Journey Through 75 Years
For 75 years, the Flexible Packaging Association has been at the heart of the flexible packaging industry, driving innovation, shaping public policy, and fostering collaboration across the supply chain. What began as a vision among industry pioneers has evolved into a dynamic force that continues to lead with resilience, ingenuity, and an unwavering commitment to progress.
As we reflect on our history, we also look ahead to the future—one filled with new opportunities to push the boundaries of what’s possible. Join us in celebrating the people, milestones, and innovations that have shaped the past 75 years and will continue to define the decades to come.
Even the most knowledgeable observer struggles to grasp how far our nation has come since July 19, 1950, when the National Flexible Packaging Association (NFPA) was founded. Harry Truman was president, and the U.S. was engaged in the Korean War. Less than a year earlier, the Soviet Union detonated its first atomic bomb, breaking America’s nuclear monopoly. After World War II, the U.S. emerged as the world’s strongest nation and economy. By 1950, American industry was growing, yet companies faced significant challenges in securing raw materials and accessing civilian markets.
One of the greatest challenges during the Association’s early years was to be effective without violating the government’s antitrust laws. The issue, common to all industrial organizations, concerned NFPA as it matured.
As the years passed, the NFPA’s relationship with the government evolved into one based on cooperation and regulation. The NFPA continued to seek areas where voluntary cooperation could address industry-wide concerns without violating the letter or spirit of antitrust laws. In this way, the Association literally created its own mission, a task that continues today.
Recognizing a need for improved communication and cooperation between packaging manufacturers and suppliers, the National Flexible Packaging Association (NFPA) was incorporated in Chicago, IL, by Bagcraft Corporation’s founder and first Chair, Albert A. Meister, Oneida Paper Products, R. E. Pentz, and Milprint’s R. E. Hanson. Hanson was named NFPA’s first President, and its offices were located in the home of executive secretary R. K. Vinson.
In addition to the founders’ companies, Paramount Paper Products, Union Bag and Paper, American Paper Goods, Columbia Paper Products, and Comet Envelope and Paper Company also joined in the creation of NFPA.
Initially, extruders were built vertically to save space, operating under the assumption that a vertical flow was the simplest method since the film needed to go upwards. Today, we recognize that the vertical positioning of extruders resulted in a loss of critical length or height for the film.
Photo courtesy of Reifenhäuser: Vertical extruder “SV 050.1” for film lines
The first industrial vacuum bag packagers appeared in the 1940s but didn’t become commercially widespread until the 1950s.
The development of catalysts that promoted polymerization led to increased commercialization of polyethylene. The demand for PE grew from 5 million pounds annually to 1.2 billion pounds annually by the end of 1960.
Campbell Wrapper introduced the first horizontal flow wrapper in the U.S. It was used worldwide to wrap candy, chocolates, crackers, cheese, baked goods, and other products.
Photo courtesy of PMMI's "Pack to the Future"
John M. Cowan was appointed the Association’s first Managing Director, and the office was moved to Chicago, IL. Having worked in the packaging industry for over twenty years, Cowen’s experience was split between the Cellophane Division of DuPont and the Dobeckmun Company of Cleveland, OH.
The NFPA headquarters were moved from Chicago to Cleveland, Ohio. Cleveland was an ideal location for the newly formed group. The largest groups of NFPA members were in the metropolitan areas surrounding New York and Chicago, and Cleveland was midway between the two.
1951 Board of Directors
The First Annual Meeting was held in New York City at the Hotel Astor.NFPA had more than 50 members, generating an annual volume of $150,000,000 in the flexible packaging field. By 1952, the membership increased by approximately 70 percent. At the meeting, James P. Duffy was officially elected as the NFPA’s first-ever Chair and leader.
Associates (suppliers) are admitted to NFPA membership
Michigan State establishes the first Packaging School in its Forest Products department. In 1957, it became an independent school.
- At a meeting held in Atlantic City, the Association appointed the Technical Committee on Specification Packaging “to cooperate with the government in solving flexible barrier problems.”
- John M. Cowan, NFPA’s managing director, warned that polyethylene (PE) bags are too thin. The committee, in cooperation with The Society of the Plastics Industry, Inc., advised converters to identify polyethylene gauge from suppliers on every order and urged suppliers to include film gauges on all invoices and packages.
- During their annual meeting in New York, 60 converters unanimously supported the resolution, marking the first step toward voluntary polyethylene film standards.
In the early 1950s, the Association combined efforts with the United Fresh Fruit and Vegetable Association and the U.S. Department of Agriculture (USDA) to measure the effect that prepackaging had on the sale of lettuce, the marketing of seedless grapes in cellophane bags, and the commercial possibilities for harvesting nearly ripe peaches, further ripening them under controlled temperature and humidity, and prepackaging them in consumer packages for immediate distribution.
During this time, the ongoing Korean conflict tempered the energy and prosperity of the post-World War II era. The military buildup in Korea created shortages of certain flexible materials for civilian use. NFPA monitored the availability of these materials and advised the industry accordingly. Each year, NFPA announced the projected capacity and availability of key materials while advising its members on how to remain financially healthy.
Minigrip resealable bags were invented.
American chemist William R. Scholle invented the first commercial bag-in-box packaging system for transporting and dispensing battery acid. Scholle later teamed up with scientists from Purdue University to combine bag-in-box technology with Phil Nelson’s work on aseptic storage. Their work paved the way for new food preservation and packaging systems. In 1991, Scholle was inducted into PMMI’s Packaging Hall of Fame.
Photo courtesy of PMMI’s “Pack to the Future”
NFPA initiated its inaugural Packaging Awards (now Achievement Awards) competition in collaboration with the magazine Paper, Film, and Foil Converter. Six judges evaluated entries and chose the top packages across sixteen categories. The Packaging Machinery Manufacturers Institute (PMMI) showcased the winning designs at the inaugural Packaging Machinery and Materials Exposition in Cleveland.
Quaker Oats Company’s Aunt Jemima Corn Bread Mix package, produced by Reynolds Metals Co., received the President’s Award for the best package.
Printpack acquired its first bag machine. John Samples, Printpack’s first employee, stood by the machine in 1956 and later in 2022 when it was installed in the headquarter’s lobby. This machine produced clear cellophane bags for the snack industry. At the time, the film wasn’t printed; instead, a pressure-sensitive label was affixed to the bag for branding and ingredient information.
