Battery Packaging Market Size, Share & Industry Analysis, By Material (Paperboard, Plastic, Metal, and Others), By Casing Type (Cylindrical, Prismatic, Coin, and Others), By Battery Type (Lithium-ion, Lead-acid, Nickel-metal hydride, Nickel-cadmium, and Others), and Regional Forecast, 2025-2032

The global battery packaging market size was valued at USD 27.50 billion in 2024. The market is projected to grow from USD 29.89 billion in 2025 to USD 55.56 billion by 2032, exhibiting a CAGR of 9.26% during the forecast period. Asia Pacific dominated the battery packaging market with a market share of 31.24% in 2024.

The market for battery packaging is expanding due to the increasing popularity of electric vehicles (EVs), heightened demand for energy storage systems, and growth in the consumer electronics sector, all of which necessitate specialized, safe, lightweight, and sustainable packaging solutions to safeguard high-performance batteries such as lithium-ion cells.

Increasing use of energy storage systems (grid, residential, utility scale) adds to battery use and need for packaging solutions for transport, safety, and protection. Rising consumer electronics demand (portable devices, tools, etc.) contributes further to the packaging needs. Important factors contributing to this trend include environmental issues, government incentives, innovations in battery technology, and the rising significance of packaging for e-commerce.  It thus contributes to the growth of the industry.

Furthermore, the market encompasses several major players Nefab Group, Toppan Inc., Wellplast AB at the forefront. Broad portfolio with innovative product launch, and strong geographic presence expansion have supported the dominance of these companies in the global market.

MARKET DYNAMICS

MARKET DRIVERS

Rising Electric Vehicle (EV) Adoption Drives Market Growth

One of the key factors driving the growth of the battery packaging market is the rapid expansion of the electric vehicle sector. Electric vehicles necessitate high-capacity lithium ion batteries that require durable, fire-resistant, and thermally stable packaging to guarantee safety during usage, storage, and transportation. As the global adoption of EVs rises, automakers and battery manufacturers are seeking innovative packaging solutions capable of managing increased energy densities and thermal management requirements, which in turn stimulates the demand for specialized battery packaging, and drives the global battery packaging market growth.

• As reported by the International Energy Agency (IEA), electric vehicles represented 21% of global car sales in 2024, indicating that one out of every five cars sold globally was electric. The number of EV brands increased significantly in 2024, with more than 150 brands in competition on a global scale. This expansion features both long-standing car manufacturers shifting to electric models and new companies dedicated solely to EV innovation.

MARKET RESTRAINTS

High Cost of Advanced Packaging Materials Impedes Market Growth

Advanced materials such as aluminum alloys, engineered plastics, composites, and thermal insulation coatings play a crucial role in modern battery packaging. However, these materials significantly drive up the overall costs of packaging, especially for applications such as electric vehicles (EVs), where large battery packs need substantial protection. For manufacturers already striving to lower battery pack costs to below USD 100 per kilowatt-hour, the added expense of packaging poses cost challenges. Striking a balance between affordability, performance, and compliance continues to be a challenge, particularly in competitive markets where reducing costs is vital.

MARKET OPPORTUNITIES

Growing Consumer Electronics Sector Create Lucrative Growth Opportunities

Consumer electronics such as smartphones, laptops, wearables, and power tools still account for a large share of global battery usage. These products necessitate packaging solutions that are compact, lightweight, and safe, balancing the need for protection with ease of transport. The ongoing trend of making electronics slimmer and lighter compels packaging manufacturers to develop thinner, yet durable materials and designs, which is fostering steady growth in this area. The battery packaging industry has considerable potential for growth, driven by the ongoing expansion of the consumer electronics market.

• According to the Australian Bureau of Statistics, 91% of households with internet access own desktop or laptop computers. Similarly, 91% of homes that are connected to the internet have mobile phones or smartphones. Additionally, 66% of these households report that tablets are their second most prevalent internet-connected devices.

BATTERY PACKAGING MARKET TRENDS

Integration of Thermal Management, Automation and Smart Manufacturing Booms as a Market Trend

Modern battery packaging is transitioning from merely offering protection to actively enhancing battery performance. Packaging solutions are progressively integrating thermal management features such as cooling channels, phase-change materials, and heat-dispersing coatings to maintain stable operation and extend battery lifespan. This development is becoming commonplace in packaging for electric vehicles (EVs) and energy storage systems (ESS). As battery gigafactories expand, the production of packaging is also moving toward increased automation and the adoption of Industry 4.0 technologies. Automated packaging lines, AI-based quality assessments, and digital twins are being utilized to minimize mistakes, accelerate processes, and ensure consistency. This movement supports the mass production of high-quality packaging while reducing costs.

