Battery Packaging Market Size and Outlook 2031

Report Description

Forecast Period	2027-2031
Market Size (2025)	USD 32.88 Billion
CAGR (2026-2031)	10.54%
Fastest Growing Segment	Corrugated
Largest Market	Asia Pacific
Market Size (2031)	USD 59.99 Billion

Market Overview

The Global Battery Packaging Market will grow from USD 32.88 Billion in 2025 to USD 59.99 Billion by 2031 at a 10.54% CAGR. Battery packaging consists of the external casings, thermal management layers, and structural components designed to house energy storage cells while ensuring electrical insulation and protection against physical impact. The sector is fundamentally driven by the accelerating production volume of electric vehicles and the expanding deployment of grid-scale renewable energy storage systems which necessitate robust containment solutions. According to the European Automobile Manufacturers' Association, battery-electric vehicles captured a market share of 13.6% in 2024, underscoring the sustained industrial demand for specialized packaging materials to support this production output.

One significant challenge impeding broader market expansion is the ongoing volatility in raw material prices coupled with supply chain instability. Manufacturers frequently encounter fluctuating costs for essential inputs such as aluminum and high-performance polymers which complicates financial planning and disrupts pricing strategies. Furthermore, the increasing strictness of international regulations regarding material recyclability and full lifecycle traceability imposes additional operational costs and technical hurdles for packaging suppliers attempting to scale their global operations.

Key Market Drivers

Rapid expansion within the global electric vehicle industry acts as the primary catalyst for the battery packaging sector, necessitating high-durability casings and thermal regulation systems to ensure safety. As automakers scale production to meet emission targets, the requirement for materials that withstand thermal runaway has intensified. According to the International Energy Agency, April 2024, in the 'Global EV Outlook 2024', electric car sales reached nearly 14 million in 2023, driving higher consumption of specialized aluminum and composite packaging housings. This surge compels suppliers to innovate in lightweighting and structural integrity to support heavier battery packs while maintaining rigorous impact protection standards.

The increasing deployment of grid-scale energy storage systems further propels market growth, demanding robust containment solutions for stationary applications. Utility companies are installing large-scale battery farms to stabilize renewable energy integration, requiring modular and weather-resistant packaging capable of enduring outdoor exposure. According to the U.S. Energy Information Administration, February 2024, in the 'Preliminary Monthly Electric Generator Inventory', developers planned to expand United States battery storage capacity by 14.3 GW in 2024. This infrastructure build-out underscores the need for scalable packaging. Additionally, the broader trajectory supports this trend; according to the International Energy Agency, in 2024, total global demand for batteries increased by more than 40% during the previous year, signaling a sustained requirement for diverse packaging formats.

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Key Market Challenges

The ongoing volatility in raw material prices coupled with supply chain instability constitutes a critical barrier impeding the expansion of the Global Battery Packaging Market. Manufacturers in this sector are heavily dependent on consistent access to aluminum and high-performance polymers to fabricate structural casings and thermal management systems. When the costs of these essential inputs fluctuate unpredictably, it disrupts financial planning and forces suppliers to frequently adjust pricing strategies, which can strain relationships with automotive clients. Furthermore, instability within the global supply chain often results in material shortages, causing production delays that prevent packaging companies from meeting the rigid delivery schedules required by electric vehicle manufacturers.

This operational strain is intensified by tangible contractions in material availability. According to The Aluminum Association, in 2024, imports of aluminum and aluminum products into North America decreased by 14% year-to-date, creating a significant deficit in the supply of this primary feedstock. Such a reduction in accessible raw materials, occurring amidst a period of industrial need, directly restricts the manufacturing capacity of packaging suppliers. This scarcity not only inflates procurement costs but also limits the volume of finished units that can be produced, thereby hampering the market's overall growth potential.

Key Market Trends

The adoption of Cell-to-Pack (CTP) and Cell-to-Chassis structural designs is fundamentally reshaping battery enclosures by removing intermediate module components to optimize volumetric efficiency and reduce overall weight. This architectural shift allows manufacturers to significantly increase energy density within the same physical footprint, directly addressing the demand for extended vehicle range without expanding the battery pack size. The industrial scale of this transition is evidenced by major production milestones; according to CATL, April 2024, in the '2023 Annual Report', the company's module-free Qilin battery technology achieved mass production and contributed to a global electric vehicle battery market share of 36.8%, signaling a widespread departure from traditional modular packaging formats.

