Corrugated Cardboard Insert Market, Global Outlook and Forecast 2025-2032

MARKET INSIGHTS

Global corrugated cardboard insert market size was valued at USD 888 million in 2024 and is projected to grow from USD 928 million in 2025 to USD 1,186 million by 2032, exhibiting a CAGR of 4.3% during the forecast period. While the growth appears moderate compared to other packaging segments, the market remains essential across multiple industries due to its critical protective functions.

Corrugated cardboard inserts are protective packaging components designed to stabilize and cushion products during transportation and storage. These lightweight yet durable solutions consist of fluted paper sheets sandwiched between linerboards, creating a shock-absorbing structure that prevents product damage. Key variants include partitions, dividers, end caps, and custom-shaped inserts - all serving to immobilize packaged goods within outer containers.

The market growth is driven by several factors, including rising e-commerce activities requiring secure packaging, increasing demand for sustainable solutions, and growth in fragile product categories like electronics and glassware. The food and beverage sector currently dominates application segments, accounting for over 35% of market share, as corrugated inserts effectively protect packaged goods while meeting food safety requirements. Meanwhile, technological advancements in die-cutting and digital printing enable more complex, cost-effective insert designs.

MARKET DYNAMICS

MARKET DRIVERS

E-Commerce Boom Accelerates Demand for Protective Packaging Solutions

The exponential growth of e-commerce has become a primary driver for corrugated cardboard inserts. With global e-commerce sales projected to surpass $7 trillion by 2025, the need for effective product protection during shipping has intensified. Corrugated inserts provide cushioning, stability and compartmentalization, reducing damage rates in transit by up to 40% compared to unprotected shipments. Major retailers and logistics providers are increasingly specifying these solutions as standard packaging components, particularly for fragile electronics, glassware and pharmaceutical products where damage prevention is critical.

Sustainability Initiatives Favor Corrugated Over Plastic Alternatives

Corporate sustainability commitments and regulatory pressures are driving brands toward eco-friendly packaging solutions. Corrugated cardboard inserts offer a 93% recycling rate compared to just 14% for plastic foams, making them the preferred choice for environmentally conscious companies. The EU's Packaging and Packaging Waste Directive has set ambitious recycling targets of 70% for all packaging materials by 2030, further accelerating adoption. Leading consumer brands including Apple and Samsung have publicly committed to eliminating plastic from their packaging entirely within the next five years, creating substantial opportunities for corrugated solutions.

MARKET RESTRAINTS

Raw Material Price Volatility Impacts Profit Margins

The corrugated packaging industry faces ongoing challenges from fluctuating prices of key raw materials. After stabilizing at $650 per tonne in early 2023, old corrugated container (OCC) prices surged to nearly $900 per tonne by Q3 due to supply chain disruptions. These input cost increases have compressed manufacturer margins by 7-12% for standard insert products. While some costs can be passed through to customers, competitive pressures in mature markets limit pricing flexibility. The situation is exacerbated by rising energy costs, which account for 20-25% of total production expenses for corrugated manufacturers.

MARKET CHALLENGES

Design Limitations for Heavy or Irregularly Shaped Products

While corrugated inserts excel at protecting standard consumer goods, they face technical limitations with heavier industrial products. Items exceeding 50 pounds often require additional structural reinforcement that increases material usage by 30-40%, negating cost advantages over plastic or foam alternatives. Similarly, products with complex geometries frequently need custom die-cutting, which can extend lead times to 4-6 weeks compared to 1-2 weeks for standard configurations. These constraints limit adoption in sectors like automotive parts and industrial equipment where protective packaging remains essential.

MARKET OPPORTUNITIES

Emerging Markets Present Untapped Growth Potential

Developing economies represent a significant growth frontier as e-commerce penetration rises. While North America and Europe account for 65% of current market value, Southeast Asia and Latin America are projected to grow at 7.2% CAGR through 2030. Countries like Indonesia and Brazil, where 40% of shipments currently use inadequate packaging, offer particularly strong prospects. Localized production facilities combined with trade-friendly designs could capture this potential while avoiding the 25-35% import duties currently applied to finished packaging in some markets.

Segment Analysis:

By Type

Paper and Cardboard Segment Dominates Due to Its Eco-Friendly Properties and Wide Availability

The market is segmented based on type into:

• Paper and Cardboard

  • Subtypes: Single-face, Single-wall, Double-wall, Triple-wall

• Foam

  • Subtypes: Polyethylene, Polyurethane, Polystyrene

• Plastic

  • Subtypes: PET, PVC, Polypropylene

• Others

By Application

Food and Beverages Segment Leads Due to High Demand for Protective Packaging Solutions

The market is segmented based on application into:

• Food and Beverages

• Personal Care

• Pharmaceutical

• Electronics

• Others

COMPETITIVE LANDSCAPE

Key Industry Players

Strategic Partnerships and Sustainability Initiatives Drive Market Competition

The global corrugated cardboard insert market features a dynamic mix of established corporations and emerging players, all competing fiercely to capitalize on the growing demand for sustainable packaging solutions. While the market remains moderately fragmented, a handful of industry leaders dominate through extensive distribution networks, advanced manufacturing capabilities, and continuous product innovation. Mondi Group and DS Smith currently lead the segment, collectively holding over 25% of market share in 2024, primarily due to their vertically integrated operations across Europe and North America.