Photo courtesy of Printpack
Traveling sales case containing solvent-based flexo inks. Photo courtesy of Sun Chemical Corporation.
NFPA held its Annual Meeting in Boca Raton, FL, for the first time. This location was extremely popular and became a regular meeting site for the next 30 years. While much business was conducted at these Annual Meetings, they also provided an opportunity for competitors, customers, and suppliers to meet socially.
Rovema manufactured the first Vertical/Form/Fill/Seal machine with rotating belts in the market. In the early 1960s, this machine was used to package boil-in-bag rice.
The 1960s marked a period of transformation for the nation, the flexible packaging sector, and the NFPA. By the end of the decade, changes had occurred in membership, leadership, and even the NFPA logo. At the same time, American society began to focus on issues such as space exploration, environmental protection, and civil rights. These emerging concerns were reflected in NFPA initiatives. Unlike the technical emphasis of the 1950s, the Association’s education and information programs shifted toward human factors, prioritizing topics like effective communication and employee relations safety.
The Laminated Foil Manufacturers Association, Industrial Bag and Cover Association, and the Waxed Paper Institute merge into NFPA.
Blown film and shrink film technology expanded. Initially, the design of blown film plants was purely functional, with no aesthetic considerations—performance and output were the primary concerns. At this time, only single-layer films were available. Multilayer barrier films, now common for protecting sensitive products, had not yet been developed.
- From Glass and Metal to Plastic: The market experienced a revolution as plastic packaging offered an alternative to traditional glass and metal containers. Plastic bags were a novel concept, completely transforming the packaging industry.
- Protection Against Moisture: Plastic films provided a new solution for moisture-sensitive products, enabling safe and dry packaging previously unattainable with other materials.
The Rovema Vertical/Form/Fill/Seal machine was built to package boil-in-bag rice. In 1959, Rovema manufactured the first Vertical/Form/Fill/Seal machine with rotating belts in the market.
New ways and approaches had to be developed to achieve a relatively high orientation of the film within reasonable and workable extrusion conditions, yet without the need for expensive orientation equipment.
A system that integrated blown shrink film extrusion with a market-proven, high-efficiency shrink film oven was developed. The high-efficiency shrinkage oven consisted of a centrally located heating register above the shrink chamber to ensure a maximum supply of constant temperature, which is vital during shrink operations.
It wasn’t only blown film extrusion that picked up speed in the 1960s, but also flat film extrusion. For example, the production of relatively simple flat bags was characterized by their particularly good sealability.
Individually quick frozen vegetables (IQF) were introduced in flexible packages.
Blister Packs were invented by David Wagner for his design of oral contraceptive packaging. When “the Pill” was first introduced in 1960, it was packaged in small glass bottles, similar to other pharmaceuticals.
Wagner and his wife, who had four children, wanted a memory-aid that would help indicate when the contraceptive should start being taken each month and a daily reminder. He designed the cases to be small enough to carry discreetly in a purse and have push through holes that indicated when a pill was taken. He was awarded a patent in 1964.
Wagner’s prototypes for his patent application for the first blister packaging for oral contraceptives. Photo courtesy of the Smithsonian, National Museum of American History.
A small firm developed the AMF Mark 50 Bread Bagger, which transformed bread processing and shifted the baking industry’s practices from roll-fed overwrapping to polyethylene bags for bread and bakery items.
French inventor Louis Doyen invented the stand-up pouch. Doyen named and trademarked his invention, the Doypack. The stand-up pouch has become a popular flexible package that has continued to evolve with new materials, designs, retorts, and packaging equipment.
Kellogg's Corn Flakes® launched a semi-automatic packaging line.
Photo courtesy of PMMI’s “Pack to the Future”
The U.S. Department of Defense (DOD) begins developing Meals Ready to Eat (MREs), a ration that would rely on modern food preparation and packaging technology to create a lighter replacement for C rations. Early prototypes used freeze-dried and dehydrated foods that required rehydration. Continued research led to the development of the first retort pouch, which became special issue MREs in 1981.
Form/Fill/Seal machines that form a paper bag from a continuous roll, fill it with the proper amount of product, then seal the bag and cut it from the packaging roll in one process enter the market.
The NFPA logo was updated from its original circular design to an oval. The new logo was officially adopted at the 1966 Annual Meeting.
E. C. (Pete) Merkle became the Association’s Managing Director, and John M. Cowan was named an NFPA consultant. Under Cowan’s direction, converter membership had grown to 103, representing more than 75 percent of the industry’s volume, and associate members numbered 42.
In the mid-1960s, Totani was approached by a major Japanese packaging manufacturer who wanted to develop pouches for a newly created technology by the United States Army. This new product was a flexible package, originally a two-layer polyethylene terephthalate (PET)/PE film and later a three-layer (PET/Aluminum Foil/PE) film, that could handle aseptic processing. This is commonly known now as a “retort pouch.” In 1967, Totani developed the “H-510” pouch making machine to manufacture these retort pouches. In 1968, this machine was used to produce the first commercially available retort pouches. The “Bon Curry” product by Otsuka Foods Company of Japan then became the first retort food product in the world.
Photo courtesy of Totani America
Cowan was named a “Life Member” for his accomplished career as the NFPA’s first Managing Director.
Food storage bags, Ziploc's® were first used.
Polypack designs and builds the first bucket machine to shrink-wrap unstable products. The bucket machine proved to be a simple and effective way to convey products that would otherwise resist traveling in groups.
Space Food Sticks were introduced to consumers in 1969.
Photo courtesy of General Mills Historical Archives
“The birth of Earth Day in 1970 marked a new regulatory era for American industry,” recalled Glenn Braswell, FPA president from 1986 to 1999. “This landmark event,” Braswell said, “set up a whole new political, social, and legal system that required American businesses to accept greater environmental responsibility for their products and manufacturing operations.” The first nationwide observance of Earth Day occurred on April 22, 1970, and its effects were felt throughout that decade, into the 1980s and the 1990s.
The government’s recognition of its mission to protect the environment was also increasing. The U.S. Environmental Protection Agency (EPA) was established in 1970 with the mandate to set and enforce standards for air and water quality, while working to reduce noise pollution, radiation hazards, and exposure to pesticides and other potentially toxic substances.
