U.S. Rigid Packaging Market Size By Material 2025-2030 (Value - USD Billion)

U.S. Rigid Packaging Market Size By Product Type 2025-2030 (Value - USD Billion)

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  Sustainable Development Trends in Rigid Packaging

  Berry Global Highlights Global Scale and Diversified Strength with $13 Billion in Revenue

  Berry Global Group, Inc. (NYSE: BERY), a leading global supplier of innovative packaging and engineered products, today released key operational and financial metrics underscoring its expansive global footprint, diversified business model, and strategic focus on key consumer and industrial end-markets.

  The overview confirms the Company's commanding position in the global packaging industry USD $13 billion in annual revenue and an operational network of approximately 290 manufacturing locations worldwide.

  Geographic Dominance and Operational Scale

  Berry Global's global presence is strategically aligned with major consumer markets, with a clear focus on the Western hemisphere and Europe:

  • Sales Concentration: North America remains the Company's primary sales driver, accounting for a majority (57%) of net sales.
  • EMEA (Europe, Middle East & Africa) represents the next largest market, contributing a substantial 35% of net sales.
  • Manufacturing Footprint: The operational base is heavily concentrated in its two largest markets, with Europe hosting the highest number of sites (130) and North America close behind (121). This dual regional strength ensures robust supply chain resilience and customer proximity.
    

  CEO Quote (Example): "Our operational footprint of nearly 290 sites is a critical competitive advantage, allowing us to serve global customers with local expertise and speed. The clear alignment between our manufacturing sites in Europe and North America and our primary revenue streams underscores a well-executed strategy focused on global scale with regional execution."

  Diversified and Balanced Divisional Strength

  Berry Global maintains a highly balanced and diversified revenue profile across its four main business segments, minimizing exposure to volatility in any single market:

  Division	% of Total Revenue	Strategic Insight
  Consumer Packaging – International	38	%	The single largest division, highlighting the success of the Company's international consumer strategy.
  Consumer Packaging – North America	21	%	Core domestic strength in consumer markets.
  Health, Hygiene & Specialties (HHS)	21	%	Provides stability and access to high-growth, non-cyclical end markets.
  Engineered Materials	20	%	A significant, balanced contributor, serving diverse industrial and specialty markets.

  CFO Quote (Example): "The even split across our four core divisions-each contributing approximately 20% of revenue, with International Consumer Packaging providing a solid anchor at 38%-is a testament to the strength of our business model diversification. This balance ensures financial resilience and supports our investment strategy focused on Innovation for a Circular Economy."

  Berry Global continues to integrate its financial strength and global scale with its core mission to lead the industry in sustainable solutions. The Company is leveraging its vast network and deep innovation expertise to advance materials science and product designs that promote recyclability and the use of post-consumer recycled content, accelerating the transition to a net-zero economy.

  About Berry Global At Berry Global Group, Inc. (NYSE: BERY), we create innovative packaging and engineered products that we believe make life better for people and the planet. We do this every day by leveraging our unmatched global capabilities, sustainability leadership, and deep innovation expertise to serve customers of all sizes around the world. Harnessing the strength in our diversity and industry-leading talent, we partner with customers to develop, design, and manufacture innovative products with an eye toward the circular economy.

  Significant Reduction in Freight & GHG Emissions Achieved Through Sustainable Packaging Conversion

  This report highlights the dramatic positive impact of converting from a composite can to a non-round, nestable, single-substrate PP (Polypropylene) container for our 2 million unit volume product. The transition has yielded a 320% increase in freight efficiency per truck, resulting in a 67.92% reduction in annual truck shipments and a total annual Greenhouse Gas (GHG) emission reduction of 98 MT. This initiative showcases a clear commitment to operational sustainability and a lower carbon footprint across the supply chain.

  Key Findings & Metrics: Life Cycle Assessment (LCA) and Freight

  The following data, derived from the Life Cycle Assessment (LCA) focusing on freight, demonstrates the immediate and quantifiable benefits of the packaging change.

