Die Cut Carton Market Size, Share & Industry Analysis, By Wall Type (Single Wall, Double Wall, and Triple Wall), By End-use Industry (Food & Beverages, Pharmaceuticals, E-commerce, Chemicals, Building & Construction, and Others), and Regional Forecast, 2025-2032

The global die cut carton market size was valued at USD 39.96 billion in 2024. The market is projected to grow from USD 41.80 billion in 2025 to USD 58.01 billion by 2032, exhibiting a CAGR of 4.79% during the forecast period. Asia Pacific dominated the die cut carton market with a market share of 41.89% in 2024.

The global die cut carton market growth is driven by various factors such as advancements in packaging technology, sustainability trends, and the expansion of e-commerce. Die-cut cartons are custom-shaped boxes made from cardboard, which are used extensively in industries such as e-commerce, food and beverage, electronics, and pharmaceuticals. These cartons are created using specialized die-cutting machines, which cut, crease, and shape cardboard into various designs for packaging. The global die cut carton market is influenced by the rising demand for eco-friendly material packaging solutions and the expansion of e-commerce platforms. E-commerce companies require packaging that offers protection and a premium unboxing experience, which is where die-cut cartons come into play.

• The International Trade Administration states that the global e-commerce revenue for B2B companies has consistently increased annually over the past ten years, with the worldwide B2B e-commerce market expected to be worth USD 36 trillion by 2026. Sectors including advanced manufacturing, energy, healthcare, and professional business services in heavy industry account for most of this B2B sales value.Mondi and Smurfit WestRock are the leading manufacturers, accounting for the largest global die cut carton market share.

MARKET DYNAMICS

MARKET DRIVERS

Rising Sustainability Focus among Consumers and Manufacturers Drives Market Growth

The shift toward sustainable packaging material is a significant trend. Companies, including WestRock and International Paper, invest in recycled fibers and alternative materials to reduce their environmental impact. Adopting eco-friendly die-cut cartons is expected to grow due to consumer preferences for sustainable products and stricter environmental regulations. Companies are exploring biodegradable, recyclable, and compostable materials for packaging, aligning with global sustainability goals. Furthermore, custom-designed die-cut packages are becoming increasingly popular as they offer brands an opportunity to stand out in a competitive market. Customized boxes can be made in various shapes and sizes, and their unique designs can serve as marketing tools that boost brand recognition. It thus drives the global die cut carton market.

• According to the Fibre Box Association, in 2022, the corrugated sector produced 401 billion square feet of material for creating boxes, displays, and various other corrugated packaging. This amounted to 40 billion packages that were securely transported and safeguarded food, apparel, and durable goods for delivery to millions of local and global customers.

MARKET RESTRAINTS

Wall Type Limitation and Regulatory Compliance Restrain Market Expansion

One of the primary challenges in the die-cut carton market is the material limitations of corrugated cardboard. While it offers excellent protection, it is vulnerable to moisture, which can cause it to lose its structural integrity. Additionally, the cutting process can sometimes leave jagged edges, affecting the overall quality of the final product. Thus limiting the market expansion of the die cut box industry. Furthermore, different countries have varying regulations regarding packaging, especially in industries such as food and pharmaceuticals. Companies operating in multiple regions face challenges in meeting these different regulatory standards, which could involve additional costs related to compliance and certification, hampering the global die cut carton market growth.

MARKET OPPORTUNITIES

Advancements in Technologies and Innovations Will Offer Potential Growth Opportunities

Advanced technologies such as automation, the Internet of Things (IoT), and enhanced printing methods such as digital and flexographic printing enhance the die-cut carton market. These technologies help achieve high-speed production, improved efficiency, and the ability to produce customized and intricate designs. Automation also reduces labor costs and improves operational efficiency, which is crucial for companies aiming to stay competitive. Such advancements create lucrative opportunities for the global die cut carton market.

DIE CUT CARTON MARKET TRENDS

Demand for Single-serve and Food Delivery Booms

The surge in food delivery services fuels the demand for secure and convenient die-cut packaging for single meals. The growing prevalence of online food delivery and e-commerce is a significant influence on this trend, compelling businesses to seek out strong, lightweight, and tamper-resistant packaging options to enhance logistics efficiency. Key factors driving this demand include urbanization, busier lifestyles, demand for custom packaging boxes, and technological advancements, particularly the increasing use of smartphones and internet access. Henceforth, the growing demand for single-serve meals and food delivery increases the use of die-cut cartons and booms as a market trend.