An environmentally conscious government, reflecting growing public awareness, would challenge American businesses to improve performance. NFPA was ready to meet this challenge, focusing on education to shape public perceptions and equip members as better industry advocates.
Reifenhäuser introduces the first Reifocol automatic control, microprocessor RMP 80, featuring operating and monitoring components. The initial advantages of this automation include a reduced start-up time, time savings in changing film dimensions, and the elimination of scrap.
Photo courtesy of Reifenhäuser
The introduction of multilayer films, also known as coextrusion films, was a significant advancement in the packaging industry, as it enabled the extension of food shelf life, improved product protection, and reduced the need for preservatives. This technology has continued to evolve and is now a standard in many packaging applications.
Amstar was the first flexible packaging company to provide and use “portion controlled” packaging for the flexible market. Amstar partnered with Domino to create the very first single-portion packaging that allowed consumers to use the amount they needed and keep waste to a bare minimum.
Pioneers Hell and Crosfield introduced drum scanning technology, allowing converters to gain access to precise, high-quality image reproduction capabilities, setting a new standard for pre-press workflows. These advanced scanners provided unparalleled image quality, becoming indispensable for pre-press workflows. They enabled precise reproduction of photographic materials, critical for packaging artwork.
Water-based inks are created.
Under the direction of NFPA’s Executive Vice President, Ralph March, NFPA took steps to notify the government of the potential ramifications of shortages. A letter sent to the Commissioner of the Federal Energy Office stated the industry’s concerns regarding the energy crisis and the consequences the industry would face if the petrochemical sector did not receive an adequate supply of petroleum feedstocks.
Acknowledging the power of a unified voice, the Association established a foundation to address increasingly important environmental issues. With public attention centered on recycling and the environmental impacts of nearly every type of product, the Association crafted a formal policy statement to guide the industry’s response to these new pressures.
Recycling symbol introduced. The symbol was created by 23-year-old student Gary Anderson as an entry for a graphic design competition organized by the Container Corporation of America. The Recycling Symbol is available for anyone to use, although product labeling laws limit its application use.
Whereas, the National Flexible Packaging Association is committed to excellence and industry leadership in environmental improvement; and
Whereas, the Association and its member companies support federal standards for environmental quality and the reasonable uniform enforcement of these standards on both state and regional levels; and
Whereas, the Association and its members believe that satisfactory environmental conditions and products can be achieved only by the concerted action of the flexible packaging making and using industries and the public through its various governments;
Be It Therefore Resolved: That the Association and its both classes of members will, to the best of their ability conduct and support research relating to the environmentally sound production of our products and to the improved disposability or recyclability of them;
Further, the Association and its members will acquaint itself with developments in the compacting, recycling, and incineration industries and, where possible, support developments in those or other industries which would tend to lessen the overall solid waste burden;
Finally, the Association of itself and through the actions of its individual members will make known to concerned public current/ acts on our industry and its practices so as to encourage a full range or understanding and action on a given environmental subject.
American Packaging Corporation’s Columbus, Wisconsin location utilized its slitter machine to slit Cascade® detergent rollstock and Ivory soap wrap. Still used today, this specialized piece of equipment is designed to cut large rolls of flexible packaging materials, such as film, paper, or foil, into narrower, more manageable rolls.
American Packaging Corporation’s slitter machine cutting Cascade® detergent rollstock
In the early 1970s, a cut-off of oil shipments from Middle Eastern producers caused a nationwide energy crisis, with visible consequences like gasoline rationing and long service station lines. The flexible packaging industry faced similar challenges, as material availability became a concern again, reminiscent of the 1950s. The Association resumed monitoring raw material availability and projecting the supply of converted materials.
Photo courtesy of Owen Franken/Corbis Historical/Getty Images
Pat and Bill Lancaster introduced the first stretch wrapping machines to unitize products on pallets, launching Lantech.
Cyrel® flexographic plates were the first photopolymer plate for flexographic printing which significantly improved durability and print consistency, setting a new standard in flexographic printing.
Amstar’s engineers worked to enhance packaging for the 1980s. Amstar provides DominAde with a more robust structure that not only protects the product but reduces machine sealing temperatures and allows for faster production speeds.
Photo courtesy of AMGRAPH Packaging, Inc.
Pete Merkle resigned as the Association’s Managing Director. Richard Lillquist becomes FPA President.
Although the retort pouch was invented in the 1960s, the United States Army Natick R&D Command, Reynolds Metals Company, and Continental Flexible Packaging collaborated on an ongoing effort to enhance retort pouches, particularly MRE rations that were lightweight, had a long shelf life, and could be opened and consumed directly from the package when necessary.
MREs in retort pouches. Source: U.S. Army Natick Soldier Research, Development & Engineering Center, Public Domain.
DOWLEX™ Polyethylene Resins – One of the first commercially successful LLDPE resins, the family of DOWLEX™ resins has been a multi-application workhorse for the flexible packaging industry for almost 50 years.
Throughout the 1980s, as the flexible packaging industry experienced significant advancements—such as the introduction of coextrusion technology, expanded use of barrier films, and the growth of stand-up pouches—the FPA supported these developments by fostering collaboration among manufacturers, suppliers, and stakeholders.
The FPA’s enduring mission to support the growth and innovation of the flexible packaging industry adapted to evolving trends and challenges throughout the decade.
PET plastic packaging for hot food becomes available.
The first 8-color CI press was installed in the United States in the early 1980s. The 8-color flexo press technology later became the standard for printing and offered a more cost-effective yet high quality option to compete with rotogravure printing. While rotogravure remains a viable technology today, the evolution of flexo technology, beginning with the wide-web 8-color press, established flexo as the preferred printing method for most flexible packaging converters from the 1980s onward.
These Dr. Pepper® labels demonstrated how the introduction of inkjet technology for labels unlocked endless promotions and gaming opportunities for major brands. The randomization of the codes enabled the label image to be printed on a large flexo press while allowing each label to feature a unique code or number for promotions or games.
The development of metalized oriented polypropylene (OPP) became a standardized structure for salted snacks in the 70s and 80s, allowing for extended shelf life for products with high oil content that needed oxygen and moisture barrier.
1980s Metalizer. Photo courtesy of Printpack.