MARKET CHALLENGES

Environmental and Sustainability Pressure Challenges Market Growth

Battery packaging, particularly when it involves plastics, metals, or multi-layer composites, presents considerable recycling challenges. As sustainability emerges as a key global focus, packaging manufacturers encounter the task of devising recyclable or biodegradable options without sacrificing durability or safety. For instance, although lightweight corrugated or bio-based packaging is environmentally friendly, it might not offer adequate protection for high-risk scenarios such as electric vehicles. Developing eco-conscious yet dependable solutions demands substantial investment in research and development, and numerous companies are still exploring practical alternatives.

Download Free sample to learn more about this report.

Segmentation Analysis

By Material

Remarkable Benefits Offered by Paperboard Material Propels Segment Growth

In terms of material, the market is categorized into paperboard, plastic, metal, and others.

The paperboard segment captured the largest share of the market in 2024. In 2025, the segment is anticipated to dominate with 53.54% share. Paperboard material for batteries provides advantages such as superior shock absorption, the ability to be customized for different battery dimensions, and a high level of protection against environmental elements and physical harm. It is also an environmentally friendly and sustainable option that is lightweight, convenient to handle, and suitable for printing, branding and informational content, which aids businesses in complying with regulations and attracting eco-conscious customers.

Plastic material segment is expected to grow at a CAGR of 9.10% over the forecast period. 

By Casing Type

Outstanding Features of Cylindrical Casing Enhances Segmental Growth

In terms of casing type, the market is categorized into cylindrical, prismatic, coin, and others.

The cylindrical segment captured the largest share of the market in 2024. In 2025, the segment is anticipated to dominate with 50.26% share. Cylindrical casings offer batteries a durable, mechanically stable, and economical design, attributed by well-established manufacturing techniques and sturdy metal enclosures. The primary advantages include consistent heat dissipation for enhanced thermal management, uniform pressure distribution that helps prevent swelling and leaks, established reliability derived from standardized designs and ongoing mass production, and a reduced cost per kWh resulting from improved yields. Their natural mechanical strength also makes them resilient against physical stress, making them suitable for demanding applications such as electric vehicles and high-performance tools.

Prismatic casing type segment is expected to grow at a CAGR of 9.13% over the forecast period. 

By Battery Type

Rising Demand for Lithium-ion Batteries in Electric Vehicle Sector Propelled Segment Growth

Based on battery type, the market is segmented into lithium-ion, lead-acid, nickel-metal hydride, nickel-cadmium, and others. In 2024, the global market was dominated by lithium-ion in terms of battery type. Furthermore, the segment is set to hold 32.94% share in 2025.

Lithium-ion batteries have the capability to store significant energy relative to their weight and volume, which makes them well-suited for uses where weight and size are essential considerations, such as in portable electronics and electric vehicles. This favorable demand forecast for lithium-ion batteries boosts the need for specialized packaging solutions for these batteries. Additionally, the use of lithium-ion batteries has grown in the electrical industry due to increased industrialization, urban development, and rising consumer demand for a range of electric devices and vehicles. The heightened focus on sustainable energy solutions is anticipated to boost the demand for lithium-ion batteries, thereby enhancing potential sales in the market.

To know how our report can help streamline your business, Speak to Analyst

In addition, lead-acid battery type is projected to grow at a CAGR of 9.49% during the study period.

Battery Packaging Market Regional Outlook

By geography, the market is categorized into Europe, North America, Asia Pacific, Latin America, and Middle East & Africa.

ASIA PACIFIC

To get more information on the regional analysis of this market, Download Free sample

The Asia Pacific held the dominant battery packaging market share in 2023 valuing at USD 7.81 billion and also took the leading share in 2024 with USD 8.59 billion. Asia Pacific region is emerging as a large share contributor, both from manufacturing of batteries and high adoption of EVs and storage systems

Countries in the Asia Pacific, including China, Japan, South Korea, and India, possess a vast consumer base and serve as significant manufacturing centers for consumer electronics including smartphones, laptops, and tablets. The production of these devices necessitates batteries, which in turn fuels the demand for battery packaging solutions across the region.

Various prominent battery manufacturers, such as Contemporary Amperex Technology Co. Limited (CATL), LG Chem, Samsung SDI, and Panasonic, are based or have substantial manufacturing operations in the Asia Pacific. These firms require sophisticated battery packaging solutions to safeguard their products during transport and storage, further driving the market growth.

In the region, India and China both are estimated to reach USD 2.32 and USD 2.76 billion each in 2025.

NORTH AMERICA

During the forecast period, the North American region is projected to record a growth rate of 9.88%, which is the second highest among all the regions and touch the valuation of USD 7.39 billion in 2025.

In recent times, North America has witnessed a massive increase in adoption of EV’s. Moreover, the growth is also fueled by the presence of significant battery manufacturers such as Tesla, Panasonic, and LG Chem, which are propelling market growth. Furthermore, the rising need for lithium-ion batteries across multiple uses, including consumer electronics, electric vehicles, and energy storage systems, is contributing to the market's expansion.