  Case Study: Composite Can to Rigid Plastic Container (Volume: 2 Million Units)

  Metric	Before (Composite Can)	After (PP Container)	% Change	Interpretation
  Parts per Truck	37,800	120,960	+320	%	Massive increase in loading density due to the nestable, non-round design.
  Trucks per Year	53	17	−67.92%	Significant reduction in logistics volume, cutting the need for more than two-thirds of annual truck trips.
  Gallons of Diesel per Year	2,609	1,569	−39.86%	Substantial fuel savings directly lowering operational costs and fossil fuel consumption.
  **Emissions per Year (MT CO2) **	27 MT CO2	16 MT CO2	−40.74%	Direct reduction in transport-related carbon emissions due to fewer trucks on the road.

  Environmental Impact: GHG Emissions Comparison

  The analysis of total annual Greenhouse Gas (GHG) emissions across the entire product lifecycle shows a significant environmental win.

  • Composite Can (Before): 631 MT/year
  • PP Container (After): 533 MT/year
  • Total Annual Reduction: 98 MT/year
    

  Impact Equivalencies (for Stakeholder Communication):

  To put the 98 MT/year reduction into relatable terms for a broader audience, this is equivalent to:

  • 21 passenger vehicles driven for one year.
  • 227 barrels of oil consumed.
  • The carbon sequestration of 128 acres of U.S. forest for one year.
    

  The successful conversion to the non-round, nestable, single-substrate PP container is a testament to our commitment to both operational excellence and environmental stewardship. By prioritizing smart, space-saving design, we have not only achieved a 320% improvement in freight loading but also directly translated that efficiency into tangible environmental benefits, significantly reducing our transportation carbon footprint and overall product emissions. This project is a model for how strategic design can deliver both cost savings and a lower-impact supply chain.

  Lightweighting & Nestable Design Achieves Significant Environmental and Cost Savings

  The findings of a case study demonstrating the significant environmental and economic benefits achieved by transitioning from an HDPE Blow-Molded Canister to a PP Thermoformed Container. The design focused on lightweighting and nestability for a product volume of 10 million units over a transportation distance of 200 miles.

  Key Performance Improvements

  The shift to the "Eco Canister" yielded substantial benefits across weight, efficiency, and sustainability:

  • Weight Reduction: 34% package weight reduction.
  • Logistics Improvement: 7.4× more canisters per truck load was achieved due to the nestable design (Units per truck increased from 35,000 to 259,200).
  • Cubic Efficiency: Increased cubic efficiency in transportation.
  • Recyclability: Improvement in end-of-life recyclability.

  Inbound Freight Environmental and Economic Impact

  The dramatic increase in units per truck led to major reductions in freight requirements and associated costs:

  Metric	Annual Reduction	Detail
  Trucks Eliminated	247 inbound trucks	Reduced road congestion and overall logistics footprint.
  Diesel Savings	7,600 gallons	Significant reduction in fossil fuel consumption.
  Cost Savings	$	20,520	Calculated based on diesel at $2.70 per gallon.

  Emissions Comparison and Total Reduction

  The project resulted in a significant reduction in annual Greenhouse Gas (GHG) emissions across both manufacturing and freight.

  Parameter	Current (HDPE Blown Canister) (MT/year)	Eco (PP Thermoformed Container) (MT/year)	Reduction (MT/year)
  Package Manufacture	1,134	670	-464
  Freight	90	12	-78
  Total	1,224	682	542

  The Total GHG Reduction is 542 metric tons per year.

  Equivalent Environmental Impact

  The annual GHG savings are equivalent to a substantial positive environmental impact, illustrating the scale of the reduction:

  • 117 passenger vehicles driven for one year.
  • 1,255 barrels of oil consumed.
  • 708 acres of forests storing carbon.
    

  This information highlights the compelling business case for sustainable design changes, demonstrating how lightweighting and nestability can deliver simultaneous benefits in environmental performance, operational efficiency, and cost reduction.

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  About Us

  Towards Packaging is a global consulting and market intelligence firm specializing in strategic research across key packaging segments including sustainable, flexible, smart, biodegradable, and recycled packaging. We empower businesses with actionable insights, trend analysis, and data-driven strategies. Our experienced consultants use advanced research methodologies to help companies of all sizes navigate market shifts, identify growth opportunities, and stay competitive in the global packaging industry.

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