Polypropylene Foams Market Size, Share and Trends 2024 to 2034

Polypropylene Foams Market Size and Forecast 2024 to 2034

The global polypropylene foams market size is calculated at USD 1.67 billion in 2024 and is projected to surpass around USD 3.08 billion by 2034, growing at a CAGR of 6.32% from 2024 to 2034. The rising demand for lightweight automobiles is the key factor that is driving the growth of the global polypropylene foams market.

Polypropylene Foams Market Key Takeaways

• Asia Pacific dominated the polypropylene foams market in 2023.
• North America is anticipated to grow at a notable CAGR over the projected period.
• By product type, the expanded polypropylene segment dominated the market in 2023.
• By product type, the extruded polypropylene segment is expected to show the fastest growth in the market over the forecast period.
• By end-use, the packaging segment led the market in 2023.
• By end-use, the automotive segment is projected to witness the fastest growth in the market during the forecast.

Market Overview

Polypropylene foams are known for their lightweight, durable, and resilient properties, resisting chemicals and moisture. These foams can endure a wide range of temperatures, which makes them versatile for various applications. The polypropylene foams market products are commonly used in cushioning, automotive parts, packaging, and more. Available in several forms, such as expanded polypropylene and extruded polypropylene, these foams are manufactured using different methods. Beyond their roles in the automotive and packaging sectors, polypropylene foams find applications in consumer products, construction, and other industries. Polypropylene foams are particularly useful for protective packaging, reusable transport containers, and insulation materials.

How is AI Changing the Polypropylene Market?

Technological advancements have significantly transformed the polypropylene foams market, leading to remarkable growth. Innovations such as Artificial Intelligence (AI) and IoT are reshaping the industry by improving operational efficiency and creating new revenue opportunities. AI, for instance, can process vast amounts of data in real-time, analyzing billions of intersecting data points generated during manufacturing. Also, this capability enables AI to identify crucial patterns and insights, which can be directly delivered to frontline teams. As a result, the reliance on intuition and experience for decision-making can be greatly reduced or even eliminated.

Polypropylene Foams Market Growth Factors

• The rising demand for protective packaging solutions in the e-commerce and electronics industries is expected to fuel the polypropylene foams market growth.
• Increasing demand in the construction industry can drive the polypropylene foams market growth further.
• The growing need for lightweight structural components can boost the polypropylene foams market shortly.

Market Scope

Market Dynamics

Driver

Temperature-controlled packaging for food and beverages

There is a notable surge in the demand for frozen food and cold beverages today. Effective packaging is essential to maintaining the required temperatures for these products, and polypropylene foam is widely favored for this purpose. Additionally, the food and beverage industry is seeing increased demand for items like hot and cold catering boxes, cake rings, synthetic corks, and wine packs, which rely heavily on polypropylene foams. This rising need in the food and beverage sector is significantly driving the polypropylene foams market.

• In February 2022, Wayne, PA-based Tekni-Plex Consumer Products expanded its packaging options for fresh meat and produce packers with the launch of foam polypropylene (FPP) food trays. The company reports that a major wholesale company was the first customer to use the FPP trays at retail for meat. Designed for fresh food products such as meat, poultry, pork, fruits, and vegetables, the foam PP trays are a drop-in replacement for conventional foam polystyrene (FPS) trays.

Restraint

Difficulties in recycling

New materials and technologies are continuously emerging, which could potentially replace polypropylene (EPP) foam in various applications. Although EPP foam is commonly used in certain areas, it may not be as well-known or easily accessible in other regions, which can potentially affect its adoption and growth in those areas. While foam can be recycled, the process requires specialized equipment and facilities, making it more challenging. This difficulty in recycling could limit the amount of PP foam that gets recycled and impact its sustainability. Thus hampering the growth of the polypropylene foams market.

Opportunity

Expanded polypropylene

Expanded polypropylene (EPP) foam is increasingly being adopted in the medical field for both packaging and cushioning applications. Its lightweight nature and impact resistance make it an attractive option for medical device manufacturers who need to protect delicate instruments during shipping. The growing demand for sustainable packaging solutions, driven by companies aiming to reduce their environmental footprint and meet consumer preferences for eco-friendly products, has elevated the appeal of EPP foam. Its recyclability and light weight make it a strong candidate for sustainable packaging. Furthermore, the aerospace industry is progressively incorporating EPP foam for interior components like seating and overhead compartments. This creates opportunities for the key players in the polypropylene foams market.

• In April 2024, Texas-based AmeriTex Pipe & Products LLC is building a new facility to extrude corrugated pipe from virgin high-density polyethylene and polypropylene in Conroe, Texas, to serve demand for infrastructure products in the state.