Extrusion lamination was a significant advancement for the flexible packaging industry, allowing two films to be laminated together while adding bulk to the packaging. This innovation provided a more cost-effective solution compared to a lamination with a similar total gauge, while also delivering improved puncture resistance and a reduced tendency to tear upon opening.
FPA headquarters moved from Cleveland to Vermont Avenue, NW in downtown Washington, D.C. to be closer to decision-making politicians and other powerful associations.
Fres-co System USA, Inc. launches its first retail flexible coffee package, the Vacuum Brick.
The Association published an informational pamphlet, "Packaging, Who Needs It?" The brochure outlined the general benefits of packaging, with a particular focus on flexible packaging. It was presented in a question-and-answer format and addressed questions such as:
What would happen to America without packaging?
Does packaging waste energy?
Does packaging cause solid waste problems?
Is packaging an expensive luxury?
Johnson & Johnson introduces first triple tamper-evident seals on a consumer product package after TYLENOL® Extra Strength Capsules are tampered with in the Chicago area.
Photo courtesy of PMMI's "Pack to the Future"
The multilayer films were further developed using an upstream distribution block and a spiral mandrel distribution system, which ensured a uniform melt flow for all layers. As environmental awareness grew and the need to reduce production waste became more apparent, recycling extruders gained importance.
Recycling extruders enabled the grinding, melting, and reintroduction of edge trims, off-spec batches, and other waste back into the production process, often without the material having to leave the facility. This not only contributed to cost efficiency but was also a step towards more sustainable production practices, as less waste had to be sent to landfills or recycling facilities.
The Sealstrip easy open and easy reseal innovation significantly impacted the frozen meat industry by introducing resealable bags, enhancing consumer convenience, boosting labor productivity by 35%, reducing material costs, and improving product shelf life, thus providing a competitive edge and setting new packaging standards.
Amstar utilizes its web offset printing to deliver superior quality for short-run quantities, alongside low upfront tooling costs, providing Concord Foods the competitive edge they sought.
Advances in automation and computer-aided process control led to more consistent and higher quality products. Sensors and control technology enabled more precise control of film thickness and material distribution.
Ohio Gravure Technologies launched digital engraving machines for gravure cylinders. It revolutionized gravure printing with precise, efficient cylinder engraving directly from digital data.
Photo courtesy of eProductivity Software
The Web Society is established to honor retired industry leaders for their years of service to the industry and the Association.
FPA forms The Plastic Grocery Sack Council. Led by Jeffrey Siebenaller, its main role was to facilitate supermarkets’ move toward the plastic grocery sack.
The full-scale public relations campaign, “Check out the Sack. It’s coming on Strong,” emphasized benefits such as lower operating, labor, storage, and transportation costs, as well as superior convenience, strength, and carrying ease for the consumer. The public relations kits were targeted at 100 trade media outlets and 600 general consumer media outlets, as well as government officials.
Flexible packaging is exempted from environmental legislation for recycling.
FPA sponsors the first government relations conference to help members successfully communicate with Congress.
The Fres-co Industrial Bag became the flexible replacement for rigid packages such as fiber drums, plastic drums, poly box-in-box, or other bags such as kraft paper poly bags or polywoven bags, designed for dry products.
Color management systems standardized color reproduction across devices and workflows, ensuring consistency in flexible packaging outputs, thereby maintaining brand identity in flexible packaging.
As FPA and the country entered the 1990s, a revolution in information exchange began. Faxes, modems, and email became routine tools for conducting business. FPA had always focused on providing information to its members, but during the 1990s, the audience for these services and the information conveyed grew dramatically, along with the media used for information delivery.
The Association not only offered comprehensive and complex information about technology, industry statistics, trends, laws, and regulations to its members but also delivered information to legislators, regulators, educators, and the general public.
Throughout the 1990s, environmental legislation and regulation were still a significant concern to the flexible packaging industry. Representatives from the Association and the industry worked to provide regulators with information to assure that whatever rules were adopted would carry out the intent of the law, without stifling the ability to do business.
In 1990, the Clean Air Act Amendments identified 189 Hazardous Air Pollutants (HAPS) and instructed EPA to set emissions standards for each of them. EPA was also instructed to establish categories of similar types of “major sources” and establish Maximum Achievable Control Technologies (MACTs) for each.
The concept of extended producer responsibility (EPR) was first formally introduced by Thomas Lindhqvist in a 1990 report to the Swedish Ministry of the Environment.
Flexible standup pouches establish a strong market presence.
Modified atmosphere packages lead to greater shelf life and freshness for fresh-cut produce.
Computer-to-Plate (CtP) technology was introduced. Digital imaging on flexographic plates replaced traditional film workflows, with Cyrel® plates leading the way. This increased efficiency and accuracy, reducing production lead times and costs.
EFI introduced digital front-end (DFE) workflow systems for printers, enhancing pre-press and job management. This improved integration between pre-press and production workflows.
ERP and scheduling tools revolutionized operations with solutions such as Radius ERP and PrintFlow by integrating financial, operational, and production data.
Printpack, a winner of the FPA Flexible Packaging Achievement Awards Competition, showcased innovations that highlight the potential of flexible packaging. Their Caesar’s antifog coating ensured product visibility in the refrigerator section, while Healthy Choice® utilized microwavable film technology, unlocking further opportunities for flexible packaging solutions.
Photo courtesy of Printpack
AMGRAPH Packaging, Inc. revolutionized the term “quick to market” with film printing. The implementation of EB technology enabled AMGRAPH to produce pre-laminated film-based rollstock that can be surface printed in short order, thus reducing turnaround times for customers.
Photo courtesy of AMGRAPH Packaging, Inc.
Germany became the first country to establish a countrywide law to put the “producer pays” concept of EPR into practice, focusing on packaging. Manufacturers registered with the first producer responsibility organization (PRO), the nonprofit Duales System Deutschland GmbH, to set up a system for collecting, sorting, and recycling packaging after consumers were done with it.
FPA’s Chairperson’s Advisory Council acknowledged the need for more detailed information on industry statistics and trends, appointing Bret Biggers as the FPA’s Director of Statistics. Bret later served as FPA’s Director of Business and Economic Research.
FPA publishes the first State of the U.S. Flexible Packaging Industry Report. Biggers initiated the report, which became the definitive source for flexible packaging professionals. It examines future trends, aids budget planning, and serves as a current and historical data reference.
