Form Fill and Sealing (FFS) Equipment Market

Form Fill and Sealing (FFS) Equipment Market Outlook (2024 to 2034)

The global form fill and sealing (FFS) equipment will be valued at US$ 10.5 billion by 2024 end and has been forecasted to expand at a noteworthy CAGR of 6.2% to end up at US$ 19.2 billion by 2034. Food & beverages by application of form fill and sealing (FFS) equipment will be worth around US$ 5.8 billion in 2024 and account for a 55.0% global market share.

Form fill and sealing (FFS) equipment market is a key component of packaging technology and refers to filling and sealing machines used across sectors such as food and beverage, drugs, and cosmetics. FFS machines help in the entire process of packaging products by designing pouches, bags, or containers, putting a product in them, and sealing the packages before distribution as one complete unit. This equipment saves a lot of time and money since manual work is cut down, production efficiencies are improved and wastage of materials is low.

Global form fill and seal (FFS) equipment market can be on the increase owing to the climbing number regarding the packaging requirements due to the clients' values for time and money and environment/green friendly factors. The major ones are the global growth of the food and beverage sector, which has increased the demand for other faster than ready-to-eat and convenience foods.

The other major sector in which FFS machines are used is the pharmaceutical sector as there is the need for sterile and more secure packages that protect the product. FFS equipment is also commonly used in the personal care products industry as such packaging is flexible and can allow changes with the customers’ demands for portable and beautiful inner packaging.

Report Attributes	Details
Form Fill and Sealing (FFS) Equipment Market Size (2023A)	US$ 9.9 Billion
Estimated Market Value (2024E)	US$ 10.5 Billion
Forecasted Market Value (2034F)	US$ 19.2 Billion
Global Market Growth Rate (2024-2034)	6.2% CAGR
East Asia Market Share (2024)	22.4%
United States Market Growth Rate (2024-2034)	6.6% CAGR
Key Companies Profiled	Accutek Packaging Equipment Companies, Inc; Bosch Packaging Technology; Filling Equipment Co., Inc.; GEA Group AG; JBT Corporation; KHS GmbH; Krones AG; Ronchi Mario SpA; Rovema GmbH; Tetra Laval International SA; Other Market Players

Sales Analysis of Form Fill and Sealing (FFS) Equipment (2019 to 2023) vs. Market Forecasts (2024 to 2034)

The value of the fill and seal (FFS) equipment market was US$ 7.7 billion in 2019 and it increased to US$ 9.9 billion by 2023, expanding at a CAGR of 5.1%

• Short Term (2024 to 2028): The global form fill and seal (FFS) equipment market is seeing demand mainly due to growing automation and efficient packaging, especially in the food, beverage, and pharmaceutical industries. Some of the prominent short-term drivers pertain to the demand for packaged convenience foods, the rapid growth in e-commerce leading to the use of expensive and damage-resistant packaging, and external pressure from regulatory norms in the case of pharmaceutical packaging. The sophisticated integration of FFS systems with new controls like AI-enabled quality checks and using sustainable materials is in keeping with the current corporate social responsibility (CSR) objectives.
• Medium Term (2028 to 2030): Increasing demand for specialized packaging, especially for high-viscosity and sensitive materials applicable to the pharmaceuticals, biotechnology, and specialty foods. As companies make more complicated assemblages of sensitive viscous products more so, advanced biologics, nutraceuticals, and high-end food pastes there is an increased demand for FFS machines to fill such products with much higher filling customization and precision within the parameters that will not allow the products to be contaminated or altered. There is a growing pressure on manufacturers to enhance their FFS equipment investment given their ability to be adapted for unique sealable materials specific packaging, automatic adjustment of material dosage features, and provision of sterilization capabilities.
• Long Term (2030 to 2034): High performance and compatibility with advanced materials in flexible packaging solutions have become the major driving force for the global form fill and sealing (FFS) equipment market. The industry is highly expected to accelerate as many industries are innovating with high-performance packaging materials, such as bio-polymers, compostable films, and multilayer barrier materials. To ensure the needed speed and sealing integrity, FFS machines that are compatible with these materials are now in high demand. This is particularly an important necessity for food, pharmaceutical, and chemical industries, where product safety, freshness, and shelf-life are essential. Such high-precision FFS systems require flexibility to address this unique set of material requirements for specialty materials and assure quality control.

