Form-Fill-Seal Machines Market Size, Share and Trends 2025 to 2034

Form-Fill-Seal Machines Market Size and Forecast 2025 to 2034

The global form-fill-seal machines market size accounted for USD 7.30 billion in 2024 and is predicted to increase from USD 7.78 billion in 2025 to approximately USD 13.86 billion by 2034, expanding at a CAGR of 6.62% from 2025 to 2034.The rising consumer demand for packaged products across many industries is the key factor driving market growth. Also, the increasing demand for automation in packaging processes coupled with the escalating trend towards smaller portions can fuel market growth further.

Form-Fill-Seal Machines Market Key Takeaways

• Asia Pacific dominated the global form-fill-seal machines market with the largest market share of 37% in 2024.
• North America is expected to grow at a CAGR of 5.4% over the studied period.
• By technology, the vertical form-fill-seal (VFFS) segment has held a major market share of 57% in 2024.
• By technology, the horizontal form-fill-seal (HFFS) is anticipated to grow at a CAGR of 6.33% over the forecast period.
• By packaging type, the bags and pouches packaging type segment contributed the highest market share of 37% in 2024.
• By packaging type, the blister packaging type segment is projected to grow at a solid CAGR of 7.4% during the forecast period.
• By end use, the food segment accounted for a largest market share of 26% in 2024.
• By end use, the pharmaceuticals segment is expanding at a notable CAGR of 7.7% during the projected period.

Artificial Intelligence (AI) Transforming the Form-Fill-Seal Machines Market 

Artificial intelligence in industrial engineering uses deep learning to improve overall process efficiency, decrease downtime, and optimize real-time decisions. Furthermore, AI in additive production processes identifies detection, improves real-time monitoring, and facilitates processes through Machine Learning techniques. It enables predictive maintenance and design automation, enhancing quality, scalability, and efficiency.

• In November 2024, Microsoft introduced new adapted AI models for the industry. In collaboration with industry partner experts like Bayer, Cerence, Rockwell Automation, Saifr, Siemens Digital Industries Software, Sight Machine, and more, Microsoft is making these fine-tuned models, pre-trained using industry-specific data, available to address customers' top use cases.

Asia Pacific Form-Fill-Seal Machines Market Size and Growth 2025 to 2034

The Asia Pacific form-fill-seal machines market size was exhibited at USD 2.70 billion in 2024 and is projected to be worth around USD 5.20 billion by 2034, growing at a CAGR of 6.77% from 2025 to 2034.

Asia Pacific dominated the global form-fill-seal machines market in 2024. The dominance of the region can be attributed to rapid urbanization and industrialization, along with the increasing demand for packaged food and beverages. Also, innovations in automation and packaging technology are improving production efficiency. Moreover, the increasing disposable incomes and the region's huge populations contribute to the need for convenient packaging solutions, impacting market growth positively.

North America is expected to grow at the fastest rate in the form-fill-seal machines market over the studied period. The growth of the region can be credited to the booming beverage and food industry. The rising consumer preferences for ready-to-eat products and convenient food are impelling market players to invest in innovative packaging solutions. In North America, the U.S. led the market owing to the advancements in sustainable packaging materials.

• In January 2024, Jintian Packaging Machinery Co. Ltd unveiled the Multi-Lane Packing Machine. It is a vertical form fill seal machine made especially for sugar, salt, and instant coffee packaging, among other powdered products.

Market Overview

Form fill seal (FFS) is a small machinery that is made with a flat type of plastic that involves polypropylene and polyethylene sheets to manufacture packaging products like pouches. This equipment depends on computer-operated technology for manufacturing various packages and decreasing the prevalence of contamination during the production process. It has low operational costs and provides product information utilizing film printing. The form-fill-seal machines market services are largely utilized in the food and beverage industry for the packaging of extruded snack food, beverages, granulates, and spices.

Form-Fill-Seal Machines Market Growth Factors

• The increasing demand for in-vitro diagnostic (IVD) kits and catheters is expected to boost the growth of the form-fill-seal machines market.
• The sustainable features of these machines, such as decreased plastic usage, can propel market growth shortly.
• The growing Integration of form-fill-seal machines in the food and beverage industry will likely propel market growth over the forecast period.

Market Scope

Market Dynamics

Driver

Increasing sustainable packing solutions

Regulatory authorities and consumers across the globe are concerned regarding the environmental effects of packaging waste. Hence, there is an increasing preference for sustainable packaging designs and materials. The form-fill-seal machines market is leveraging this trend by integrating features that facilitate the use of eco-friendly materials, decreasing overall packaging waste. Market players are heavily investing in FFS machines that can work with biodegradable films.

• In May 2023, Syntegon launched two of its four new vertical forms, fill, seal (VFFS) machines for various food applications and a second package for its cloud-based monitoring solution. Aspiring to provide customers with a safe, flexible, and efficient packaging line. The SVX Agile is compatible with basic tubular bag styles and can reportedly be upgraded with modules for corner sealed bags, three-sided seal bags, and doy-style and doy-style zip bags.

Restraint

Incompatibility with other material

There is a certain limitation to the material handled by these machines, which is the major factor hampering the form-fill-seal machines market. Paper is the most significant incompatible material. However, sustainability is a key concern in the packaging industry. There are rising sanctions and disdain over the utilization of plastic. Also, form-fill-seal machines are not suitable for liquid packaging. Therefore, a vast majority of the food market is deducted from the customer base.