Senator Max Baucus (D-MT) introduced the first bill in the United States that, if it had passed, would have directed the EPA to explore the principles of EPR. The U.S. Federal Trade Commission (FTC) issues the Green Guides, which are designed to assist marketers avoid making environmental health claims that mislead consumers.
Poly Print, Inc.’s first press installation, the CI section of a Schiavi Padini wide web printing press in 1992.
Photo courtesy of Poly Print, Inc.
INSITE™ Technology – the landmark metallocene catalyst technology that helped create some of Dow’s most popular products of the late 20th century, including AFFINITY™ Polyolefin Plastomers, VERSIFY™ Elastomers, and ELITE™ Enhanced Polyethylene Resins.
Photo courtesy of Dow
Solid waste legislation remained dynamic in the 1990s. Misconceptions about solid waste and source reduction were not exclusive to government officials; the general public also needed information. From 1993 to 1998, FPA provided information about source reduction and flexible packaging to the nation’s educators.
Dr. Robert Testin from Clemson University and Dr. William Rathje from the University of Arizona conducted workshops titled “The Science of Packaging: Beyond Store Shelves and Landfills” for teachers across various cities. The workshop reached thousands of students, receiving rave reviews, with all respondents stating they gained a better understanding of packaging issues and would recommend it to colleagues. Many educators requested the FPA to offer the workshop again the next year.
Each educator left the workshop with a complete set of lesson plans that could be implemented in the classroom. Lesson plans were so popular among educators that, at one point, there was a 1,000 person-waiting list.
FPA developed the first source reduction logo: Source Reduction, Less Waste in the First Place®. Working with Baltimore-based designer, Charles Frank, FPA developed the logo with a diminishing dot pattern “to convey the minimization of waste achieved through source reduction.”
The logo is available to all members at no charge and can be used on any type of non-specific promotional materials.
The European Parliament and the Council of the European Union adopt Directive 94/62/EC on Packaging and Packaging Waste, acting as a broad set of regulations and guidelines covering packaging throughout its entire lifecycle—from design concept to end-of-life disposal. Simultaneously, The Organization for Economic Cooperation and Development’s (OECD) Pollution Prevention and Control Group begins work on EPR policy on behalf of its member countries.
The FPA convened a “MACT Task Group” and began collaborating with the EPA to develop the standard. For the first time, the FPA had the opportunity to work with the EPA on rule development before it was even published in the Federal Register. The Task Group:
- Provided information about processes, substrates, and technology used industry wide.
- Voiced concerns regarding the application of a universal standard or single level of emissions control for such a varied group.
- Worked as a team with the EPA to develop feasible regulations.
The Sterilization Packaging Manufacturing Council (SPMC) of the Flexible Packaging Association was formed in June 1994 to develop sterile packaging standards and reproducible test methods that could improve the safety of medical device packaging.
The Packaging Recovery Organization Europe formed as an umbrella PRO organization to manage the Green Dot Program as more European Countries established EPR programs. Japan becomes the first Asian nation to implement an EPR program following the passage of the Act on the Promotion of Sorted Collection and Recycling of Containers and Packaging.
FPA launched an improved, comprehensive website under the direction of Susan Dorn, FPA’s Director of Public Relations. FPA President Braswell stated that Karen Malling Vasquez, the project’s creative leader, and Michael Flanigan, who oversaw its technical aspects, “did a tremendous job.”
The Flexible Packaging: The Official Magazine for the Flexible Packaging Association debuted. The magazine was produced as a joint venture between FPA and Independent Publishing Company.
FPA was given the “APEX 99 Award for Publication Excellence” in the category of special reports for the 1998 State of the U.S. Flexible Packaging Industry Report.
At the turn of the 21st century, concerns about plastic pollution, climate change, and excessive waste led to a growing demand for sustainable alternatives, causing the push for more sustainable product packaging to gain significant traction, although it was still in its early stages compared to today. This decade laid the groundwork for the modern sustainable packaging movement, as growing consumer awareness, corporate responsibility, and government policies began shaping industry practices.
While large consumer packaged goods (CPGs) companies started setting environmental goals to reduce waste and incorporate more recycled materials into their packaging, they faced challenges – sustainable packaging materials were often pricier than traditional plastics, recycling and composting consumer education was limited, leading to contamination in waste streams, and greenwashing posed a significant issue as companies made misleading claims about the sustainability of their packaging.
While sustainable packaging was not yet commonplace, the early 2000s witnessed significant strides toward its adoption. The groundwork established in this decade—bioplastics, corporate responsibility, regulatory shifts, and consumer demand—would pave the way for rapid advancements in the 2010s and beyond.
Web inspection and defect detection systems became critical, providing real-time monitoring of print quality using cameras and algorithms
Membership in the SPMC was open to FPA member companies whose primary activity was the conversion of raw materials into flexible packaging or packaging components for medical devices.
Shortly after its founding, SPMC developed its first standard for medical packaging peel strength. This standard was later incorporated into ASTM F88 Standard Test Method for Seal Strength of Flexible Barrier Materials. By 1998, SPMC had published Standards and Test Methods, a printed manual which contained nine standards.
During the 2000s, the SPMC contributed to the industry by collaborating with other standards setting organizations. Several of SPMC’s standards formed the basis for eventual ASTM standards.
In 2006, members of the Council performed an intra-laboratory study for ASTM F88 and published an article about the study titled “A Round-Robin Approach to Seal Strength” in Pharmaceutical and Medical Packaging News magazine.
The Student Flexible Packaging Design Challenge recognizes innovative flexible packaging solutions created by students. This competition offers packaging students a valuable opportunity to apply their classroom knowledge in developing real-world flexible packaging solutions while contributing to the growth of the fastest-evolving sector within the packaging industry.
In 2006, Walmart made a groundbreaking announcement that significantly influenced the packaging industry: the creation of its Packaging Sustainability Scorecard. This tool was designed to assess the environmental impact of a product’s packaging and drive reductions in packaging waste. It marked the first effort of its kind by a major retailer to hold their suppliers accountable for the sustainability of their packaging practices.
High-definition flexographic plates (HD Flexo) improved resolution and print consistency to near-offset quality. This technology facilitated “offset-like” exceptional quality, meeting increasing color demands.
