McKinsey & Company published packaging industry guidance in 2020 addressing COVID-19's impact on demand patterns, supply chain resilience, and capital allocation. Flexible packaging converters used the analysis to distinguish temporary pantry-loading spikes from structural shifts—such as accelerated e-commerce and away-from-home food declines.
McKinsey highlighted scenarios where health concerns increased preference for sealed, individually portioned formats—boosting certain flexible applications while depressing bulk and self-serve packaging. Converters reallocated slit capacity and inventory toward SKUs serving retail grocery while food-service laminates faced order cancellations.
Supply chain recommendations emphasized dual sourcing for critical resins and adhesives, safety stock policies for long-lead spare parts, and digital tools for remote collaboration with brand owners unable to visit plants for press approvals. Flexo shops accelerated virtual proofing workflows to keep artwork cycles moving during travel restrictions.
Capital expenditure guidance suggested prioritizing debottlenecking and automation over greenfield expansion until demand visibility improved—though sustainability investments with clear regulatory drivers retained board support. McKinsey framed recyclable packaging development as a medium-term competitive necessity rather than a discretionary project.
For plant managers, McKinsey's 2020 publications provided a structured lens on chaos—helping leadership teams communicate with boards about workforce safety investments, overtime policies, and selective equipment upgrades that would support post-pandemic SKU portfolios.