Films for snack packaging provide a combination of barrier properties and heat-sealing capabilities- Berry Global provides a wide range of extrusion-coated films for snack packaging.
Raw Material Suppliers- Leading companies including Dow Chemical Company, ExxonMobil Chemical, SABIC, LyondellBasell, BASF, and others continue to supply Polyethylene (PE), Polypropylene (PP), Ethylene Vinyl Acetate (EVA), Acrylics, Bio-based Polymers, and other materials.
Extrusion Coating Formulators- AkzoNobel develops high-performance coatings, PPG Industries formulates for multiple end-use sectors, Axalta Coating Systems Specializes in formulating industrial applications, Kansai Paint Co Focuses on coatings for packaging and automotive sectors, Sherwin-Williams offers formulations tailored for different materials. Water-based, solvent-based, and bio-based extrusion coatings for different substrates (paper, plastic, aluminum), and others are gaining demand growth.
Extrusion Coating Equipment Manufacturers- Companies are marketing advanced machinery and technologies including Extruders, lamination machines, and coating lines for high-speed, multi-layer coating applications. Davis-Standard (flexible packaging and industrial), Windmoeller & Hoelscher (flexible packaging and technical laminates), Nordmeccanica (extrusion and lamination machines), Jinming Machinery (high-speed production in packaging applications), BMB (designing extrusion machinery for multi-layer coating applications), and others are leading players.
End-Product Manufacturers- Packaging, Automotive, Construction, Electrical, and Electronics Companies involved in the production of various finished goods, from food packaging and liquid cartons to automotive and construction materials are included in the industry.
Distributors and Retailers- Univar Solutions distributes raw materials, including polymers and additives used in extrusion coatings, Brenntag supplies chemicals and additives for the coatings industry, facilitating the supply chain between raw material manufacturers and formulators, IMCD Group provides technical distribution services for specialty coatings and raw materials, including polyolefins and acrylic resins.
Packaging industry is the dominant user of extrusion coatings, accounting for 72.6% market share. In particular, liquid packaging is the main sub-user with 21.8% market share, followed by flexible packaging with 17.1%, medical packaging (13.2% revenue share), personal care and cosmetics packaging (10.3%), and others. Extrusion coatings provide essential barrier properties, enhance durability, and improve the visual appeal of packaging, making them indispensable across various packaging sectors.
Liquid packaging, which includes packaging for beverages like milk, juices, soups, and liquid pharmaceuticals, is the largest sub-segment within the packaging industry using extrusion coatings. The coatings provide a barrier against moisture, oxygen, and light, ensuring product safety and extending shelf life. For instance, Tetra Pak has developed Tetra Recart, Amcor introduced AmLite Ultra Recyclable. Flexible packaging is another significant sub-segment used for products such as snack foods, frozen foods, and consumer goods driven by flexibility, strength, and resistance to punctures, enabling manufacturers to deliver lightweight, cost-effective packaging. Berry Global introduced new recyclable Flexibles Film Solutions while Mondi Group launched NextLoom, a flexible film for the frozen food sector.
Extruded Polyethylene Coated Sterile Barrier Systems for medical instruments, High-Barrier Laminate Films for pharmaceuticals owing to enhanced barrier properties required for protecting sensitive medical products from contamination. Amcor launched its AmSky™ blister packaging solution while DuPont introduced Tyvek® 40L, an extrusion-coated material used in medical device packaging. Personal care and cosmetics packaging is an emerging sector within the extrusion coatings market. Extrusion-Coated Tubes and Pouches, Polyethylene-Coated Laminates, and others drive the industry. AptarGroup unveiled a new range of sustainable cosmetic packaging, including extrusion-coated airless pumps, L’Oréal partnered with Albéa to develop PE-based cosmetic tubes that use extrusion coatings for improved recyclability.
Paperboards and cardboards dominate the extrusion coatings substrate market with a 44.1% share, driven by widespread use in packaging applications due to their strength, rigidity, and ease of handling. In addition to sustainability of the materials, Paper-based substrates are generally more cost-effective, making them a preferred choice for many applications. Further, Coated paperboards are used to enhance moisture and grease resistance, extending shelf life and maintaining product integrity of food and beverages, durability and aesthetic appeal features drive sales in consumer goods industry. Similarly, in the shipping and logistics industries, cardboards are coated to improve their resistance to environmental factors during transportation.
Polymer films, on the other hand, are estimated to be the fastest growing substrates with 5.8% CAGR forecast driven by their versatile properties such as flexibility, transparency, and excellent barrier characteristics and expanding applications including electronics, medical devices, and industrial applications. Further, innovations in polymer chemistry and extrusion technology have led to the development of high-performance films with enhanced properties such as better barrier resistance, increased durability, and specialized functionalities. The shift towards flexible and lightweight packaging solutions encourages Polymer film applications requiring high-performance barriers and customization. Toray Industries and Jindal Films are focusing new product launches in the segment.
