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US Pallet Market

  • August 2015
  • -
  • Freedonia
  • -
  • 317 pages

US pallet stock to reach 2.6 billion units by 2019

The total number of pallets in use in the US will increase 1.9 percent annually through 2019 to 2.6 billion units, supported by gains in US manufacturing and warehousing activity. Demand for pallets is forecast to expand 1.7 percent per year through 2019 to 1.4 billion units. When production activity and shipments fell during the 2007-2009 economic recession, pallet users had a significant number of pallets sitting idle and opted to utilize the pallets on hand to satisfy product handling requirements, purchasing pallets only when absolutely necessary. This lowered the overall quality of pallet stocks, as pallets were not repaired or replaced at normal intervals. When the economy recovered, users began to replace these pallets in disrepair with new units, resulting in pallet demand gains of nearly nine percent per annum between 2009 and 2014.

Wood to remain dominant pallet material

Wood will remain the most widely used material, comprising 84 percent of total pallet stocks in 2019 and 93 percent of the sales in unit terms. Wood strikes a balance between low cost and high durability and is suitable for use in most applications. However, because wood already accounts for such a large share of the total pallet market, opportunities for additional growth will be limited through 2019. On the other hand, materials such as plastic and metal, which account for substantially smaller shares of pallet unit demand, will record stronger market gains. Plastic is becoming particularly important in the food and beverage and pharmaceutical industries because of its resistance to biological and fungal infestation.

