United States Anti-caking Market Size & Share Analysis - Growth Trends And Forecast (2025 - 2030)

United States Anti-Caking Market Trends and Insights

Processed foods, spice blends, and instant mix adoption in the u.s.

Instant soups, seasoning blends, and meal-kit sachets, collectively forming a USD 3.5 billion processed-food subsegment, prioritize moisture blocking to ensure product quality and shelf stability. These powders, designed to sit on shelves for months in 60-75% relative humidity, rely on silicon dioxide (1.5–2%) and calcium silicate (0.5–1%) to remain free-flowing. This prevents a 2–3% moisture pick-up, which would render the product unsaleable by causing clumping and degradation of texture. The USDA's 2024 Food Availability Data System indicates that per capita consumption of dried soups and sauces has stabilized at approximately 2.3 kilograms annually, yet the shift toward premium spice blends, organic turmeric, smoked paprika, and specialty salts commands 40-60% higher retail prices and tolerates proportionally higher anti-caking agent costs^{[1]Source: United States Department of Agriculture, "Food Availability (Per Capita) Data System", ers.usda.gov}.  While McCormick adheres to these inclusion rates to maintain product integrity, it is also experimenting with rice concentrate in its organic line to align with Whole Foods’ ingredient policies, which emphasize natural and clean-label components. The stakes are higher for single-serve meal kits, as sachets endure temperature fluctuations during last-mile delivery, which can exacerbate moisture-related issues. In these scenarios, silica grades with hydrophobic surfaces prove superior to hygroscopic calcium salts, offering enhanced performance in maintaining product flowability and quality under challenging conditions.

Regulatory certainty (GRAS) for silicon dioxide and cellulosics

In the U.S., the FDA's GRAS listings for silicon dioxide (21 CFR 172.480) and powdered cellulose (21 CFR 182.90) provide manufacturers with confidence in minimal reformulation risks^{[2]Source: Food and Drug Administration, "CFR - Code of Federal Regulations Title 21", accessdata.fda.gov}. This contrasts with the European Union, where E551 is subject to periodic scrutiny due to evolving regulatory standards and safety evaluations. Cabot's AEROSIL fumed silica, with a surface area of 200–300 m²/g, achieves anti-caking targets at a mere 0.2–0.5% inclusion, solidifying its status as a staple in pharmaceutical excipients. Its high surface area enhances its ability to prevent clumping, ensuring consistent product quality and performance. Meanwhile, organic operators are capitalizing on the benefits of silicon dioxide. Thanks to 7 CFR 205, which permits its use when derived without synthetic solvents, brands like Annie's can uphold their USDA Organic labels while adhering to flow-control specifications. This regulatory allowance enables organic brands to maintain both product integrity and compliance with organic certification standards.

Expansion in nutraceutical and OTC pharma manufacturing (glidants)

In 2024-2025, U.S. nutraceutical contract capacity surged by 15-18%, driven by advancements in manufacturing technologies and increased demand for dietary supplements. In California and New Jersey, tablet presses, now exceeding 10,000 units per hour, have started incorporating colloidal silicon dioxide to enhance production efficiency and tablet quality. Meanwhile, calcium phosphates from Innophos are being utilized as disintegrants, improving tablet dissolution and bioavailability. Although SPI Pharma’s magnesium stearate continues to be the preferred lubricant due to its effectiveness in preventing tablet sticking and ensuring smooth production, IFF’s divestiture to Roquette in 2025 may constrict the domestic supply, potentially impacting manufacturers. In 2024, WHO reaffirmed the 0-3 mg/kg ADI for magnesium stearate, paving the way for elevated supplement dosages and providing manufacturers with greater flexibility in formulation.

High-speed packaging and free-flow needs in salt, bakery, beverage mixes

Manufacturers fill over 120 packs per minute with table salt, baking mixes, and sports-nutrition products, ensuring high-speed production to meet growing consumer demand. In premium iodized salt, calcium silicate, which can absorb 600% of its weight in water, has replaced ferrocyanides. This shift is driven by consumer concerns, as the term “cyanide” is often associated with toxicity, despite its safe usage in regulated amounts. Clumping downtime, which can disrupt production lines, costs manufacturers between USD 500-1,000 per hour. To mitigate these losses, manufacturers invest in hydrophobic silica. This material not only resists Gulf-Coast humidity, a common challenge in humid climates, but also disperses instantly in shaker tests, ensuring product quality and consistency.