In 2008, the Council developed a searchable online database of its Frequently Asked Questions (FAQs) to help users find key guidance on everything from package development to validation. The FAQs quickly became the most frequently visited section of SPMC’s website. The resource continues to serve thousands of professionals yearly.
Ten years later, the Council’s technical committee began developing white papers to help packaging engineers and others with common sterile packaging challenges. As of 2024, six white papers have been written and made available for download on SPMC’s website.
On March 10, 2021, the SPMC celebrated its first Sterile Packaging Day, an event founded by the Council to celebrate the medical packaging industry and raise awareness for the critical role sterile packaging plays in everyone’s health and well-being. The celebration was held online and coincided with the initial launch of the first nationwide COVID-19 vaccination rollout. Sterile Packaging Day has become a yearly event now celebrated in-person at MD&M West in Anaheim, California, and online on LinkedIn.
Dhuanne Dodrill, SPMC Chair and PAXXUS, Inc. President & CEO celebrates Sterile Packaging Day 2024 at MD&M West in Anaheim, California
In the 2010s, sustainable packaging evolved from a niche issue to a widespread movement. Consumers became more vocal about reducing plastic waste, governments enacted stricter regulations, and corporations invested heavily in eco-friendly packaging solutions. By the mid-2010s, plastic pollution, especially in oceans, emerged as a global crisis, with campaigns like the “Plastic Free” movement and initiatives such as The Ocean Project gaining worldwide attention. Several cities banned plastic bags, straws, and other disposable plastics, replacing them with renewable and reusable alternatives.
The push for post-consumer recycled (PCR) content in packaging became widespread, and biodegradable and compostable materials such as polylactic acid (PLA), polyhydroxyalkanoate (PHA), and paper-based alternatives gained traction, especially in food packaging. Many multinational companies announced their brand commitment to sustainability and continued moving toward a “less is more” packaging strategy to reduce excess materials. This included e-commerce companies like Amazon streamlining their packaging to eliminate unnecessary plastic.
While recycling infrastructure and greenwashing challenges remained, the decade saw real progress in reducing plastic waste, embracing recycled and alternative materials, and shifting toward a circular economy model. By the end of the decade, sustainability was no longer just a trend—it had become a corporate and consumer expectation.
The FPA advocated for policies that favored the industry and lobbied against bans on plastic packaging, promoting instead EPR programs that encouraged companies to invest in recycling solutions. It collaborated with the U.S. EPA and other regulatory bodies to develop strategies for reducing packaging waste, ensuring that the industry’s interests were considered.
2002: Packaging EPR arrives in North America with the province of Ontario passing legislation to implement a shared responsibility program.
2011: AMERIPEN is founded as the only material-inclusive organization focused on U.S. public policy for the entire packaging industry.
2012: British Columbia passes legislation to implement the first full producer responsibility program for packaging EPR in North America.
2017: Florida becomes the first state in the country to exempt chemical recycling from solid waste regulations and ensure it would be regulated as manufacturing.
2019: The Product Stewardship Institute and FPA publish “Shared Elements of EPR Legislation for Packaging,” which serves as the basis for FPA’s EPR advocacy.
Multi-color process printing expanded gamut printing (CMYK + OG/V) to reduce reliance on spot colors. It greatly improved efficiency while maintaining brand consistency in flexible packaging.
Photo courtesy of eProductivity Software
3-layer blown film of bio raw materials primarily used for ordinary shopping bags or compostable garbage bags.
Digital printing technologies (e.g., HP Indigo) enabled very short runs, market testing, versioning, and high-quality output.
Photo courtesy of eProductivity Software
Originally packaged in a thin shrink film within an outer carton, General Mills Totino’s™ transitioned to a more sustainable product by eliminating both the inner wrap and cardboard, replacing them with a lamination. This change in format reduced its overall carbon footprint, and this format is still sold today.
Photo courtesy of Printpack
Innovations in air pollution control equipment enhance the consumer experience. The flexible packaging industry, along with state and federal regulators, support the development of volatile organic compound (VOC) control to reduce emissions from industrial facilities. VOCs react with nitrogen oxides from industrial activities, forming harmful ozone and smog, particularly affecting plant operators.
Early emission control technologies were inefficient and expensive, requiring significant natural gas. Since the 1980s, regenerative thermal oxidizer (RTO) technology has improved, achieving 99% destruction efficiency and up to 97% thermal efficiency. This advancement lowers costs for environmental stewardship in the flexible packaging industry, along with potential incentives for Ship & Shore Environmental, Inc. RTOs.
Kashi®, a Kellogg’s company, launched the first cereal in a resealable, reusable stand-up pouch.
Photo courtesy of Kellogg’s Historical Archives
Fresh-Lock® launched Child-Guard® Track & Slider technology, which for the first time enabled child-resistant reclosability on flexible packaging. This innovation enabled many rigid products to transition to flexible ones.
Photo courtesy of Fresh-Lock®
A milestone product in the advancement of recycling, RETAIN™ polymers allow scrap films containing ethylene vinyl alcohol (EVOH) or nylon to be recycled into new films without sacrificing physical or optical properties. This technology is just one example of Dow’s ongoing commitment to circularity and Design for Recyclability.
Photo courtesy of Dow
FPA unveils its refreshed logo and tagline designed to reflect the association’s core values and longstanding mission as the industry’s leading authority. With a focus on government and issue management, industry research and data, and leadership, FPA is committed to promoting and protecting the flexible packaging industry. The bold, modern block letters of the new logo symbolize the strength of both the industry and the association, while the dynamic “spark” element represents the heart of a vibrant collective. This spark embodies FPA’s mission to connect knowledge, people, resources, and ideas, driving the growth and innovation of the flexible packaging sector.
Flexible packaging continues to be one of the fastest-growing segments in the packaging industry, generating over $42 billion in annual sales in the U.S. With around 83,000 people employed across the country, workforce development remains a key challenge for the industry. To address this, the FPA launched FlexPackCareers.org, an innovative career website that highlights the wide range of career opportunities available with FPA members nationwide. The user-friendly platform allows job seekers to search for opportunities by location or company name and provides direct links to FPA member websites and their career pages (when available).