Table Of Contents

US Pallet Market
INTRODUCTION xi
I. EXECUTIVE SUMMARY 1
II. MARKET ENVIRONMENT 4
General 4
Macroeconomic Environment 4
Consumer Income and Spending 8
Demographic Trends 11
Construction Outlook 15
Manufacturing Outlook 18
Plastic Resin Outlook 21
Plastic Foam Characteristics 25
Competitive Materials 27
Blowing Agents 28
Environmental and Regulatory Considerations 30
Materials-Based Regulation 30
Energy-Based Regulation 34
Recycling 35
International Activity 37
III. MARKETS 40
General 40
Packaging 42
Plastic Foams Demand by Resin and Application 42
Foodservice and Consumer Disposables 45
Foodservice Disposables Market Outlook 46
Plastic Foam Foodservice and Consumer Disposables 49
Protective Packaging 58
Protective Packaging Market Outlook 58
Plastic Foam Protective Packaging 61
Molded Foam 64
Rolled Foam 67
Foam-in-Place 70
Loose-Fill and Other Foam 73
Containers 77
Food Container Market Outlook 78
Plastic Foam Containers 79
Construction 86
Plastic Foams Demand by Resin and Application 86
Insulation 89
Construction Insulation Market Outlook 90
Plastic Foam Insulation 92
Flooring and Carpet Backing 96
Carpet and Rug Market Outlook 96
Plastic Foam in Flooring and Carpet Backing 98
Other Construction 100
Household Products 103
Plastic Foams Demand by Resin and Application 103
Bedding 105
Bedding Industry Outlook 105
Plastic Foams in Bedding 107
Furniture 109
Furniture Industry Outlook 110
Plastic Foams in Furniture 111
Appliances 113
Major Appliance Industry Outlook 113
Plastic Foams in Appliances 114
Other Household Products 116
Motor Vehicles 118
Motor Vehicle Outlook 119
Plastic Foams Demand 121
Other Markets 123
IV. PRODUCTS 127
General 127
Demand by Resin 127
Pricing Trends 130
V. POLYURETHANE FOAMS 133
General 133
Flexible Polyurethane Foams 135
Household Products 138
Bedding 139
Furniture 141
Textiles 142
Motor Vehicles 143
Flooring Underlay 144
Packaging 147
Other Markets 148
Rigid Polyurethane Foams 150
Construction 152
Demand by Segment 153
Demand by Type 154
Household Products 156
Appliances 157
Other Household Products 158
Packaging 159
Motor Vehicles 160
Other Markets 161
Producers 163
VI. POLYSTYRENE FOAMS 166
General 166
Extruded Polystyrene Foams 169
Packaging 171
Dinnerware 172
Clamshells 173
Meat, Seafood, and Poultry Trays 173
Lunch Trays 174
Egg Cartons 174
Construction 175
Other Markets 177
Expanded Polystyrene Foams 178
Packaging 181
Drinking Cups 182
Molded Foam Protective Packaging 183
Insulated Shipping Containers 184
Loose-Fill 184
Other 185
Construction 185
Other Markets 188
Producers 189
VII. OTHER PLASTIC FOAMS 191
General 191
Polypropylene Foams 193
High Density Polyethylene Foams 196
Engineering Plastic Foams 198
Vinyl Foams 202
Low Density Polyethylene Foams 205
Acrylonitrile-Butadiene-Styrene Foams 208
Biodegradable Plastic Foams 210
All Other Plastic Foams 213
VIII. INDUSTRY STRUCTURE 217
General 217
Market Share 219
Mergers and Acquisitions 223
Marketing and Distribution 227
Research and Development 228
Competitive Strategies 229
Cooperative Agreements 231
Company Profiles 235
ACH Foam Technologies LLC 236
American Excelsior Company 239
Arkema SA 241
Armacell International Holding GmbH 243
Atlas Roofing, see Hood Companies
BASF SE 245
Bayer AG 249
Berkshire Hathaway Incorporated 252
Bridgestone Corporation 254
Carlisle Companies Incorporated 256
Carpenter Company 259
CertainTeed, see Saint-Gobain
Crest Foam Industries, see INOAC
Dart Container Corporation 263
Dolco Packaging, see Tekni-Plex
Dow Chemical Company 266
DuPont (EI) de Nemours 270
Evonik Industries AG 273
Firestone Building Products, see Bridgestone
Flexible Foam Products, see Ohio Decorative Products
Free-Flow Packaging International Incorporated 275
FXI Incorporated 276
Hood Companies 280
Hunter Panels, see Carlisle Companies
Huntsman Corporation 282
INOAC Corporation 284
Insulfoam, see Carlisle Companies
Inter-Pac, see Pregis
Johns Manville, see Berkshire Hathaway
Johnson Controls Incorporated 287
New WinCup Holdings Incorporated 288
Noël Group LLC 290
Nomaco, see Noël Group
Nomacorc, see Noël Group
Ohio Decorative Products Incorporated 292
Owens Corning 294
Oxid, see Huntsman
Packaging Alternatives, see UFP Technologies
Pactiv, see Reynolds Group
Pak-Lite Incorporated 295
Pregis Corporation 296
Protexic Brands, see Sonoco Products
RAPAC, see Ring Companies
Reynolds Group Holdings Limited 299
Ring Companies 302
Rmax Incorporated 303
Rogers Foam Corporation 305
Rubicon, see Huntsman
Saint-Gobain 306
Schweiter Technologies AG 309
Sealed Air Corporation 311
Sekisui Chemical Company Limited 313
Solo Cup, see Dart Container
Solvay SA 314
Sonoco Products Company 316
StarchTech Incorporated 318
Storopack Hans Reichenecker GmbH 319
Tegrant, see Sonoco Products
Tekni-Plex Incorporated 321
3A Composites International, see Schweiter Technologies