On the back of the aforementioned facts, the form fill and seal (FFS) equipment is anticipated to grow at a CAGR of 6.2% during the forecast period from 2024-2034, according to the Fact.MR, a market research and competitive intelligence provider.

Market Dynamics

Why are form-filling and sealing equipment sales rapidly increasing?

"Constant Innovations in Automated Packaging Technology"

Constant innovations in automated packaging technology are evolving the form fill and sealing (FFS) equipment market. In the wake of labor shortages among packaged consumer goods firms, there is a growing demand for equipment that allows smooth switching of operations, as well as advanced problem-solving. This has reinforced the phenomenon of advancing innovative technologies such as motion control systems and human-machine interface (HMI) integrations in FFS machines that radically change the landscape of the market.

These advancements allow operators to have more accurate control and monitoring over packaging processes, which is higher in efficiency and has reduced dependence on manpower. The technology behind FFS is largely automated and can produce flexible, semi-rigid, and rigid packaging solutions for different industries. FFS machines are capable of efficiently loading the base packaging with dry and liquid content ensuring that the range of application stretches from food and beverage industries to that of pharmaceuticals.

This flexibility is further enhanced with automation and therefore reduces the amount of operational force required while increasing productivity and safety of the products. There are also motion control systems and Human Machine Interface (HMI) that allow in-line quick adjustments to reduce wastage of time in changeovers and also enhance flexibility of operations.

“Increasing Demand for Packaged Food Driving FFS Equipment Adoption”

Ready-to-eat meals will be the single most important factor contributing to the growth of FFS equipment across the globe. It is said that the postmodern society has spawned foods that are overly decorated due to the fact that most if not all people in society today are used to ready to eat healthy and preserved meals containing edible fats. Available food packaging solutions are compact and fitted in FFS (gas flushing) machines allowing for quick and effective packing of different kinds of food - whether they include chips, instant foods, ice foods, beverages or any other food category. With this equipment, it is possible to produce many kinds of packaging including flexible, semi-rigid and rigid which caters for the various needs of clients.

The aim of FFS equipment is to achieve precise sealing and protection of food products which contributes to longer shelf lives of the goods with minimal wastage. FFS technology is integrated in the production lines thus aiding organization in efficient scaling in the quality of product it provides and in the ability of the organization to meet the growing demand in safer and more presentable foods which is a challenge considering the rapid growth of packaged food markets in the developed and developing countries.

What are the challenges encountered by manufacturers of form fill and sealing (FFS) equipment?

“High Initial Investment Costs and Maintenance Complexity”

One of the concerns associated with the form fill and sealing equipment is the fact that the initial investment costs and the upkeep of the equipment is fairly complicated. Due to advances in technology, users of FFS machines usually the latest machines which tend to be more expensive compared to the older models. These costs make it hard for small and medium enterprises to compete with larger firms that are able to afford the costs.

Using this type of equipment adds to the operational costs considerably because it is not enough to have any unskilled person operating it. Such sophisticated equipment is expected to depend on the expertise of highly qualified personnel trained to avoid possible operational downtimes or breakdowns. Servicing such complex equipment on a regular basis does not only require skilled workers, but Maintainers must also regularly order new updated parts and make adjustments to the positioning of the systems, which furthermore increases dependency on external sources, or even in-house programs for training.

Country-wise Insights

What makes Japan a leading market for form fill and sealing (FFS) equipment?

“Growing Customer Preference for Convenient Packaging in Japan”

The market in Japan is estimated at US$ 0.7 billion in 2024 and is projected to expand at a CAGR of 6.7% through 2034. This market is projected to generate a US$ 0.6 billion absolute opportunity from 2024 to 2034.

Japan is witnessing a noticeable focus on packaging which is easy to open, store and carry especially for food as well as beverages and personal care items. Therefore, the attention turns to the flexible forms of packaging such as pouches, zippered bags, and single-serve packs, which enable on-the-go consumption and cater to the needs of smaller households. This has pushed companies to begin implementing form fill and sealing technologies that are capable of producing a high volume of such convenient formats and also maintaining the quality of the product inside the package. In addition to that, such FFS devices allow industries to diversify their product range in offering various packages for different product varieties improving the attractiveness of the brand.