Smurfit Kappa Group has strengthened its position through strategic acquisitions, including recent expansions in South American markets. Meanwhile, International Paper Company maintains strong foothold in the U.S. market with its patented DuraBloc® partition systems that offer superior product protection. These leaders continue to invest heavily in automation and digital printing technologies to enhance production efficiency and customization capabilities.

Environmental sustainability has become a key differentiator in this space, with companies like Cascades and GWP Group pioneering fully recyclable inserts made from post-consumer waste. The industry has seen particular growth in pharmaceutical and electronics applications, where protective packaging requirements are most stringent. As e-commerce continues its upward trajectory, manufacturers are developing innovative designs specifically optimized for parcel shipping durability.

Regional players such as NEFAB Group in Europe and Mount Vernon Packaging in North America are expanding through specialized solutions for automotive and industrial components. The market also sees increasing competition from Asia-Pacific based manufacturers who offer cost-effective alternatives, though often with lower customizability. Product differentiation through advanced die-cutting technologies and value-added services (like just-in-time delivery) remains crucial for maintaining competitive advantage.

List of Key Corrugated Cardboard Insert Companies Profiled

• Mondi Group (UK)

• DS Smith (UK)

• Cascades (Canada)

• International Paper Company (U.S.)

• Innerpak (U.S.)

• Smurfit Kappa Group (Ireland)

• Mount Vernon Packaging (U.S.)

• Packaging Corporation of America (U.S.)

• Multicell Packaging (U.S.)

• Riverside Paper (U.S.)

• Storopack Hans Reichenecker GmbH (Germany)

• NEFAB Group (Sweden)

• GWP Group (UK)

CORRUGATED CARDBOARD INSERT MARKET TRENDS

Sustainability and Eco-Friendly Packaging Solutions Driving Market Growth

The global corrugated cardboard insert market is experiencing significant growth due to the rising demand for sustainable and eco-friendly packaging solutions. With increasing environmental regulations and consumer awareness, over 67% of companies are now prioritizing recyclable materials for their packaging needs. Corrugated cardboard inserts, being biodegradable and cost-effective, have become the preferred choice over plastic alternatives. Furthermore, advancements in manufacturing technologies have enabled the production of lightweight yet durable inserts, reducing transportation costs by up to 20% while maintaining product protection. The circular economy model is gaining traction, with 78% of packaging industry leaders investing in closed-loop recycling systems for corrugated materials.

Other Trends

E-Commerce Boom Accelerating Demand

The exponential growth of e-commerce has directly impacted packaging requirements, with corrugated cardboard inserts becoming indispensable for secure product transportation. Global e-commerce sales surpassed $5.7 trillion in 2023, creating unprecedented demand for protective packaging solutions. Inserts are particularly crucial for fragile items, electronics, and luxury goods, with shipping damage claims reduced by 35% when using properly designed corrugated solutions. Market leaders are developing innovative insert designs with enhanced cushioning properties and space optimization features to meet the specific needs of online retailers.

Technological Advancements in Customization and Digital Printing

The packaging industry is witnessing a revolution in digital printing and customization technologies for corrugated inserts. Advanced die-cutting machines now enable complex geometric designs with precision tolerances of ±0.5mm, allowing for perfect product fits. Digital printing on inserts has grown by 28% annually, enabling brands to incorporate logos, instructions, and marketing messages directly onto packaging components. Smart packaging integrations, including QR codes and NFC-enabled inserts, are creating new opportunities for customer engagement while maintaining the structural integrity of the packaging. These innovations are particularly valuable in pharmaceutical and electronics applications where both protection and information delivery are critical.

Automation and Smart Manufacturing Reshaping Production

The corrugated insert manufacturing sector is undergoing rapid automation, with 62% of major producers implementing AI-driven production lines in the past three years. Computer-aided design (CAD) systems have reduced prototyping times by 40%, while robotic assembly systems can now produce customized inserts on-demand with minimal human intervention. Industry 4.0 technologies are enabling real-time quality control through vision systems that detect defects with 99.8% accuracy. These advancements are particularly crucial as demand fluctuates across different sectors, allowing manufacturers to quickly adapt their production to meet varying industry requirements from food packaging to automotive components.

Regional Analysis: Corrugated Cardboard Insert Market

North America
The North American corrugated cardboard insert market benefits from a robust e-commerce sector and stringent sustainability regulations. With the U.S. e-commerce market projected to reach $1.6 trillion by 2027, demand for protective packaging solutions like corrugated inserts continues to rise. Major players such as International Paper Company and Packaging Corporation of America dominate the region, leveraging advanced manufacturing techniques to produce lightweight yet durable solutions. However, rising raw material costs and competition from alternative materials like molded fiber present challenges. The emphasis on recyclability and reduced packaging waste aligns with consumer preferences, driving innovation in eco-friendly designs.