3M Company 322
UFP Technologies Incorporated 325
WineLoc Packaging Products, see ACH Foam
Technologies
Other Companies Mentioned in Study 328
Summary Table 3
SECTION II -- MARKET ENVIRONMENT
1 Macroeconomic Indicators 8
2 Personal Consumption Expenditures 11
3 Population and Households 15
4 Construction Expenditures 18
5 Manufacturers' Shipments 21
6 Plastic Resin Supply and Demand 24
SECTION III -- MARKETS
1 Plastic Foams Demand by Market 41
2 Packaging Market for Plastic Foams by Resin and Application 44
3 Foodservice Disposables Demand by Type 49
4 Foodservice and Consumer Disposables Market
for Plastic Foams 50
5 Protective Packaging Demand by Material 61
6 Protective Packaging Market for Plastic Foams
by Resin and Type 63
7 Molded Foam Protective Packaging Demand 67
8 Rolled Foam Protective Packaging Demand 70
9 Foam-in-Place Protective Packaging Demand 73
10 Loose-Fill and Other Foam Protective Packaging Demand 77
11 Food Container Demand by Type 79
12 Container Market for Plastic Foams 80
13 Construction Market for Plastic Foams by Resin and Application 88
14 Construction Insulation Demand by Type 91
15 Construction Insulation Market for Plastic Foams 95
16 Carpet and Rug Supply and Demand 98
17 Flooring and Carpet Backing Market for Plastic Foams 100
18 Other Construction Markets for Plastic Foams 102
19 Household Product Market for Plastic Foams by Resin
and Application 104
20 Mattress and Sleep System Shipments 107
21 Bedding Market for Plastic Foams 109
22 Furniture Shipments 111
23 Furniture Market for Plastic Foams 112
24 Major Appliance Shipments 114
25 Appliance Market for Plastic Foams 116
26 Other Household Product Markets for Plastic Foams 118
27 Motor Vehicle Production 121
28 Motor Vehicle Market for Plastic Foams by Resin 123
29 Other Markets for Plastic Foams 126
SECTION IV -- PRODUCTS
1 Plastic Foams Demand by Resin 129
2 Selected Plastic Foams Pricing 132
SECTION V -- POLYURETHANE FOAMS
1 Polyurethane Foams Demand by Type and Market 135
2 Flexible Polyurethane Foams Demand by Market 137
3 Household Product Market for Flexible Polyurethane Foams 139
4 Motor Vehicle Market for Flexible Polyurethane Foams 144
5 Flooring Underlay Market for Flexible Polyurethane Foams 146
6 Packaging Market for Flexible Polyurethane Foams 148
7 Other Markets for Flexible Polyurethane Foams 149
8 Rigid Polyurethane Foams Demand by Market 151
9 Construction Market for Rigid Polyurethane Foams 153
10 Household Product Market for Rigid Polyurethane Foams 157
11 Packaging Market for Rigid Polyurethane Foams 160
12 Motor Vehicle Market for Rigid Polyurethane Foams 161
13 Other Markets for Rigid Polyurethane Foams 163
SECTION VI -- POLYSTYRENE FOAMS
1 Polystyrene Foams Demand by Processing Method and Market 168
2 Extruded Polystyrene Foams Demand by Type and Market 170
3 Packaging Market for Extruded Polystyrene Foams 172
4 Construction Market for Extruded Polystyrene Foams 176
5 Other Markets for Extruded Polystyrene Foams 178
6 Expanded Polystyrene Foams Demand by Market 180
7 Packaging Market for Expanded Polystyrene Foams 182
8 Construction Market for Expanded Polystyrene Foams 187
9 Other Markets for Expanded Polystyrene Foams 189
SECTION VII -- OTHER PLASTIC FOAMS
1 Other Plastic Foams Demand by Resin 192
2 Polypropylene Foams Demand by Market 195
3 High Density Polyethylene Foams Demand by Market 198
4 Engineering Plastic Foams Demand by Market 202
5 Vinyl Foams Demand by Market 205
6 Low Density Polyethylene Foams Demand by Market 207
7 Acrylonitrile-Butadiene-Styrene Foams Demand by Market 209
8 Biodegradable Plastic Foams Demand by Market 213
9 All Other Plastic Foams Demand by Market 216
SECTION VIII -- INDUSTRY STRUCTURE
1 US Plastic Foam Sales by Company, 2012 218
2 Selected Acquisitions and Divestitures 226
3 Selected Cooperative Agreements 233

LIST OF CHARTS
CHART NUMBER PAGE
1 Plastic Foams Demand by Market, 2012 42
2 Packaging Market for Plastic Foams by Application, 2012 45
3 Protective Packaging Market for Plastic Foams by Resin,
2012 64
4 Construction Market for Plastic Foams by Application, 2012 89
5 Household Product Market for Plastic Foams by Application,
2012 105
SECTION IV -- PRODUCTS
1 Plastic Foams Demand by Resin, 2012 130
SECTION V -- POLYURETHANE FOAMS
1 Flexible Polyurethane Foams Demand by Market, 2012 138
2 Rigid Polyurethane Foams Demand by Market, 2012 151
SECTION VI -- POLYSTYRENE FOAMS
1 Polystyrene Foams Demand by Processing Method, 2012 169
2 Extruded Polystyrene Foams Demand by Market, 2012 170
3 Expanded Polystyrene Foams Demand by Market, 2012 180
SECTION VII -- OTHER PLASTIC FOAMS
1 Other Plastic Foams Demand by Resin, 2012 193
SECTION VIII -- INDUSTRY STRUCTURE
1 US Plastic Foams Market Share, 2012 220

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