Simultaneously, there is a distinct industry shift towards utilizing recycled and bio-based sustainable packaging materials, driven by the imperative to lower Scope 3 emissions and secure critical mineral supply chains. Suppliers are increasingly substituting virgin aluminum and high-grade plastics with recovered alloys and renewable composites to create circular casing loops that minimize environmental impact. This movement is bolstered by substantial federal support; according to the U.S. Department of Energy, September 2024, in the 'Biden-Harris Administration Announces Over $3 Billion to Support America’s Battery Manufacturing and Supply Chain', the government awarded funding to 25 projects, including initiatives specifically focused on expanding domestic capacity for processing recycled battery materials to support sustainable packaging production.

Segmental Insights

The corrugated segment is positioning itself as the fastest-growing category in the Global Battery Packaging Market, driven by its dual advantages of sustainability and superior protective capabilities. Industry preference is shifting toward corrugated materials as their fluted structure offers critical shock absorption, safeguarding sensitive battery components during transit. Moreover, this packaging type is highly cost-effective and lightweight, optimizing logistics efficiency. Its extensive adoption is further validated by its compliance with rigorous international safety standards, such as the United Nations regulations for the transport of dangerous goods, which mandate secure containment for hazardous lithium-ion shipments.

Regional Insights

Asia Pacific commands the global battery packaging market due to the high volume of electric vehicle and consumer electronics manufacturing in China, Japan, and South Korea. The presence of major battery producers in this region creates consistent demand for specialized packaging to ensure safety during transit. Additionally, supportive initiatives from authorities such as China's Ministry of Industry and Information Technology regarding electric mobility have significantly boosted battery production rates. This rapid industrial expansion, combined with the need to adhere to rigorous safety standards for hazardous material transport, solidifies the region's leading status in the sector.

Recent Developments

In January 2025, Energizer Holdings launched a new plastic-free, fully recyclable packaging solution for its portfolio of household batteries. The company introduced the paper-based packaging design to replace traditional plastic blister packs, addressing consumer demand for more sustainable products and reducing environmental waste. The redesigned packaging featured a user-friendly peel-open mechanism and was engineered to optimize shelf space and merchandising efficiency for retailers. This product launch represented a major shift in the consumer segment of the battery packaging market, with the new sustainable cartons set to roll out across North America throughout the year.
In September 2024, Constellium announced the successful results of its ALuminium Intensive Vehicle Enclosures (ALIVE) research project, which focused on developing next-generation battery housings for electric vehicles. The £15 million initiative, led by the company's University Technology Center and part-funded by the UK government, demonstrated that the new structural aluminium enclosure designs achieved weight savings of 12% to 35% compared to existing solutions. The project validated the use of high-strength alloys and agile manufacturing processes to produce cost-effective, lightweight battery protection systems that meet rigorous safety standards, marking a breakthrough in metal battery packaging technology.
In May 2024, Webasto announced the completion of a significant expansion at its battery pack manufacturing facility in Dangjin, South Korea. The automotive supplier inaugurated a new plant with over 15,000 square meters of production and storage space, designed to increase its annual capacity by an additional 100,000 battery packs. This strategic development was aimed at meeting the rising demand for electric vehicle battery systems in the Asian market. The expanded facility was projected to reach a total production capacity of 300,000 battery packs per year by 2025, reinforcing the company’s capabilities in battery assembly and packaging.
In January 2024, SGL Carbon entered into a technology partnership with E-Works Mobility to supply battery cases made of glass fiber-reinforced plastic (GFRP) for the HEERO electric transporter. This collaboration involved replacing the vehicle's previous aluminum battery boxes with the advanced composite material, which offers superior thermal insulation and fire protection due to its lower heat conduction. The company emphasized that the new GFRP housings provided significant weight savings and improved raw material efficiency compared to traditional metal solutions. This development highlighted the growing adoption of lightweight composite materials in the electric vehicle battery packaging market to enhance performance and safety.

