North America Cast Films Market Size, Share and Trends Analysis Report – Industry Overview and Forecast to 2033

North America Cast Films Market Size

• The North America Cast Films Market size was valued at USD 2.95 Billion in 2025 and is expected to reach USD 4.3 Billion by 2033, at a CAGR of 4.9% during the forecast period
• Cast film is a type of plastic film produced by melting polymer resins and extruding them through a flat die onto a chilled casting roll, resulting in a smooth, uniform film. Cast films are commonly made from materials such as polypropylene (CPP) and polyethylene (PE). The North America Cast Films Market refers to the production and consumption of flat, extruded plastic films manufactured using the cast film extrusion process, primarily utilizing materials such as polypropylene (PP), polyethylene (PE), and specialty polymers.

North America Cast Films Market Analysis

• The North America Cast Films Market represents a critical segment within the North America flexible packaging and industrial materials landscape, supporting applications across food & beverages, pharmaceuticals, personal care, agriculture, and industrial packaging. Cast films are characterized by their superior clarity, uniform thickness, excellent sealing properties, and high production efficiency compared to blown films.
• Market growth is driven by rising demand for flexible packaging, lightweight materials, and sustainable packaging solutions. Increasing consumption of packaged food, ready-to-eat meals, and pharmaceutical products, along with a shift toward recyclable and downgauged materials, is accelerating adoption of cast films across both consumer and industrial sectors.
• U.S. is projected to lead the North America Cast Films Market share 81.30%. Growth in the region is supported by rapid urbanization, expanding food processing industries, rising consumer goods production, and strong manufacturing bases in North America.
• U.S. is projected to be the fastest-growing region CAGR 5.0% in 2025. driven by strong demand for high-performance packaging, advanced manufacturing technologies, and growth in food, healthcare, and consumer goods sectors. Sustainability trends, increasing use of recyclable materials, and innovation in barrier films further accelerate market growth.
• The Polyethylene (PE) cast films segment is anticipated to hold the largest market share 64.97% in 2026, driven by its cost-effectiveness, flexibility, excellent sealability, and recyclability. PE cast films are widely used in food packaging, shrink films, stretch wraps, and agricultural films, making them highly versatile across applications.

Report Scope and North America Cast Films Market Segmentation     

North America Cast Films Market Trends

“Rowing Adoption of Recyclable Mono-Material Cast Films”

• The increasing adoption of recyclable mono-material cast films represents a significant growth opportunity for the North America cast film market. Regulatory pressures, sustainability goals, and consumer awareness are driving demand for packaging solutions that align with circular economy principles. Mono-material cast films, designed to be fully recyclable, address both performance and environmental requirements, offering a viable alternative to multilayer and composite films that face recycling challenges.
• Italian pasta brand Garofalo introduced pasta packaging made from mono‑polypropylene (PP) films created by GT Polifilm using SABIC’s certified circular polypropylene. The resulting mono‑material PP bags can be recycled within existing polypropylene waste streams, demonstrating practical application of mono‑material film in food packaging
• SÜDPACK launched recyclable mono material polypropylene and polyethylene films under its Pure Line product family for coffee packaging. The films offer a recyclable alternative to conventional composite structures while maintaining packaging functionality.

North America Cast Films Market Dynamics

Driver

Rising Demand for High-Performance Flexible Packaging Solutions

• The North America Cast Films Market has been significantly propelled by the rising demand for high-performance flexible packaging solutions across key end-use sectors such as food & beverage, personal care, pharmaceuticals, and consumer goods. Flexible packaging formats including pouches, sachets, overwraps, and laminated structures are increasingly preferred over rigid counterparts due to their superior combination of lightweight properties, mechanical strength, clarity, and barrier performance, all of which are hallmarks of cast films such as cast polypropylene (CPP) and related structures. This shift stems from evolving consumer preferences toward convenience, extended shelf life, attractive product presentation, and cost efficiencies in transportation and material usage, which rigid packaging often cannot match.
• In 2025, Jindal Poly Films announced a major USD 84 Million investment to expand its Nashik facility with new BOPP, PET, and CPP film production lines. This strategic capital expenditure is explicitly aimed at augmenting capacity for flexible packaging films to meet surging market demand, particularly in food, personal care, and pharmaceutical applications, underscoring industry recognition of flexible packaging as a key growth driver.
• UFlex commissioned an advanced 6.5-meter-wide CPP film line with 18,000 tonnes per annum capacity at its Russia facility in 2024, directly responding to customer requirements for high-performance flexible films used in packaging solutions worldwide. This expansion not only enhances production capability but also reflects strategic alignment with increasing demand for flexible film substrates that deliver enhanced clarity, sealability, and durability.

