Extruded Polypropylene (XPP) Foam Market

Extruded Polypropylene (XPP) Foam Market Outlook (2024 to 2034)

The global extruded polypropylene (XPP) foam market size is projected to be valued at US$ 1.03 billion in 2024 and thereafter expand at a CAGR of 7.1% to double in valuation and end up at US$ 2.05 billion by 2034.

• The packaging end use of XPP foam is expected to generate an absolute dollar opportunity of US$ 338.4 million between 2024 and 2034.
• Low-density XPP foam accounts for 64.5% share of overall sales in 2024.

XPP foam is a type of thermoplastic foam composed of polypropylene. It is well widely used due to its high stress tolerance, sound absorption, and insulating benefits. Product sales are expected to increase steadily over the coming years due to the growing demand for XPP foam across a range of end-use sectors. The market for XPP foam expanded at a CAGR of 6.8% from 2019 to 2023 to reach a value of US$ 957.8 million.

• Short Term (2024 to 2027): Growing need for lightweight and energy-efficient insulation materials in the building and automotive sectors will propel the short-term expansion of the XPP foam market. Demand for infrastructure development is set to rise in response to growing urbanization and industrialization, which will boost building activity globally and push the consumption of XPP foam.
• Medium Term (2027 to 2030): Production of recyclable and bio-based XPP foam products will pick up to fall in line with strict environmental regulations. One of the main reasons why XPP foam is being used in more industry verticals is to comply with sustainability regulations since it is recyclable. Companies will concentrate on broadening their product offerings and enhancing the mechanical and thermal characteristics of XPP foam.
• Long Term (2030 to 2034): Over the extended period, XPP foam consumption is expected to show consistent growth, driven by a growing focus on sustainability and the requirement for environment-friendly materials across diverse sectors. Advanced technologies such as additive manufacturing and nanotechnology will be combined to produce high-performing XPP foam products.

Report Attribute	Detail
XPP Foam Market Size (2023A)	US$ 957.8 Million
Estimated Market Value (2024E)	US$ 1.03 Billion
Forecasted Market Value (2034F)	US$ 2.05 Billion
Global Market Growth Rate (2024 to 2034)	7.1% CAGR
North America Market Share (2024E)	32.5%
East Asia Market Growth Rate (2024 to 2034)	7.5% CAGR
China Market Growth Rate (2024E)	7.7% CAGR
Key Companies Profiled	Borealis AG; LyondellBasell Industries; Mitsubishi Chemical Holdings; Formosa Plastics Group; BASF; Sekisui Voltek; Sonoco Products; DS Smith Plc; NMC SA; Pregis LLC; Zotefoams Plc; Furukawa Electric Co. Ltd.; Toray Industries Inc.; Mitsui Chemicals Tohcello Inc.; Braskem; Kuraray Co., Ltd.; JSP Corporation; Other Prominent Players.

Why is Global Demand for Extruded Polypropylene Foam Rising Significantly?

“High Rate of Consumption in Automotive and Construction Sectors”

Extruded PP foam consumption growth is expected to be driven by the automotive and construction sectors. XPP foam has the ideal characteristics and finds wide application owing to its high-temperature resistance and chemical resistance, high weight-to-strength ratio, and recyclability features.

Automobile manufacturers will account for steady demand growth for XPP foam, driven by the high need for lightweight vehicle components.

"Flexible End Uses and Distinctive Characteristics of XPP Foam”

In light of its distinctive characteristics and wide range of end uses across several industries, extruded PP foam is popular as a substitute for more conventional materials. Due to its superior thermal insulation qualities, XPP foam is an excellent material for insulation applications in the automotive, refrigeration, and building industries. The insulating properties of XPP foam benefits pipe insulation, car headliners, and insulated concrete.

Furthermore, due to its chemical stability, moisture resistance, and lightweight nature, XPP foam is used in packaging applications to protect electronics and breakable items. Because of its excellent weight-to-strength ratio and dimensional stability, XPP foam has become popular across a range of industries, which is driving up market demand.

What is Denting Extruded PP Foam Market Progress?

“Fluctuating Raw Material Supply and Prices”

XPP foam market growth is being primarily hindered by the limited supply and high prices of raw materials where polypropylene resins have been used as its major raw material in production. Profit margins are being impacted and production costs are rising as a result. Furthermore, manufacturers are facing difficulties in complying with strict environmental requirements about the use of blowing agents and the disposal of foam waste.

Market players also have to deal with the need for product differentiation, and this makes it hard to be outstanding in the marketplace. Examples are specialized insulation panels with improved thermal qualities, lightweight packaging options with personalized designs, and acoustic insulation materials for the automobile sector.

Country-wise Insights

Country	CAGR
United States	7.6%
China	7.7%
Japan	7.5%
South Korea	6.7%

How is the XPP Foam Market Evolving in the United States?