Why is Germany a lucrative market for form fill and sealing (FFS) equipment manufacturers?

“Germany’s stringent regulations on packaging quality and sustainability”

Countries like Germany which have stringent packaging legislations and focus more on sustainable solutions are going to be one of the major factors enhancing demand for FFS equipment in the region for the years spanning 2030-2034. The federal republic of Germany is among the most powerful economies in Europe and has put policies and measures aimed at minimizing waste creation and encouraging the sustainable use of various types of packaging materials. This has placed a greater importance with the use of new technologies in packaging, for instance FFS equipment, which enables the manufacturers to comply with these regulations.

The existing demand for FFS machinery that accepts environmentally friendly pack formats such as bio-degradable and compostable materials will also be deepened by the emphasis placed on packaging sustainability by the German government which places limits on the usage of plastic as well as increases the percentage of recycled content. Provision for the safety and quality of the packagings is also on the rise increasing the need for effective and dependable FFS systems in the country that will provide the necessary shelf life for finished products.

Category-wise Insights

Why is there a rising demand for flexible packaging in the food industry?

“The demand for flexible packaging is driven by convenience and sustainability”

Flexible package designs are lightweight, customizable to different user and production requirements, and easy to handle, thus attracting both producers and users. It is more effective in material usage and reduction of waste generation, hence more sustainable than the traditional paper or plastic coverings. Flexible package also elongates the shelf life of a product and facilitates safe transport of the products. These qualities meet the demands of a large group of consumers looking for packaging that is eco-friendly and convenient.

Because FFS machines are made to package a present product with flexible materials in an effective manner, the flexible packaging segment is more pertinent to the FFS equipment market. The flexible packaging is anticipated to extend the demand for FFS equipment market in various sectors such as food and beverages, pharmaceuticals, and personal care. Convenience and Sustainability factors have led to the demand for sophisticated FFS machines.

Which application is expected to generate high revenue for market players?

“Growing demand for bags and pouches boosts revenue in FFS equipment market”

It is expected that the contribution of bags and pouches will be a large share of the revenues of the players in the form fill and sealing (FFS) equipment market. Such packaging solutions are very versatile and convenient making them ideal in the packaging of food, drinks, drugs as well as beauty products. And they as well seal firmly the contents in the pouch or bag, lengthen the usability of the products and are lightweight hence reducing transport and material costs. Moreover, there is an increasing demand for these goods as there are more and more people who prefer using light and eco-friendly carrying bags and other products.

There has instead been an increasing demand for the bags and pouches embarking on the FFS equipment market, particularly because, FFS machines improve production efficiency by making it possible to pack the products in such bags and pouches. While industries appear to be slowly but surely changing their traditions and integrating more flexible packaging options in the course of their operations, bags and pouches are bound to account for a good proportion of revenue generation for the players in the market, thus stimulating the growth of FFS equipment market.

Competitive Landscape & Market Developments

• Accutek Packaging Equipment Companies, Inc: On October 2024, The Accutek Packaging Equipment Companies, Inc. presented their growth & innovations at the PACK EXPO International where advanced filling machines and a heavy-duty labeling machine were on display to improve efficiency and accuracy in the packaging process.
• Ronchi Mario SpA: November 2023, Ronchi Mario SpA introduced a new series of filling machines that enhance precision and speed for liquid packaging. This development is part of their ongoing efforts to innovate and meet the increasing demands of the beverage industry.

Fact.MR has provided detailed information about the price points of key manufacturers of form fill and sealing (FFS) equipment positioned across regions, sales growth, production capacity, and speculative technological expansion, in the recently published report.

Segmentation of Form Fill and Sealing (FFS) Equipment Market Research

• By Type :

  • Horizontal FFS Equipment
  • Vertical FFS Equipment

• By Packaging Type :

  • Bags & Pouches
  • Cups & Trays
  • Blisters
  • Bottles
  • Other Packaging Type

• By Application :

  • Food & Beverages
  • Pharmaceuticals
  • Personal Care
  • Chemicals
  • Other Applications

• By Region :

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