Top 4 Dairy Packaging Trends for 2025

Hello! In case we haven’t crossed paths before, my name is Dan Thompson and I am the Commercial Director, FFS & FS machinery for BW Filling & Closing's ARCIL and DAIRY PACK solutions. I recently had the pleasure of attending the IDFA's Dairy Forum 2025 in San Antonio, where industry leaders gathered to discuss the future of dairy in North America. The event was packed with insightful sessions and discussions on the latest trends and challenges facing the North American dairy industry. I thought it might be useful to share my thoughts on how these key drivers and trends are impacting packaging machinery selection. In this post, I’ll share four important trends in dairy packaging for 2025 and why they matter for your business.

1. Sustainable Packaging Solutions

Sustainability continues to be a top priority for the dairy industry. Consumers are increasingly demanding eco-friendly packaging, and producers are responding by adopting more sustainable materials. One notable trend is the growing desire among yogurt processors to shift from packaging their product in polystyrene (PS) cups to fully recyclable polyethylene terephthalate (PET) cups for yogurt form-fill-seal (FFS) packaging lines. The industry’s largest and most recognizable yogurt producers have already begun converting to PET. Before long the rest of the industry will follow closely behind out of necessity.

While PET has a recyclability advantage over other materials like PS and polypropylene (PP) cups, the expense of investing in new FFS equipment that is capable of running this material can be prohibitive for some dairy processors. For this reason, BW Filling & Closing continuously develops solutions to support packaging and material transformation for its clients. We offer solutions for both new equipment and existing equipment by proposing upgrades to already installed ARCIL form-fill-seal (FFS) lines.

2. Energy Efficient Solutions

Along the same lines, consumers are pressuring dairy processors to become more energy-efficient due to the high energy demands of dairy processing operations. In addition to positive environmental impact, implementing energy-efficient solutions can lead to a significant reduction in your operational costs. For this reason, our product development teams are constantly looking for ways to reduce the amount of energy required to operate our machines, enabling us to deliver more energy-efficient equipment to our customers.

In addition, we understand that energy efficiency goes far beyond operating machinery. As a division of BW Packaging – Barry-Wehmiller’s packaging machinery group – BW Filling & Closing is contributing to BW Packaging’s pledge to reduce emissions on its path to net zero. As a key piece of our customers’ supply chains, we understand and take very seriously our responsibility to reduce our own scope 1 and 2 emissions, and by extension the scope 3 emissions of our customers.

3. Flexible Manufacturing Capabilities

With the proliferation of dairy products and various packaging options, the ability to quickly switch between different products and packaging types is essential for modern dairy processors. Flexibility in manufacturing allows producers to respond to market demands and consumer preferences – whether related to sustainability, food safety or shelf appeal – more effectively.

For this reason, BW Filling & Closing’s form-fill-seal and preformed cup fill-seal machines are designed for quick and easy changeovers. Whether you need to switch over to a new packaging material, cup size, or product type, the flexibility of our solutions ensures that yogurt producers can maintain efficiency and hygiene standards while adapting to consumer trends.

4. Addressing Labor Shortages

Lastly, labor shortages remain a significant challenge for dairy processors. High operator turnover and difficulties in finding skilled personnel can disrupt production. To address this issue, companies are investing in technologies that simplify training and reduce dependency on manual labor. This trend is crucial for maintaining smooth operations and ensuring consistent product quality.

One of the ways we’re solving this challenge for our customers is through development of smart HMIs. Our smart machine interfaces – including Efidrive – make it easier for operators to learn and manage equipment, reducing training time and costs. 

What’s Next for Dairy Packaging Solutions? 

Staying informed about the latest dairy packaging trends is essential for producers looking to thrive in a competitive market. By embracing the consumer trends of today and staying tuned into where things might be going tomorrow, you can position your dairy processing business for success in 2025 and beyond. If you found this content helpful, I encourage you to subscribe for updates below.