Key Market Players

Söhner Kunststofftechnik GmbH
Trinseo
GWP Protective
EaglePicher Technologies
CHEP
Wellplast AB
Targray
NEFAB GROUP
CL Smith
Cadenza Innovation Inc

By Type of Casing	By Type of Packaging	By Material	By Level of Packaging	By Region
Cylindrical Prismatic Pouch	Corrugated Blister Others	Metals Plastics Cardboard Others	Cell & Pack Packaging and Transportation Packaging	North America Europe Asia Pacific South America Middle East & Africa

Report Scope:

In this report, the Global Battery Packaging Market has been segmented into the following categories, in addition to the industry trends which have also been detailed below:

Battery Packaging Market, By Type of Casing:

Cylindrical
Prismatic
Pouch

Battery Packaging Market, By Type of Packaging:

Corrugated
Blister
Others

Battery Packaging Market, By Material:

Metals
Plastics
Cardboard
Others

Battery Packaging Market, By Level of Packaging:

Cell & Pack Packaging and Transportation Packaging

Battery Packaging Market, By Region:

North America

United States
Canada
Mexico

Europe

France
United Kingdom
Italy
Germany
Spain

Asia Pacific

China
India
Japan
Australia
South Korea

South America

Brazil
Argentina
Colombia

Middle East & Africa

South Africa
Saudi Arabia
UAE

Competitive Landscape

Company Profiles: Detailed analysis of the major companies present in the Global Battery Packaging Market.

Available Customizations:

Global Battery Packaging Market report with the given market data, TechSci Research offers customizations according to a company's specific needs. The following customization options are available for the report:

Company Information

Detailed analysis and profiling of additional market players (up to five).

Global Battery Packaging Market is an upcoming report to be released soon. If you wish an early delivery of this report or want to confirm the date of release, please contact us at [email protected]