Polyethylene (PE) stands as the most widely used material in the extrusion coatings market, generating an impressive $2.4 billion in sales for 2024. Polyethylene’s ability to provide a robust barrier against moisture, gases, and contaminants makes it a preferred choice for liquid packaging, flexible packaging, and medical applications. Low-density polyethylene (LDPE) and high-density polyethylene (HDPE) are commonly used due to low production costs and high availability compared to other polymers like polypropylene (PP) and ethylene-vinyl acetate (EVA). Tetra Pak uses polyethylene in its carton packaging for beverages, Berry Global introduced its Sustainable Flexibles line in 2023, Amcor’s AmSky™ packaging replaces traditional materials like PVC, L’Oréal and Albéa partnered to develop fully recyclable polyethylene-based cosmetic tubes, Dow offers products like Dowlex, ExxonMobil’ Exceed™ XP line, LyondellBasell’s innovations in PE production, including its Hyperzone PE technology, and others continue to generate significant business revenue.
The Extrusion coatings market is characterized by a competitive landscape with companies focusing technological advancements, strategic expansions, and localized product offerings to boost market shares. Key companies included in the report are- Akzo Nobel NV, Borealis AG, Celanese Corp, Chevron Phillips Chemical Company, Davis Standard, DuPont de Nemours Inc, Dura Coat Products Inc, LyondellBasell Industries Holdings BV, Optimum Plastics, PPG Industries, Qenos Pty Ltd, SABIC, The Lubrizol Corp, The Sherwin-Williams Company, Transcendia, Westlake Chemical Corp, and others.
|
Parameter |
Details |
|
Market Size (2024) |
$2.0 Billion |
|
Market Size (2032) |
$3.1 Billion |
|
Market Growth Rate |
5.8% |
|
Largest Segment- Product |
Packaging (72.6% Market Share) |
|
Largest End-User Industry |
Polyethylene (PE) ($2.4 Billion Sales) |
|
Largest Coating Material |
Paperboards & Cardboards (44.1% Sales Revenue) |
|
Segments |
Types, Substrates, Coating Materials, Applications |
|
Study Period |
2018- 2023 and 2024-2032 |
|
Units |
Revenue (USD) |
|
Qualitative Analysis |
Porter’s Five Forces, SWOT Profile, Market Share, Scenario Forecasts, Market Ecosystem, Company Ranking, Market Dynamics, Industry Benchmarking |
|
Companies |
Akzo Nobel NV, Borealis AG, Celanese Corp, Chevron Phillips Chemical Company, Davis Standard, DuPont de Nemours Inc, Dura Coat Products Inc, LyondellBasell Industries Holdings BV, Optimum Plastics, PPG Industries, Qenos Pty Ltd, SABIC, The Lubrizol Corp, The Sherwin-Williams Company, Transcendia, Westlake Chemical Corp |
|
States |
California, Texas, New York, Florida, Illinois, Pennsylvania, Ohio, Georgia, New Jersey, North Carolina, Others |
Table of Contents
1. Executive Summary
US Extrusion Coatings Market Introduction- 2024
Report Scope
Methodology
Market Size Outlook, USD Million, 2021- 2032
2. US Extrusion Coatings Market Entropy
Competitive Landscape
US Market Share by Company, 2023
Recent Market Developments
Regulatory Scenario
3. US Extrusion Coatings Market Dynamics
Market Ecosystem- Industry Stakeholders
Porter’s Five Forces Analysis
SWOT Profile
US Industry Trends and Drivers
US Industry Challenges
Inflation, Macroeconomics and Demographics Forecast
4. US Extrusion Coatings Scenario Analysis
Low Growth
Reference Case
High Growth
5. US Extrusion Coatings Market Outlook by Type
Polyethylene
-Low Density Polyethylene (LDPE)
-High Density Polyethylene (HDPE)
-Others
Ethylene Vinyl Acetate (EVA)
Ethylene Butyl Acrylate (EBA)
Polypropylene
Polyethylene Terephthalate
Others
6. US Extrusion Coatings Market Outlook by Substrate
Paperboard and Cardboard
Polymer Films
Metal Foils
Others
7. US Extrusion Coatings Market Outlook by Application
Liquid Packaging
Flexible Packaging
Medical Packaging
Personal and Cosmetic Packaging
Photographic Film
Industrial Packaging
Others
8. US Extrusion Coatings Market by State
California
Texas
New York
Florida
Illinois
Pennsylvania
Ohio
Georgia
New Jersey
North Carolina
Others
9. Company Profiles of Leading US Extrusion Coatings Companies
Celanese Corp
Chevron Phillips Chemical Company
Davis Standard
DuPont de Nemours Inc
Dura Coat Products Inc
Optimum Plastics
PPG Industries
The Lubrizol Corp
The Sherwin-Williams Company
Transcendia
Westlake Chemical Corp
10. Appendix
Data Sources
Methodology and Research Approach
Conclusion
Type
Polyethylene
-Low Density Polyethylene (LDPE)
-High Density Polyethylene (HDPE)
-Others
Ethylene Vinyl Acetate (EVA)
Ethylene Butyl Acrylate (EBA)
Polypropylene
Polyethylene Terephthalate
Others
Substrate
Paperboard and Cardboard
Polymer Films
Metal Foils
Others
Application
Liquid Packaging
Flexible Packaging
Medical Packaging
Personal and Cosmetic Packaging
Photographic Film
Industrial Packaging
Others
States
California
Texas
New York
Florida
Illinois
Pennsylvania
Ohio
Georgia
New Jersey
North Carolina
Others
Companies
Celanese Corp
Chevron Phillips Chemical Company
Davis Standard
DuPont de Nemours Inc
Dura Coat Products Inc
Optimum Plastics
PPG Industries
The Lubrizol Corp
The Sherwin-Williams Company
Transcendia
Westlake Chemical Corp