Restraint/Challenge

Recycling Limitations of Multilayer Cast Film Structure

• Recycling limitations associated with multilayer cast film structures present a significant restraint on the growth of the North America cast film market. Multilayer films are widely used due to their superior barrier performance, mechanical strength, and functional versatility across food, pharmaceutical, and consumer packaging applications. However, these structures typically combine multiple polymer layers with different chemical compositions, which complicates separation and recycling processes within existing waste management systems..
• Most recycling infrastructures across regions are designed to process mono-material plastics. Multilayer cast films require advanced separation technologies that remain limited in availability and commercial viability. This structural complexity reduces recyclability efficiency, increases processing costs, and limits the acceptance of such materials within circular economy frameworks. As sustainability regulations continue to evolve, materials that face recycling challenges encounter growing scrutiny from regulatory authorities and environmental agencies .
• According to analyses from recycling coalitions in North America, recycling of plastic films including multilayer packaging films is heavily dependent on specialized drop‑off systems rather than curbside collection, limiting the ability of companies to achieve broader recycled content and circularity targets. This systemic constraint influences company efforts to scale sustainable packaging programs

North America Cast Films Market Scope

The North America Cast Films Market is segmented into five segments based on material, thickness, packaging format, layer structure, and application

• By Material

On the basis of material, the North America Cast Films Market is segmented into polyethylene, polypropylene, polyamide, PVC, others. Polyethylene is further segmented into linear low-density polyethylene (LLDPE), low-density polyethylene (LDPE), high-density polyethylene (HDPE). Polypropylene is further segmented into cast polypropylene (CPP), biaxially oriented polypropylene (BOPP). In 2026 the polyethylene segment is expected to dominate the market with a 64.97% market share. Polyethylene dominates the North America Cast Films Market due to its cost-effectiveness, excellent sealability, flexibility, and recyclability. Rising demand for lightweight, durable, and moisture-resistant packaging in food, consumer goods, and agriculture is driving adoption. Its compatibility with high-speed processing further supports widespread industrial usage.

Polyamide it is anticipated to show the fastest growing 5.4% during the forecast period. Polyamide cast films are gaining traction owing to their superior mechanical strength, puncture resistance, and high barrier properties against oxygen and aromas. Growing demand for premium food and pharmaceutical packaging requiring extended shelf life and product integrity is significantly accelerating the adoption of polyamide-based cast films.

• By Thickness

On the basis of thickness, the North America Cast Films Market is segmented into 31–50 microns, up to 30 microns, 51–70 microns, above 70 microns. In 2026, the 31–50 microns segment is expected to dominate the market with a 38.25% market share and it is anticipated to show the fastest growth during the forecast period. The 31–50 microns thickness segment is driven by rising demand for downgauged, lightweight packaging that balances material efficiency with mechanical strength. This range offers optimal durability, flexibility, and cost control, making it highly preferred in food packaging, pouches, and multilayer laminates across consumer and industrial sectors.

• By Packaging Format

On the basis of packaging format, the North America Cast Films Market is segmented into pouches, bags, laminates, wraps, labels. In 2026, the pouches segment is expected to dominate the market with a 38.93% market share and it is anticipated to show the fastest growth during the forecast period. The growing popularity of pouches is fueled by demand for convenient, portable, and resealable packaging formats. Cast films enable superior clarity, printability, and barrier performance in pouches, supporting applications in food, beverages, and pharmaceuticals. Their lightweight nature also reduces transportation and material costs significantly.

• By Layer Structure

On the basis of layer structure, the North America Cast Films Market is segmented into multilayer, monolayer. In 2026, the multilayer segment is expected to dominate the market with a 63.84%market share and it is anticipated to show the fastest growth during the forecast period. Multilayer cast films are driven by increasing need for enhanced barrier protection, mechanical strength, and shelf-life extension. Combining different polymers improves performance against moisture, oxygen, and light, making multilayer structures essential for premium food, pharmaceutical, and industrial packaging requiring superior product preservation.