Table of content

1. Product Overview

1.1. Market Definition

1.2. Scope of the Market

1.2.1. Markets Covered

1.2.2. Years Considered for Study

1.2.3. Key Market Segmentations

2. Research Methodology

2.1. Objective of the Study

2.2. Baseline Methodology

2.3. Key Industry Partners

2.4. Major Association and Secondary Sources

2.5. Forecasting Methodology

2.6. Data Triangulation & Validation

2.7. Assumptions and Limitations

3. Executive Summary

3.1. Overview of the Market

3.2. Overview of Key Market Segmentations

3.3. Overview of Key Market Players

3.4. Overview of Key Regions/Countries

3.5. Overview of Market Drivers, Challenges, Trends

4. Voice of Customer

5. Global Battery Packaging Market Outlook

5.1. Market Size & Forecast

5.1.1. By Value

5.2. Market Share & Forecast

5.2.1. By Type of Casing (Cylindrical, Prismatic, Pouch)

5.2.2. By Type of Packaging (Corrugated, Blister, Others)

5.2.3. By Material (Metals, Plastics, Cardboard, Others)

5.2.4. By Level of Packaging (Cell & Pack Packaging and Transportation Packaging)

5.2.5. By Region

5.2.6. By Company (2025)

5.3. Market Map

6. North America Battery Packaging Market Outlook

6.1. Market Size & Forecast

6.1.1. By Value

6.2. Market Share & Forecast

6.2.1. By Type of Casing

6.2.2. By Type of Packaging

6.2.3. By Material

6.2.4. By Level of Packaging

6.2.5. By Country

6.3. North America: Country Analysis

6.3.1. United States Battery Packaging Market Outlook

6.3.1.1. Market Size & Forecast

6.3.1.1.1. By Value

6.3.1.2. Market Share & Forecast

6.3.1.2.1. By Type of Casing

6.3.1.2.2. By Type of Packaging

6.3.1.2.3. By Material

6.3.1.2.4. By Level of Packaging

6.3.2. Canada Battery Packaging Market Outlook

6.3.2.1. Market Size & Forecast

6.3.2.1.1. By Value

6.3.2.2. Market Share & Forecast

6.3.2.2.1. By Type of Casing

6.3.2.2.2. By Type of Packaging

6.3.2.2.3. By Material

6.3.2.2.4. By Level of Packaging

6.3.3. Mexico Battery Packaging Market Outlook

6.3.3.1. Market Size & Forecast

6.3.3.1.1. By Value

6.3.3.2. Market Share & Forecast

6.3.3.2.1. By Type of Casing

6.3.3.2.2. By Type of Packaging

6.3.3.2.3. By Material

6.3.3.2.4. By Level of Packaging

7. Europe Battery Packaging Market Outlook

7.1. Market Size & Forecast

7.1.1. By Value

7.2. Market Share & Forecast

7.2.1. By Type of Casing

7.2.2. By Type of Packaging

7.2.3. By Material

7.2.4. By Level of Packaging

7.2.5. By Country

7.3. Europe: Country Analysis

7.3.1. Germany Battery Packaging Market Outlook

7.3.1.1. Market Size & Forecast

7.3.1.1.1. By Value

7.3.1.2. Market Share & Forecast

7.3.1.2.1. By Type of Casing

7.3.1.2.2. By Type of Packaging

7.3.1.2.3. By Material

7.3.1.2.4. By Level of Packaging

7.3.2. France Battery Packaging Market Outlook

7.3.2.1. Market Size & Forecast

7.3.2.1.1. By Value

7.3.2.2. Market Share & Forecast

7.3.2.2.1. By Type of Casing

7.3.2.2.2. By Type of Packaging

7.3.2.2.3. By Material

7.3.2.2.4. By Level of Packaging

7.3.3. United Kingdom Battery Packaging Market Outlook

7.3.3.1. Market Size & Forecast

7.3.3.1.1. By Value

7.3.3.2. Market Share & Forecast

7.3.3.2.1. By Type of Casing

7.3.3.2.2. By Type of Packaging

7.3.3.2.3. By Material

7.3.3.2.4. By Level of Packaging

7.3.4. Italy Battery Packaging Market Outlook

7.3.4.1. Market Size & Forecast

7.3.4.1.1. By Value

7.3.4.2. Market Share & Forecast

7.3.4.2.1. By Type of Casing

7.3.4.2.2. By Type of Packaging

7.3.4.2.3. By Material

7.3.4.2.4. By Level of Packaging

7.3.5. Spain Battery Packaging Market Outlook

7.3.5.1. Market Size & Forecast

7.3.5.1.1. By Value

7.3.5.2. Market Share & Forecast

7.3.5.2.1. By Type of Casing

7.3.5.2.2. By Type of Packaging

7.3.5.2.3. By Material

7.3.5.2.4. By Level of Packaging

8. Asia Pacific Battery Packaging Market Outlook

8.1. Market Size & Forecast

8.1.1. By Value

8.2. Market Share & Forecast

8.2.1. By Type of Casing

8.2.2. By Type of Packaging

8.2.3. By Material

8.2.4. By Level of Packaging

8.2.5. By Country

8.3. Asia Pacific: Country Analysis

8.3.1. China Battery Packaging Market Outlook

8.3.1.1. Market Size & Forecast

8.3.1.1.1. By Value

8.3.1.2. Market Share & Forecast

8.3.1.2.1. By Type of Casing

8.3.1.2.2. By Type of Packaging

8.3.1.2.3. By Material

8.3.1.2.4. By Level of Packaging