Sonoco Flexible Packaging was recognized with a Gold Achievement Award from the FPA for its high-performance film laminate contributions to the Daisy® Sour Cream squeezable pouch. Introduced in February 2015 and still available nationwide today, the proprietary pouch design was an inverted, wedge-shaped pouch with a flip-top dispensing closure featuring a SimpliSqueeze® valve and tamper-evident pull ring. It provides an easy-to-use, easy-to-dispense, mess-free, recloseable package.
Photo courtesy of Sonoco Flexible Packaging
An ever-growing family of innovative resins proving to be a multi-faceted and multi-application group of resins. They offer an outstanding balance of stiffness/toughness balance and can promote material substitution for mono-material packaging, be used for downgauged flexible packaging.
Photo courtesy of Dow
The Fres-co Barrel Pouch became the flexible replacement for bottles and cans.
Photo courtesy of Fres-co System USA, Inc.
FPA establishes its new advocacy program, with staff tracking 140 bills related to materials management, EPR, and packaging. By 2024, that number increased by an extraordinary 266% to 512 bills.
Officials from the FPA staff and Ohio legislators toured Ampacet Corporation’s plant and Ideation Center in Heath, Ohio, where they learned about extrusion processes and the end markets for Ampacet’s masterbatch and additive solutions.
Since 2017, FPA has actively engaged with the U.S. federal government on tariff and duty issues, advocating for policies that support the industry.
2017: President Trump directed Commerce Secretary Wilbur Ross to self-initiate investigations regarding whether steel and aluminum imports pose a threat to U.S. national security under Section 232 of the Trade Expansion Act of 1962. FPA submitted comments emphasizing the insufficient domestic production capacity for foil used in packaging.
February 2018: The U.S. Department of Commerce (DOC) released a report stating that imports threaten U.S. national security.
March 2018: President Trump announced a 10% aluminum tariff for national security. China retaliated with tariffs on aluminum waste, disrupting U.S. recycling. Canada enacted tariffs on certain steel and aluminum. The European Union (EU) imposed retaliatory tariffs on significant U.S. goods.
May 2019: The U.S. lifted Section 232 tariffs on Canada and Mexico.
2020: President Trump expanded tariffs on steel and aluminum derivative products.
2021: President Biden continued President Trump’s tariff scheme on aluminum foil. Biden encouraged dialogue with the EU to support the struggling domestic steel and aluminum industries.
December 2022: The World Trade Organization (WTO) ruled that the U.S. Section 232 tariff scheme was inconsistent with WTO rules. The Biden Administration responded by appealing to the WTO’s Appellate Body, which the U.S. had rendered defunct.
October 2023: The FPA raised transparency concerns about how the Bureau of Industry and Security approves or denies Section 232 exclusions.
2017: President Trump directed U.S. Trade Representative (USTR) Robert Lighthizer to initiate an investigation of China under Section 301 of the Trade Act of 1974.
2018: After the USTR investigation, President Trump imposed tariffs on over $350 billion in Chinese goods, including aluminum foil at 7.5% to 25%. China retaliated with tariffs on American products goods.
Ongoing Industry Engagement: FPA remained engaged through the Americans for Free Trade Coalition. The coalition highlighted industry concerns throughout both the Trump and Biden administrations.
2016: The DOC received a petition from the Aluminum Association’s Trade Enforcement Working Group to impose anti-dumping and countervailing duties on Chinese aluminum foil.
2017: FPA hired Mowry & Grimson PLLC to represent its newly launched Coalition for Aluminum Foil Security before the DOC.
2018: The DOC issued antidumping and countervailing duty orders on Chinese foil used in flexible packaging.
2020: The Aluminum Association petitioned the U.S. government to investigate aluminum foil imports from Armenia, Brazil, Oman, Russia, and Turkey.
2021: Antidumping orders were enforced on these countries.
2022: The DOC launched circumvention inquiries into aluminum foil imports completed in South Korea and Thailand using Chinese inputs.
2023: The DOC issued final affirmative determinations and established new orders, with Mowry & Grimson PLLC again representing the Coalition for Aluminum Foil Security.
The Fres-co Powder Bag became the flexible replacement for rigid packages such as fiber drums, plastic drums, poly bag-in-box, or other bags such as kraft paper, kraft paper poly bags, or polywoven bags, specifically engineered for powders.
Photo courtesy of Fres-co System USA, Inc.
FPA’s new President & CEO, Alison Keane, took the lead in promoting the sustainability benefits of flexible packaging, emphasizing the advantages over rigid packaging. In 2018, the association commissioned a study to explore how flexible packaging lends itself to brand owners’ ability to establish a reputation for environmental stewardship. Using study results, FPA developed consumer and brand owner infographics and a sustainability outreach and consumer conversations e-book to help communicate the findings to the industry.
Also, in 2018, the report “A Holistic View of the Role of Flexible Packaging in a Sustainable World” was published. It focused on the sustainability benefits of flexible packaging and provided foresight into its future sustainability implications. Several educational materials, including a fact sheet, infographic, and numerous life cycle assessment case studies, were developed to support the report.
The FPA worked with industry coalitions, such as the Sustainable Packaging Coalition (SPC) and How2Recycle, to develop clearer labeling, promote store drop-off recycling programs, and encourage brands to adopt recyclable, compostable, or bio-based flexible packaging. It also supported efforts to develop advanced recycling technologies that could process multi-layered materials.
In 2018, in collaboration with Euromonitor International, FPA developed the Flexible Packaging Market Tracker—a powerful tool designed exclusively for FPA members. This comprehensive resource covers 20 key flexible packaging markets around the world, offering valuable insights into market dynamics, trends, and global expansion opportunities.
The 2018 initiative on flexible packaging’s environmental benefits led to the launch of our microsite, PerfectPackaging.org. Developed by FPA, this site promotes flexible packaging to consumers and policymakers, sharing data on food waste, e-commerce, recyclability, and correcting misinformation about plastic packaging. FPA collaborated with TerraCycle to create a U.S. zip code locator for the nearest drop-off points for bags and films. Additionally, FPA supported the Wrap Recycling Action Program (WRAP), boosting store drop-off locations for plastic films.
Integrated Plastic Packaging (IPP) launched flat-bottom pouches.
Hershey’s revolutionary stand-up pouches produced on a Vertical/Form/Fill/Seal (VFFS) machine represent a unique innovation that allows the pouch to stand independently, as opposed to the traditional pillow pouch style. The combination of machine development and film development made this product cost-effective, and it is now being used widely by other CPGs.