Opportunity

Application in the pharmaceutical sector

Just like the food and beverage items, there is a strong focus on decreasing pollutants during the packaging process for pharmaceutical products. Hence, form-fill machines are appropriate for this purpose. Furthermore, pharmaceutical products such as capsules, powders, and tablets are increasingly being packaged with the help of these machines. FFS machines are also used in the pharmaceutical industry to package IV infusion bottles.

• In May 2024, Omnia Technologies, a platform for automation and bottling technologies for the spirits, wine, beverage, dairy, and pharma industries, launched a new high-speed beverage division focused on bottling-labeling-packaging technologies through the acquisitions of ACMI, SACMI Beverage, and SACMI Labelling. 

Technology Insights

The vertical form-fill-seal (VFFS) segment dominated the form-fill-seal machines market in 2024. The dominance of the segment can be attributed to their versatility and cost-effectiveness. Also, these machines are proffered for their capability to offer superior protection against moisture, oxygen, and UV light, which makes them crucial for packaging consumer goods and food products. Additionally, the increasing need for automation in many industries improves their appeal further in the market.

The horizontal form-fill-seal (HFFS) is anticipated to grow at the fastest rate over the forecast period. The growth of the segment can be linked to the increasing use of HFFS machines in various sectors due to their efficiency and speed. These machines are favored for their ability to handle various packaging types, such as heavy bags and stand-up pouches, making them convenient for an extensive range of applications. 

Packaging Type Insights

The bags and pouches packaging type segment held the largest share of the form-fill-seal machines market in 2024. The segment's dominance can be credited to the growing consumer preference for economical and lightweight packaging solutions. In addition, the demand for retort pouches and stand-up pouches has increased as they offer improved shelf appeal and convenience, especially in the food and beverage industry. Also, the diversity of bags and pouches carrying many products fuels their growth further.

• In September 2024, ProAmpac, a leader in flexible packaging and material science, announced the launch of its latest innovation, QUADFLEX® Recyclable LFQ. This large-format quad-seal pouch is designed to meet the growing demand for recyclable packaging solutions for premium pet food, lawn and garden care, and dry foods for products up to 40 lbs.

The blister packaging type segment is projected to grow at the fastest rate during the forecast period. The growth of the segment can be driven by increasing demand for tamper-proof and secure packaging solutions, especially in the consumer goods and pharmaceutical sector. Moreover, blister packaging gives strong protection against contamination and moisture, which is crucial for keeping product integrity. 

End Use Insights

In 2024, the food segment dominated the form-fill-seal machines market by holding the largest share. The dominance of the segment is due to the rising consumer demand for ready-to-eat and convenient packaging solutions. Safety is the top priority for these companies before packaging food products. These machines safeguard food from being unaltered and contamination in packaging. The food sector commonly depends on sealed and form-filled packaging for various products.

The pharmaceutical segment is anticipated to grow at the fastest rate during the projected period. The growth of the segment is because of the strict laws & regulations regarding integrity and safety packaging. Furthermore, the rising trend towards hygienic and single-use formats aligns with consumers' choice for convenience and safety, making form-fill-seal machines a key element in pharmaceutical manufacturing processes.

Form-Fill-Seal Machines Market Companies

• Rovema GmbH
• Syntegon Technology
• Ishida Co., Ltd.
• KHS Group
• Multivac
• IMA Group
• GEA Group
• ProMach
• WeighPack Systems Inc.
• PFM Packaging Machinery
• Hayssen Flexible Systems
• Ossid
• ULMA Packaging
• Schubert Group
• Sidel
• 3M
• CFT Group
• Cama Group
• Marchesini Group
• JLS Automation

Latest Announcement by Market Leaders

• In August 2024, Syntegon announced it will be presenting its machine and software solutions at this year's FACHPACK, taking place in Nuremberg, Germany, from September 24th to 26th - aiming to allow food manufacturers to transition to sustainability-minded packaging processes. The company says it will be presenting its 'future-proof' packaging material solutions at booth 1-257 in Hall 1:
• In November 2024, IMA Life, one of the three pharma divisions of IMA Group and global leader in advanced, aseptic pharmaceutical process and production solutions, announced a strategic partnership with RheaVita, a pioneer in controlled, continuous freeze-drying technology for biopharmaceuticals. This partnership includes a financial investment in RheaVita by IMA Life.

Recent Developments

• In May 2024, Matrix Packaging Machinery showcased its innovative vertical form-fill-seal machines at Expo Pack Mexico, held from June 4-7, 2024, in Mexico City. Visitors to booth 1702 can explore the MVI-280E, a versatile fill-form-seal machine capable of processing various bag sizes, and the Pacraft TT-8D-N pre-made pouch filler/sealer. 
• In October 2024, ProMach announced the acquisition of HMC Products, a prominent manufacturer of horizontal form-fill-seal machines and aftermarket support services. This strategic move aims to enhance ProMach's packaging solutions by integrating HMC's expertise in form-fill-seal technology, thereby expanding its capabilities in the packaging industry. 

Segments Covered in the Report

By Technology

• Horizontal FFS
• Vertical FFS

By Packaging Type

• Cups & Trays
• Bags & Pouches
• Bottles
• Blisters
• Others

By End Use

• Food
• Beverages
• Pharmaceuticals
• Personal Care
• Chemicals
• Others

By Geography

• North America
• Europe
• Asia Pacific
• Latin America
• Middle East and Africa