8.3.2. India Battery Packaging Market Outlook

8.3.2.1. Market Size & Forecast

8.3.2.1.1. By Value

8.3.2.2. Market Share & Forecast

8.3.2.2.1. By Type of Casing

8.3.2.2.2. By Type of Packaging

8.3.2.2.3. By Material

8.3.2.2.4. By Level of Packaging

8.3.3. Japan Battery Packaging Market Outlook

8.3.3.1. Market Size & Forecast

8.3.3.1.1. By Value

8.3.3.2. Market Share & Forecast

8.3.3.2.1. By Type of Casing

8.3.3.2.2. By Type of Packaging

8.3.3.2.3. By Material

8.3.3.2.4. By Level of Packaging

8.3.4. South Korea Battery Packaging Market Outlook

8.3.4.1. Market Size & Forecast

8.3.4.1.1. By Value

8.3.4.2. Market Share & Forecast

8.3.4.2.1. By Type of Casing

8.3.4.2.2. By Type of Packaging

8.3.4.2.3. By Material

8.3.4.2.4. By Level of Packaging

8.3.5. Australia Battery Packaging Market Outlook

8.3.5.1. Market Size & Forecast

8.3.5.1.1. By Value

8.3.5.2. Market Share & Forecast

8.3.5.2.1. By Type of Casing

8.3.5.2.2. By Type of Packaging

8.3.5.2.3. By Material

8.3.5.2.4. By Level of Packaging

9. Middle East & Africa Battery Packaging Market Outlook

9.1. Market Size & Forecast

9.1.1. By Value

9.2. Market Share & Forecast

9.2.1. By Type of Casing

9.2.2. By Type of Packaging

9.2.3. By Material

9.2.4. By Level of Packaging

9.2.5. By Country

9.3. Middle East & Africa: Country Analysis

9.3.1. Saudi Arabia Battery Packaging Market Outlook

9.3.1.1. Market Size & Forecast

9.3.1.1.1. By Value

9.3.1.2. Market Share & Forecast

9.3.1.2.1. By Type of Casing

9.3.1.2.2. By Type of Packaging

9.3.1.2.3. By Material

9.3.1.2.4. By Level of Packaging

9.3.2. UAE Battery Packaging Market Outlook

9.3.2.1. Market Size & Forecast

9.3.2.1.1. By Value

9.3.2.2. Market Share & Forecast

9.3.2.2.1. By Type of Casing

9.3.2.2.2. By Type of Packaging

9.3.2.2.3. By Material

9.3.2.2.4. By Level of Packaging

9.3.3. South Africa Battery Packaging Market Outlook

9.3.3.1. Market Size & Forecast

9.3.3.1.1. By Value

9.3.3.2. Market Share & Forecast

9.3.3.2.1. By Type of Casing

9.3.3.2.2. By Type of Packaging

9.3.3.2.3. By Material

9.3.3.2.4. By Level of Packaging

10. South America Battery Packaging Market Outlook

10.1. Market Size & Forecast

10.1.1. By Value

10.2. Market Share & Forecast

10.2.1. By Type of Casing

10.2.2. By Type of Packaging

10.2.3. By Material

10.2.4. By Level of Packaging

10.2.5. By Country

10.3. South America: Country Analysis

10.3.1. Brazil Battery Packaging Market Outlook

10.3.1.1. Market Size & Forecast

10.3.1.1.1. By Value

10.3.1.2. Market Share & Forecast

10.3.1.2.1. By Type of Casing

10.3.1.2.2. By Type of Packaging

10.3.1.2.3. By Material

10.3.1.2.4. By Level of Packaging

10.3.2. Colombia Battery Packaging Market Outlook

10.3.2.1. Market Size & Forecast

10.3.2.1.1. By Value

10.3.2.2. Market Share & Forecast

10.3.2.2.1. By Type of Casing

10.3.2.2.2. By Type of Packaging

10.3.2.2.3. By Material

10.3.2.2.4. By Level of Packaging

10.3.3. Argentina Battery Packaging Market Outlook

10.3.3.1. Market Size & Forecast

10.3.3.1.1. By Value

10.3.3.2. Market Share & Forecast

10.3.3.2.1. By Type of Casing

10.3.3.2.2. By Type of Packaging

10.3.3.2.3. By Material

10.3.3.2.4. By Level of Packaging

11. Market Dynamics

11.1. Drivers

11.2. Challenges

12. Market Trends & Developments

12.1. Merger & Acquisition (If Any)

12.2. Product Launches (If Any)

12.3. Recent Developments

13. Global Battery Packaging Market: SWOT Analysis

14. Porter's Five Forces Analysis

14.1. Competition in the Industry

14.2. Potential of New Entrants

14.3. Power of Suppliers

14.4. Power of Customers

14.5. Threat of Substitute Products

15. Competitive Landscape

15.1. Söhner Kunststofftechnik GmbH

15.1.1. Business Overview

15.1.2. Products & Services

15.1.3. Recent Developments

15.1.4. Key Personnel

15.1.5. SWOT Analysis

15.2. Trinseo

15.3. GWP Protective

15.4. EaglePicher Technologies

15.5. CHEP

15.6. Wellplast AB

15.7. Targray

15.8. NEFAB GROUP

15.9. CL Smith

15.10. Cadenza Innovation Inc

16. Strategic Recommendations

17. About Us & Disclaimer

Report Description

Table of content

Figures and Tables

Frequently asked questions

What was the market size of the Global Battery Packaging Market in 2025?

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