Photos courtesy of Printpack
As we entered the 2020s, the flexible packaging industry experienced significant innovations driven by sustainability, convenience, and technological advancements. However, nothing prepared us for what we would soon face: the COVID-19 pandemic. COVID-19 profoundly impacted flexible packaging innovations, accelerating trends in hygiene, sustainability, and e-commerce. The industry came together, demonstrating resilience, innovation, and collaboration to meet the urgent demands of consumers, healthcare providers, and supply chains. The flexible packaging sector not only united but also emerged stronger and more innovative after the pandemic. The crisis led to faster advancements in sustainable packaging, smart technologies, and supply chain resilience, ensuring the industry remains adaptable to future global challenges.
In partnership with the YGS Group (York, PA), in 2020 FPA publishes a new dynamic print magazine, FlexPack VOICE®, that features the latest Association news, industry updates—including supply chain developments— and highlights member achievements in sustainable flexible packaging and technical innovations. The magazine covers key areas such as product protection, e-commerce, food waste reduction, medical safety, and more.
FPA releases “A Flexible Packaging Path to a Circular Economy: Flexible Packaging Sustainability Roadmap” report.
In 2020, FPA also announced the formation and launch of its Emerging Leadership Council (ELC), a group of dynamic professionals with fewer than five years of experience in the flexible packaging industry. The ELC’s mission is to foster a network of future leaders who will address key challenges and opportunities that shape the long-term growth of the U.S. flexible packaging sector.
In 2020, the world faced an unprecedented pandemic with the outbreak of COVID-19, which began in December 2019 in Wuhan, China. The virus spread rapidly across Asia and globally, prompting the World Health Organization (WHO) to declare it a pandemic in March 2020. The crisis persisted for two years, causing severe social and economic disruption, including widespread supply chain shortages and food scarcity.
The flexible packaging industry remains focused on its advocacy on sustainability, regulatory engagement, and promoting its benefits. Efforts include supporting recycling infrastructure, advocating for EPR policies, and pushing for regulatory clarity on recycled materials in food packaging. Industry groups are engaging with lawmakers on per- and polyfluoroalkyl substances (PFAS) restrictions, chemical recycling, and fair EPR fees while emphasizing flexible packaging’s role in reducing carbon footprints and food waste.
R-Cycle, a digital product passport system designed to improve the traceability and recyclability of plastic packaging and products, paves the way for plastic products into a functioning circular economy.
Photo courtesy of Reifenhäuser
FPA releases the “Sustainability Life Cycle and Economic Impacts of Flexible Packaging in E-commerce” report.
Dow’s next step in the circularity journey offers an assortment of high-quality, PCR-rich, fully formulated, single-pellet resin grades for numerous flexible and rigid packaging applications.
Photo courtesy of Dow
Known as one of the most significant product advancements in the industry was the transition from oriented polypropylene (OPP) lamination to all polyethylene to meet store drop-off eligibility. This marked a substantial shift for General Mills and showcased that such changes are achievable for major brands to support the necessary infrastructure for recycling flexible materials packaging.
Photo courtesy of Printpack
The Fujifilm J Press FP790 is the pinnacle of advanced water-based digital inkjet printing technology. This state-of-the-art machine combines efficiency, precision, and unparalleled quality to meet the needs and high market demands of the packaging industry. With a focus on both high-quality print and adhering to the regulatory requirements of the food packaging industry, the J Press FP790 stands as a testament to Fujifilm’s commitment to innovation and excellence in the world of flexible packaging print technology.
Photo courtesy of Fujifilm
Reifenhäuser develops an advanced extrusion technology, EVO Fusion, enabling the direct processing of 100% recycled materials into new blown films without the need for energy-intensive pelletizing.
Photos courtesy of Reifenhäuser
Fluff, film snippets, and various types of production waste and PCR material can be directly processed into functional films for uses such as trash bags or mailing bags.
Photo courtesy of Reifenhäuser
The Reifenhäuser Value Sheet Inline system is introduced. It is an advanced extrusion line designed to produce high-quality thermoformable films that are directly integrated with thermoforming machines. This inline configuration streamlines the production process, enhancing both efficiency and product quality.
Photo courtesy of Reifenhäuser
Integrated Plastics Packaging (IPP) developed barrier paper-based laminates and incorporated laser scoring technology to enhance user convenience. By integrating advanced laser scoring and high-end coatings, IPP improves the user experience and product appeal.
Photo courtesy of Integrated Plastics Packaging
Amcor’s LifeSpan® Copper Based Film is a smart packaging that increases product shelf life by up to 250%. This laminated film contains copper microparticles that inhibit the development of microorganisms inside the packaging and commonly used in meat, fish, seafood, and dairy applications.
Photos courtesy of Amcor
FPA launches FlexPACTM, the federal political action committee (PAC) for the flexible packaging industry. FlexPACTM is a bi-partisan PAC and funded by voluntary personal contributions of FPA members and supports candidates for political office who understand and support the broad array of issues facing the packaging industry. In its inaugural year, FlexPAC raised nearly $50,000 from over 40 executives employed by 24 FPA member companies.
Printpack introduces compostable packaging for the sustainably conscious consumer. The Off the Eaten Path® industrially compostable bag incorporated compostable inks and laminate that reduced the “noisiness” of prior iterations using compostable films.
Photo courtesy of Printpack
The Fres-co EZHANDLE™ became the flexible replacement for buckets and pails.
Photo courtesy of Fres-co System USA, Inc.
Amcor launches Nescafé® Gold Blend,
a fully recyclable paper refill pack.
Photo courtesy of Amcor
Davide Rossello, Head of Competence Center and Process Manager Gravure at BOBST (right), and Mohamed Timol, Reifenhäuser expert for machine-direction orientation (MDO) processes (left), presents the printed and world’s first 18-micrometer thin MDO-PE film.
Photo courtesy of Reifenhäuser
When the FPA held its inaugural meeting at the Hotel Astor in 1951, the Association had approximately 50 members. Fast forward almost 75 years and membership has grown to 200—a remarkable 300% increase. In terms of annual sales volume, the industry reported $150 million in 1951, compared to $42.9 billion in 2023, marking an astounding 28,500% growth.