• By Application

On the basis of application, the North America Cast Films Market is segmented into food & beverages, industrial, personal care, pharmaceuticals, electricals & electronics, textile, others. In 2026, the food & beverages segment is expected to dominate the market with a 33.85% market share. The food and beverages segment drives cast films demand through rising consumption of packaged, processed, and ready-to-eat products. Cast films provide excellent moisture resistance, seal integrity, and visual appeal, helping extend shelf life and ensure food safety while meeting growing consumer preference for convenient packaging formats.

Pharmaceuticals it is anticipated to show the fastest growing 5.6% during the forecast period. Pharmaceutical packaging demand is boosting cast films adoption due to the need for high barrier protection, chemical resistance, and contamination prevention. Cast films ensure product stability, dosage safety, and regulatory compliance, making them essential for blister packs, sachets, and medical packaging in a rapidly expanding healthcare sector.

North America Cast Films Market Regional Analysis

• U.S. dominates the North America Cast Films Market with the largest revenue share of 81.30% in 2026
• The strong demand across food packaging, pharmaceuticals, electronics, and automotive sectors. The region benefits from a robust manufacturing base, low-cost production, rapid urbanization, and high adoption of flexible packaging solutions in China, India, Japan, and Southeast Asia.

Canada North America Cast Films Market Insight

The Canada North America Cast Films Market captured the largest share of North America revenue in 2026, fueled by extensive use in consumer electronics packaging, food processing, and pharmaceutical applications. Major domestic players continue to expand capacity and invest in advanced multilayer and recyclable cast film technologies to meet rising quality and sustainability requirements.

Mexico North America Cast Films Market Insight

The Mexico North America Cast Films Market is projected to grow steadily, driven by increasing adoption in food packaging, pharmaceutical blister packaging, and industrial laminates. Strong regulatory support for sustainable materials, recyclability, and reduced plastic waste is encouraging the development of bio-based and downgauged cast films.

North America Cast Films Market Share

The North America Cast Films Market is primarily led by well-established companies, including:

• Amcor plc (BERRY GLOBAL) (Switzerland)
• UFlex Limited (India)
• Inteplast Group (U.S.)
•  Jindal Films Limited (India)
• OBEN GROUP S.A.C. (Ecuador)
• Bischof + Klein SE & CO. KG (Germany)
• MITSUI CHEMICALS AMERICA, INC. (U.S.)
• Polifilm GmbH (Germany)
• PROFOL GmbH (Germany)
• FUTAMURA CHEMICAL CO, LTD. (Japan)
• Polyplex (India)
• Thai Film Industries Public Limited Company (Thailand)
• SCIENTEX BERHAD (Malaysia)
• Polibak Plastik Film Sanayi Ve Ticaret Aş (Turkey)
• Copol International Ltd (India)
• 3B FILMS LIMITED (India)
• Alpha Marathon Film Extrusion Technologies (U.S.)
• Cloudfilm Packaging Materials Co., Ltd. (China)
• IPG (Canada)
• Kingchuan Packaging (CPP Film) (China)
• PANVERTA CAKRAKENCANA (Indonesia)
• Plastchim-T (Russia)
• Pt. Bhineka Tatamulya Industri. (Indonesia)
• TAKIGAWA CORPORATION (Japan)

Latest Developments in North America Cast Films Market

• In July, 2025, Inteplast Group has acquired Perga, a plastics film manufacturer based in Walldürn, south-western Germany. The decision marks Inteplast’s first move into Europe and brings Perga into the company’s engineered films division. This development help the company to ear revenue in the company year.
• In June 2025, Amcor has launched a first-of-its-kind, more sustainable Perflex shrink bag with an integrated handle for Butterball’s turkey breast packaging, replacing the traditional net wrap. The new design reduces packaging material and improves production efficiency, eliminating the need for manual netting. Compared with the incumbent packaging, the Perflex bag achieves a 22% reduction in carbon footprint and 22% lower water consumption. This innovation enhances Amcor’s sustainability portfolio by offering a lower-impact packaging solution that meets growing customer and regulatory demand for eco-friendly materials.
• In, August, 2024 Jindal Poly Films to add a new BOPP film production line in India. The expansion is intended to increase output capacity and cater to growing demand in flexible packaging. It strengthens the company’s position in the packaging films market..
• In September 2025, UFlex announced a strategic partnership between Morris Packaging LLC and UFlex Packaging Inc. to deliver an innovative and sustainable woven bag series. The collaboration strengthens UFlex’s presence in the North American packaging market and expands its sustainable product offerings. This move underscores the company’s focus on innovation and North America expansion in packaging solutions.

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