• The International Energy Agency stated that in 2023, electric cars accounted for one out of every ten new vehicle registrations in the U.S. (IEA 2024d). That year, the total number of new electric vehicle registrations reached 1.4 million.
• It is anticipated that annual sales of consumer electric vehicles in the U.S. will rise to 8.8 million by 2030 and approximately 11 million by 2035 (IEA 2024d). Due to implementation of heavy-duty emissions regulations, the annual sales of electric buses and commercial trucks are also projected to increase around 97,000 and 420,000 respectively by 2035.

In 2025, the U.S. market is estimated to reach USD 5.94 billion.

EUROPE

After North America, the market in Europe is estimated to reach USD 5.98 billion in 2025 and secure the position of third-largest region in the market.  The automotive industry is a key user of battery packaging solutions for electric vehicles (EVs) and hybrid electric vehicles (HEVs). The robust presence of this sector in the region boosts the demand for battery packaging materials and solutions.

Backed by these factors, countries including the U.K. anticipate to record the valuation of USD 1.09 billion, Germany to record USD 1.28 billion, and France to record USD 0.95 billion in 2025.

LATIN AMERICA

Over the forecast period, Latin America would witness a moderate growth in this marketspace. The Latin America market in 2025 is set to record USD 4.14 billion as its valuation. Lithium-ion batteries are gaining wide traction in these regions. These batteries are commonly utilized in consumer electronics, electric vehicles, and systems for renewable energy sources, leading to a growing demand for specialized battery packaging solutions in the regions.

MIDDLE EAST & AFRICA

In Middle East & Africa, South Africa is set to attain the value of USD 0.84 billion in 2025.

COMPETITIVE LANDSCAPE

Key Industry Players

Wide Range of Product Offerings coupled with Strong Distribution Network of Key Companies Supported their Leading Position

The global battery packaging market shows a semi-concentrated structure with numerous small-to-mid-size companies actively operating across the globe. These players are actively involved in product innovation, strategic partnerships, and geographic expansion.

Nefab Group, Toppan Inc., and Wellplast AB are some of the dominating players in the market. A comprehensive range of battery packaging products, global presence through strong distribution network, and collaborations with research and academic institutes are few characteristics of these players which support their dominance.

Apart from this, other prominent players in the market Anchor Bay Packaging, C.L. Smith, Trinseo, and others. These companies are undertaking various strategic initiatives such as investments in R&D and partnerships with pharmaceutical companies to enhance their market presence.

LIST OF KEY BATTERY PACKAGING COMPANIES PROFILED

• Nefab Group (Sweden)
• Toppan Inc. (Japan)
• Wellplast AB (Sweden)
• Anchor Bay Packaging (U.S.)
• L. Smith (U.S.)
• Trinseo (U.S.)
• Söhner Kunststofftechni GmbH (Germany)
• GWP Group (U.K.)
• Manika Plastech Pvt. Ltd. (India)
• Covestro AG (Germany)
• Labelmaster (U.S.)
• Viking Plastics (U.S.)
• Great Northern Corporation (U.S.)
• TriEnda Holdings, LLC (U.S.)
• DGM (U.S.)

KEY INDUSTRY DEVELOPMENTS

• September 2025: Gold Peak is committed to improving its sustainability initiatives throughout its daily operations. Our consumer battery line, GP, is leading the charge by shifting its packaging from plastic to paper. So far, more than 1,000 GP battery products in Europe have successfully undergone this transition, leading to an annual decrease of 48 tons of plastic and 30 tons of waste material. This change emphasizes the considerable environmental benefits that innovative materials can provide. As we look ahead, Gold Peak will continue to prioritize the exploration of creative solutions that support a more sustainable future.
• August 2025: Duracell, the well-known battery producer located in Bethel, Connecticut, USA, has made a substantial move toward sustainability by introducing a new blister pack made entirely of paper. This packaging advancement represents a departure from conventional plastic clamshells and offers significant enhancements in user convenience, retail effectiveness, and environmental sustainability.
• July 2025: Enva, a prominent recycling and resource recovery expert in the U.K. and Ireland, has introduced its latest innovation, the Battery Safe Box—a specially designed solution for the secure storage and transport of waste lithium batteries, including those that are defective. The Battery Safe Box has the capability to hold up to 400kg of lithium batteries, with a maximum power capacity of 20kWh. It is designed to contain and isolate fires triggered by thermal runaway, preventing the flames from spreading and ensuring safe handling during storage and transportation.
• July 2024: Panasonic Energy Co., Ltd., the battery production branch of the Panasonic Group, introduced new paper-based packaging for consumer batteries in Australia. In line with Panasonic's commitment to sustainability, this environmentally friendly initiative is expected to eliminate approximately 500kg of plastic on an annual basis and is projected to conserve over 36,000 sqm of paper while decreasing CO2 emissions by about 1,450kgCO2e each year in both the Australian and New Zealand markets combined.

REPORT COVERAGE

To gain extensive insights into the market, Download for Customization

Report Scope & Segmentation