Europe
Europe leads in sustainable packaging adoption, with corrugated cardboard inserts favored for their recyclability and compliance with EU Circular Economy Action Plan targets. Germany and France account for over 40% of regional demand, supported by strong manufacturing and pharmaceutical sectors. The region’s focus on reducing single-use plastics has accelerated the shift toward paper-based solutions. While premium-quality inserts command higher prices, cost sensitivity in Eastern European markets slows adoption rates. Recent investments in automation, particularly by Mondi Group and Smurfit Kappa, aim to improve production efficiency and meet growing demand from the food delivery and electronics industries.

Asia-Pacific
Asia-Pacific is the fastest-growing market, driven by China’s booming e-commerce sector and India’s expanding pharmaceutical exports. The region’s corrugated insert market thrives on cost-effectiveness and scalability, though quality variations persist in price-sensitive markets. Japan and South Korea prioritize high-performance inserts for electronics packaging, while Southeast Asian countries focus on food and beverage applications. Infrastructure gaps in recycling systems hinder sustainability efforts, but initiatives like China’s mandate for green packaging in logistics are gradually reshaping practices. Local manufacturers face pressure to balance affordability with global quality standards as multinational brands expand their foothold.

South America
South America’s market growth is tied to export-oriented industries like agriculture and automotive, where corrugated inserts protect perishables and components during transit. Brazil dominates regional demand, but economic volatility and import dependencies on raw materials create pricing uncertainties. While sustainability awareness is increasing, lower recycling rates compared to North America and Europe limit the adoption of premium eco-friendly solutions. Smaller-scale producers cater to local markets, but lack of standardization affects product consistency. Strategic partnerships with global suppliers could enhance technology transfer and stability in the long term.

Middle East & Africa
The MEA region shows nascent but promising growth, fueled by urbanization and investments in retail and logistics infrastructure. The UAE and Saudi Arabia lead demand, particularly for electronics and luxury goods packaging. However, harsh climatic conditions necessitate inserts with higher durability, often increasing production costs. Limited local manufacturing capacity forces reliance on imports, though regional players like NEFAB Group are expanding operations to address this gap. While environmental regulations remain underdeveloped, multinational corporations are gradually introducing sustainable packaging mandates, creating future opportunities for compliant suppliers.

Report Scope

This market research report offers a holistic overview of global and regional markets for the forecast period 2025–2032. It presents accurate and actionable insights based on a blend of primary and secondary research.

Key Coverage Areas:

• ✅ Market Overview

  • Global and regional market size (historical & forecast)

  • Growth trends and value/volume projections

• ✅ Segmentation Analysis

  • By product type or category

  • By application or usage area

  • By end-user industry

  • By distribution channel (if applicable)

• ✅ Regional Insights

  • North America, Europe, Asia-Pacific, Latin America, Middle East & Africa

  • Country-level data for key markets

• ✅ Competitive Landscape

  • Company profiles and market share analysis

  • Key strategies: M&A, partnerships, expansions

  • Product portfolio and pricing strategies

• ✅ Technology & Innovation

  • Emerging technologies and R&D trends

  • Automation, digitalization, sustainability initiatives

  • Impact of AI, IoT, or other disruptors (where applicable)

• ✅ Market Dynamics

  • Key drivers supporting market growth

  • Restraints and potential risk factors

  • Supply chain trends and challenges

• ✅ Opportunities & Recommendations

  • High-growth segments

  • Investment hotspots

  • Strategic suggestions for stakeholders

• ✅ Stakeholder Insights

  • Target audience includes manufacturers, suppliers, distributors, investors, regulators, and policymakers

FREQUENTLY ASKED QUESTIONS:

What is the current market size of Global Corrugated Cardboard Insert Market?

-> Global corrugated cardboard insert market was valued at USD 888 million in 2024 and is projected to reach USD 1,186 million by 2032, growing at a CAGR of 4.3% during the forecast period.

Which key companies operate in Global Corrugated Cardboard Insert Market?

-> Key players include Mondi Group, DS Smith, Cascades, International Paper Company, Smurfit Kappa Group, Packaging Corporation of America, and GWP Group, among others.

What are the key growth drivers?

-> Key growth drivers include rising e-commerce activities, demand for sustainable packaging solutions, and increasing focus on product protection during transportation.

Which region dominates the market?

-> Asia-Pacific holds the largest market share (over 35% in 2024), driven by manufacturing growth in China and India, while North America shows strong adoption of innovative packaging solutions.

What are the emerging trends?

-> Emerging trends include custom-designed inserts, recycled material usage, automation in insert manufacturing, and integration of smart packaging technologies.