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Segmentation Analysis

By Wall Type

Significant Benefits Offered by Single Wall Type Boosts Segmental Growth

Based on wall type, the market is divided into single wall, double wall, and triple wall.

Single wall segment was dominating the global die cut carton market in 2024 and is expected to experience significant growth throughout the forecast period. It is created with an inner and outer liner that encases one flute layer. These cartons are ideal for lightweight items and are primarily favored by online retailers. Furthermore, due to their cost-effectiveness, visual appeal, lightweight nature, and safety in transit, single-wall corrugated cartons are experiencing significant demand from various end-use sectors.

The double wall type is the second dominating segment. The increasing need for these products is due to their enhanced rigidity, making them suitable for long-term stacking storage and for moving homes or archiving.

By End-use Industry

Rising Demand from the Food & Beverage Sector Due to their Increasing Sales

Based on end-use industry, the market is segmented into food & beverages, pharmaceuticals, e-commerce, chemicals, building & construction, and others.

Food & beverages dominated the market in 2024 and is anticipated to achieve significant growth in the coming years. Sustainability has increasingly gained importance on the consumer agenda in recent years and is emerging as a primary concern. As a result, numerous producers are using these cartons for packaging food & beverages. Consequently, the increasing use of these cartons and the substantial rise in food & beverage sales are enhancing the segment's growth.

On the other hand, the e-commerce segment is expected to witness steady growth in the forecast period. The rising internet accessibility and online shopping habits motivate producers in the e-commerce industry to adopt eco-friendly packaging, corrugated boxes for shipping, boosting segment growth.

Die Cut Carton Market Regional Outlook

By region, the market is categorized into North America, Europe, Asia Pacific, and the rest of the world.

North America

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North America is a significant market for die cut cartons. The growth is primarily driven by the booming e-commerce industry, which demands efficient, cost-effective, and aesthetically pleasing packaging solutions. Additionally, the increasing focus on producing sustainable packaging solutions and materials further propels the market's growth.

• The Fibre Box Association states that the corrugated packaging and display sector is a USD 35.5 billion annual industry essential to U.S. distribution networks. It is the most commonly utilized shipping material due to its affordability, lightweight nature, functionality, and versatility. In 2021, the sector produced an unprecedented 416 billion square feet of material for creating boxes and displays.

Europe

Europe is the second-largest market. The region's strong push toward sustainability and eco-friendly packaging solutions influences the market growth. Many European companies are adopting recycled and biodegradable materials to meet consumer demand and regulatory requirements and use corrugated packaging on a larger scale.

• The European Federation of Corrugated Board Manufacturers (FEFCO) states that Corrugated packs and protects more than 75% of European goods.

Asia Pacific

Asia Pacific dominates the global die cut carton market share and is experiencing rapid industrialization, urbanization, and increased e-commerce activities. Major regional markets, such as China, India, and Japan, contribute significantly to market growth. The region's e-commerce platforms and manufacturing hubs drive the demand for die cut box packaging solutions. Rising penetration in the e-commerce sector is paving the way for corrugated packaging in the region.

• According to Pack Print International, the number of online shoppers in Indonesia will reach 65 million in 2021. The corrugated packaging industry in Thailand is growing in tandem with the national GDP, with an average annual growth rate of 3-4%.

Latin America

The market in the Latin American region is expected to witness considerable growth in the near future. There is a notable trend in adopting environmentally friendly and recyclable materials for die-cut cartons. This encompasses biodegradable substrates, compostable films, and labels created from recycled materials. Manufacturers are seeking alternatives such as plant-based materials and water-based inks to lessen the ecological impact of die-cut packaging.

• For instance, in February 2023, NotCo, an international foodtech firm and a significant participant in the plant-based food industry, revealed its collaboration with SIG and introduced NotCreme and NotMilk High Protein products in SIG carton packaging. The alliance with SIG enhances the company’s knowledge and adaptability in the plant-based food market. NotMilk Original, zero-sugar, semi-sugar, and chocolate milk options will similarly be offered in aseptic carton packs from SIG.