“Huge Demand for High-Quality Extruded PP Foam Products"

From 2024 to 2034, the United States extruded polypropylene foam market is projected to expand at a CAGR of 7.6% and create an absolute dollar opportunity worth US$ 252.3 million.

Suppliers predict a rise in demand for XPP foam insulation products, including pipe insulation, insulated wall panels, and insulated concrete forms, as the building sector places a greater emphasis on energy efficiency. Rise in the demand for strong and lightweight XPP foam parts will be seen in the automotive industry to be used in headliners, trunk liners, and underbody shields.

Demand for XPP foam-based insulating and protective packaging solutions that appeal to the logistics and e-Commerce industries is on the rise. Manufacturers are making investments to increase their production capacity, develop advanced formulations for enhanced mechanical and thermal qualities, and investigate environment-friendly and sustainable manufacturing methods.

What’s Driving Extruded Polypropylene Foam Demand in China?

“Constantly Increasing Construction and Manufacturing Activity to Provide New Market Opportunities”

The China market for XPP foam is forecasted to expand at a CAGR of 7.7% and reach a value of US$ 289.5 million by 2034.

Due to increasing industrialization and urbanization in the country, construction activity is growing significantly. As a result, materials such as pipe insulation, insulated wall panels, and XPP foam insulated concrete forms are in high demand. Lightweight and energy-efficient components are required by China's growing automotive industry, which presents potential for XPP foam-based products such headliners, door panels, and underbody shields.

China’s expanding transportation and e-Commerce sectors have raised the need for insulating and protective packaging solutions, where XPP foam is relatively helpful. By setting up local production facilities or creating strategic alliances, XPP foam makers can take advantage of China's enormous market potential, which is being fueled by favorable government laws that encourage energy-efficient construction techniques.

Category-wise Insights

What Type of XPP Foam Accounts for Higher Revenue Streams?

“Low-Density XPP Foam Exhibiting Higher Demand across Regions”

According to the report by Fact.MR, worldwide sales of low-density XPP foam are estimated at US$ 665.0 million in 2024.

In the packaging sector, where safe and lightweight solutions are crucial for logistics and shipping, low-density XPP foam is widely used. Products that make use of low-density XPP foam's lightweight and durable properties include corner protectors, edge guards, and cushioning materials for delicate items. Because of its lightweight nature, it is simpler to handle and install, which lowers labor costs and increases construction efficiency.

Low-density XPP foam is also being used more by the auto industry for parts such as underbody shields, trunk liners, and headliners, which help reduce vehicle weight and increase fuel economy. It is also used for packaging materials that serve as protection for machinery, equipment, and cell phones. For transport and storage needs, especially where insulation and cushioning are important, this foam is preferred because of its adaptability and environment-friendly attributes.

Where is XPP Foam Most Widely Consumed?

“Automotive and Packaging Key End Uses of XPP Foam”

By 2024, it is estimated that the automotive end-use segment will account for 44.9% of the global XPP foam market share. The segment has been projected to provide an absolute $ opportunity of US$ 468.6 million between 2024 and 2034.

Increased demand for extruded polypropylene foam is being seen in the automotive and packaging industries. This is mainly due to its lightweight and excellent insulation and cushioning attributes, which are needed for auto parts and packaging alike.

Automakers largely prefer low-density extruded polypropylene, also referred to as LDEPP, with a higher rigidity than traditional ones. Given today’s high fuel prices, the importance of this foam in reducing component weight has become extremely handy.

Competitive Landscape

Key players in the extruded polypropylene foam market are DS Smith Plc, NMC SA, Furukawa Electric Co. Ltd., Mitsui Chemicals Tohcello Inc., Toray Industries Inc., JSP Corporation, Borealis AG, BAS, Sekisui Voltek, Sonoco Products, Furukawa Electric Co. Ltd., and Mitsubishi Chemical Holdings. Most of these companies are catering to the high demand for XPP foam from consumer products, construction, and automotive.

• In May 2024, Kuraray Co., Ltd. announced the manufacturing of a blister-resistant grade of GENESTAR product for heat-resistant polyamide resin, which significantly decreases the blister occurrence rate.

Fact.MR has provided detailed information about the price points of key manufacturers of extruded polypropylene (XPP) foam positioned across regions, sales growth, production capacity, and speculative technological expansion, in this recently updated market report.

Segmentation of XPP Foam Market Research

• By Type :

  • High-Density XPP Foam
  • Low-Density XPP Foam

• By End Use :

  • Automotive
  • Packaging
  • Building & Construction

• By Region :

  • North America
  • Latin America
  • Western Europe
  • Eastern Europe
  • East Asia
  • South Asia & Pacific
  • Middle East & Africa