Folding Cartons in 2025: How Digital Printing & Sustainability Are Changing the Game
Jun 5 2025
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As markets evolve and consumer expectations grow, packaging must follow suit — and folding cartons are no exception. Though global volume is forecasted to grow from 63.0B m² in 2023 to 68.5B m² by 2028 (Keypoint Intelligence), the real transformation is structural.
Two forces are reshaping the folding carton space: digital printing and sustainability. Together, they’re pushing converters, brand owners, and equipment manufacturers to rethink not only their tools — but their value propositions.
Digital Printing: From Niche to Necessity
Digital printing currently represents a modest 0.5% of the folding carton market, projected to reach 1.1% by 2028. While it excels in short-run agility and personalization, adoption remains limited due to:
Format size limitations
Higher consumable costs
Concerns around reliability and integration
Still, digital is gaining ground in markets under regulatory pressure and in sectors demanding speed-to-market and flexibility.
As technology improves, the real opportunity lies in delivering total cost optimization and enhanced customer experiences, not just cheaper print runs.
Sustainability: Mandates Are Rising
Sustainability is no longer optional. It’s becoming both a consumer expectation and a regulatory obligation. From packaging simplification to waste reduction and material choices like FBB and CRB, converters must innovate without sacrificing branding impact.
As Wettersten puts it, “Sustainability isn’t just about meeting regulations — it’s about making packaging work harder.”
Smart converters are:
Streamlining packaging formats
Reducing material waste
Adopting recyclable substrates
Preparing for stricter legislation across global markets
What’s Next: A 3-Phase Digital Roadmap
Keypoint Intelligence outlines a three-phase path for digital adoption:
Print Cost Optimization
Total Cost Optimization
New Customer Experience Enablement
As converters move through these phases, digital’s total addressable market is projected to grow to 5+ billion m² by 2027 — a tenfold increase from today.
Strategy Over Speed
The folding carton sector isn’t exploding in volume, but it is evolving rapidly. Competitive advantage will come not from reacting — but from leading.
The path forward will be defined by:
Embracing hybrid print ecosystems
Aligning packaging with sustainability regulations
Adapting to more complex supply chains
Investing in digital workflows and automation
Be Proactive. Stay Relevant.
Packaging leaders who elevate their strategy now will be better equipped to thrive in a market shaped by speed, responsibility, and adaptability.
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