Middle East & Africa

The Middle East & Africa will experience moderate growth in the forecast period. Despite being a relatively emerging market, the increasing demand for packaging solutions in industries such as food, beverage, and retail presents growth opportunities in the Middle East & African regions. Easy-to-open and easy-to-stack designs are crucial for consumers and retailers in the e-commerce & food delivery industries, thus driving the market growth.

COMPETITIVE LANDSCAPE

Key Industry Players

Continuous Development and Introduction of New Products by Key Companies Resulted in Their Dominating Position

The global die cut box market is concentrated with companies such as Mondi, Smurfit Westrock, Alpha Packaging, Inc., Georgia Pacific Packaging LLC, DS Smith, and Abbe Industrial Packaging Pty Ltd, accounting for a significant market share.

Mondi is a global leader in sustainable packaging and paper, offering customers a wide range of innovative and sustainable solutions worldwide. The company focuses on delivering value accretive growth by prioritizing its packaging businesses and leveraging strategic value drivers.

Smurfit Westrock is a global leader in sustainable paper-based packaging solutions, offering various products and services across diverse industries. They are known for their integrated production, internally sourcing raw materials and recovered fiber, and focus on circular economy principles through renewable, recyclable, and recycled materials.

Additionally, International Paper Company and Georgia Pacific Packaging LLC are among the other prominent players in the market. Focus on significant investments in the research & development of innovative products has supported the companies’ share in the market.

• In April 2025, International Paper revealed that it had begun exclusive discussions with PALM Group from Germany following an irrevocable proposal to acquire five corrugated box facilities in Europe: (i) three facilities located in Normandy, France (specifically, one box facility in Saint-Amand, one box facility in Mortagne, and one sheet facility in Cabourg); (ii) one box facility in Ovar, Portugal; and (iii) one box facility in Bilbao, Spain.

LIST OF KEY DIE-CUT CARTON COMPANIES PROFILED

• Mondi (U.K.)
• Smurfit Westrock (Ireland)
• Alpha Packaging, Inc. (U.S.)
• Georgia Pacific Packaging LLC (U.S.)
• DS Smith (U.K.)
• Abbe Industrial Packaging Pty Ltd (Australia)
• International Paper Company (U.S.)
• Garthwest Ltd (U.K.)
• Great Little Box Company Ltd. (Canada)
• Cascades Inc. (Canada)
• Duncan Packaging (Australia)
• Packaging Corporation of America (U.S.)
• Caps Cases Ltd (U.K.)
• CTP Boxes & Packaging (U.S.)
• Wadpack Pvt. Ltd (India)

KEY INDUSTRY DEVELOPMENTS

• March 2024: Kite Packaging, a packaging distributor based in the U.K., introduced a custom-size box tool that enables customers to select board grade, color, and dimensions for the desired box. The tool also offers immediate quotes for standard custom and die-cut boxes without registration, simplifying the packaging acquisition process.
• July 2023: Apex Packaging, Oman's foremost packaging solution provider, inaugurated a new facility for corrugated boxes in Samail Industrial City. The items are affordable, environmentally friendly, and completely recyclable, demonstrating the firm's dedication to sustainability. Apex Packaging is the premier Omani firm to produce and develop innovative products utilizing the finest grade of corrugated cardboard. The new plant is essential for fulfilling market needs for cardboard boxes and various packaging materials and products.
• July 2022: Menasha Packaging purchased Color-Box, specializing in packaging solutions, containerboard, corrugated boxes, and sheets. The purchase aims to enhance Menasha Packaging's regional presence and provide additional packaging choices for its clients, encompassing consumer goods, food and drinks, industrial and automotive sectors, pharmaceuticals, and electronics.
• September 2021: WestRock partnered with Lumi, a prominent U.S. marketplace for packaging and print items, to provide folding and corrugated manufacturing throughout North America. Lumi members can now obtain factory pricing from WestRock in North America. Lumi's service is groundbreaking and beneficial for both WestRock and its clients.
• August 2021: Mondi introduced its line of sustainable corrugated products to support Central Europe's growing online grocery delivery services. Mondi introduced seven packaging solutions to address the growing need for online grocery delivery services. The packaging features modern designs, is entirely recyclable, and offers convenient choices. The company has developed innovative solutions for the diverse requirements of grocery retailers, enabling them to transport a range of items, from fresh produce to wine bottles, in suitable packaging.

REPORT COVERAGE

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Report Scope & Segmentation