Product Type Insights

The expanded polypropylene segment dominated the polypropylene foams market in 2023. Expanded Polypropylene (EPP) is a versatile closed-cell bead foam known for its exceptional properties, such as excellent energy absorption, multiple impact resistance, and thermal insulation. It also offers buoyancy, resistance to water and chemicals, a high strength-to-weight ratio, and is fully recyclable. Due to these performance benefits, including energy management, lightweight nature, enhanced functionality, and durability, EPP is widely used by automotive manufacturers. Its recyclability further adds to its advantage in the industry.

• In May 2023, Kaneka Corporation created a new kind of expanded polypropylene foam that is better for the environment. The new EPP foam is made with recycled materials and can be recycled.

The extruded polypropylene segment is expected to show the fastest growth in the polypropylene foams market over the forecast period. Extruded polypropylene (XPP) foam is made by processing a blend of polypropylene resin through an extrusion process. It boasts a range of impressive properties, including high impact resistance, water and chemical resistance, excellent strength, thermal insulation, and recyclability. These versatile characteristics make XPP foam popular across various industries, such as automotive, construction, and packaging. Its lightweight nature, resistance to moisture, and ability to retain shape also make it a preferred choice for many key applications. Additionally, XPP foam is eco-friendly and recyclable, which improves its appeal for sustainable use.

End-use Insights

The packaging segment led the polypropylene foams market in 2023. The growth can be attributed to the use of different packaging materials. Polypropylene film is highly favored for packaging applications that need to meet FDA standards because of its superior chemical resistance, low odor, and inert properties. It is widely used in various products, including shrink wrap, candy wrappers, tape liners, food wraps, cigarette packaging, diapers, and sterile wraps.

The automotive segment is projected to witness the fastest growth in the polypropylene foams market during the forecast period. 0041s consumer products, packaging, and other uses saw increased demand. The rising need for innovative solutions and the drive for expansion in the polypropylene foam market have prompted companies to adopt both organic and inorganic strategies. These efforts aim to enhance their market shares and explore growth opportunities in their respective regions.

• In October 2023, BASF agreed to divest its Neopolen expanded polypropylene (EPP) business to Knauf Industries GmbH. Neopolen enables the manufacturing of lightweight molded parts for the automotive industry, as well as for heating and air conditioning applications. Knauf Industries is a leading European manufacturer of complex molded parts made of EPP foams and other materials and employs more than 2,000 people in eight countries. Its customer base is primarily in the automotive, air conditioning, and sports & leisure industries.

Regional Insights

Asia Pacific dominated the polypropylene foams market in 2023. Recently, the demand for polypropylene foams has surged in both the packaging and automotive sectors due to the rising population and growing disposable incomes in the region. This increased demand is propelling the polypropylene foams market forward. Polypropylene foams lead the market because they are fully recyclable and contribute to CO2 emissions reduction. Furthermore, due to their excellent mechanical properties, these foams can be used repeatedly over many years, even in harsh environmental conditions. The strong demand for high-quality polypropylene foams in both developing and recovering developed countries in the region is expected to drive market growth throughout the forecast period.

North America is anticipated to grow at a notable rate in the polypropylene foams market over the projected period. This can be attributed to the growing demand for fuel-efficient cars and the rising use of advanced materials in auto parts. Chemically stable EPP foam has become the preferred choice over existing options. The U.S. automotive industry's focus on electric and fuel-efficient vehicles has led to significant breakthroughs and technological advancements, boosting consumer interest in high-end electric cars.

• In July 2024, ProAmpac, a leader in flexible packaging and material science, announces the launch of its innovative ProActive Recyclable Fresh Tray FT-1000. This groundbreaking, patent-pending polypropylene-based tray is classified as plastic #5 and approved for curbside recycling. It introduces the food service and grocery markets to an easily recyclable lightweight foam tray.

Polypropylene Foams Market Companies

• BASF SE
• Kaneka Corporation
• Hanwha Corporation
• Mitsui Chemicals, Inc.
• Borealis AG
• Furukawa Electric Co., Ltd.
• Sonoco Products Company
• DS Smith PLC.
• K. K. NAG Ltd.
• Pregis Corporation

Recent Developments

• In April 2023, JSP Corporation said it expanded its EPP foam production in Japan. It will be done in 2024 and will increase their production by 50%.
• In January 2022, by using almost entirely recycled materials, JSP developed ARPRO Revolution. This product has the lowest carbon impact and is perfect for non-technical furniture, leisure, and packaging applications.
• In June 2023, BASF SE made a deal with a big car maker to supply EPP foam for a long time. It will start in 2024.

Segments Covered in the Report

By Product Type

• Expanded Polypropylene (EPP) Foams
• Extruded Polypropylene (XPP) Foams

By End-use Industry

• Automotive
• Packaging
• Consumer Products
• Others

By Geography

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