Clean-label scrutiny and retailer bans on certain E-numbers

Whole Foods, concerned about the use of silicon dioxide, scrutinizes its suppliers and has pushed for a shift towards rice hull and organic tapioca starch, moving away from roughly 230 synthetic ingredients. Following suit, private labels from Target and Kroger are incentivizing similar reformulations across their mainstream offerings. While natural agents occasionally falter in tropical humidity, drawing customer complaints, a 2024 IFIC survey found that 54% of consumers steer clear of unfamiliar ingredients. This consumer sentiment underscores brands' readiness to absorb higher costs. Meanwhile, ingredient manufacturers like Evonik are pouring resources into educational campaigns, yet they find themselves overshadowed by the marketing clout of "free-from" labels.

Talc litigation and perception risks in personal care/food

Despite being asbestos-free, food-grade talc has been shunned by users, largely due to Johnson & Johnson's staggering USD 8 billion settlements over talc-related issues. In 2024, the FDA's cosmetic tests detected asbestos in certain samples, igniting demands for stricter purity checks, with implications reaching food standards^{[3]Source: Food and Drug Administration, "Talc", fda.gov}. This has raised concerns among food manufacturers about potential regulatory scrutiny and consumer backlash. As a result, formulators of chewing gum and rice coatings have turned to a combination of calcium carbonate and stearic acid. This shift has inflated their formula costs by 20-30%, as no alternative can replicate talc's unique lubricity and whitening properties, which are critical for achieving the desired texture and appearance in these products.

Segment Analysis

By Product Type: Silica Overtakes Calcium in High-Value Niches

In 2024, calcium-based agents dominated the U.S. anti-caking agents market, securing 41.27% of total revenues. Within this segment, calcium silicate stands out in iodized salt applications, where a 0.5–1% inclusion effectively mitigates potassium iodide's hygroscopicity, ensuring a free-flowing product. Tricalcium phosphate not only fortifies calcium in cereal and flour blends, adhering to FDA nutrient regulations, but also prevents caking in bulk commodities. Suppliers such as Mississippi Lime and Omya leverage cost leadership and strategically advantageous freight distribution to maintain their dominance, particularly catering to salt and dairy processors.

Silica-based agents, currently holding a 38% market share, are the fastest-growing category, projected to advance at a 6.74% CAGR through 2030. Fumed silica grades, with surface areas of 200–400 m²/g, achieve superior flow at a mere 0.2% loading. This efficiency proves especially economical for high-value nutraceutical tablets and pharmaceutical clusters that prioritize ultra-pure colloidal variants. Meanwhile, in dried soup and beverage mixes, precipitated silica commands a premium over mineral salts, thanks to its compliance with stricter color and heavy-metal specifications. Notably, Evonik's decision to boost capacity by 50% at its Charleston plant by 2026 highlights the accelerating demand for silica, driven by rising purity standards.

Note: Segment shares of all individual segments available upon report purchase

By Application: Food and Beverages Keep the Lead, Pharma Gains Pace

In 2024, the food and beverage sector dominated the U.S. anti-caking agents market, accounting for 61.52% of total revenues. Within this sector, seasonings and condiments took the lead, using 1.5–2% of either silicon dioxide or calcium silicate. This addition prevents clumping in garlic, onion, and paprika powders, which are then distributed through grocery stores and e-commerce platforms. Bakery mixes, on the other hand, utilize mildly alkaline agents like tricalcium phosphate and magnesium carbonate. These agents blend seamlessly with leavening agents, ensuring a consistent flow. Dairy powders, including whey protein concentrate, incorporate 0.5–1% silicon dioxide. This dosage prevents particle bridging in both spray-dryer cyclones and shipping totes. The segment's growth, at a 7.71% CAGR, is driven by rising demand for spice blends, protein powders, and instant soup mixes.

While pharmaceutical applications accounted for only 9% of the 2024 volume, they emerged as the fastest-growing end-use, projected to expand at a 6.9% CAGR through 2030. In New Jersey and North Carolina, direct-compression tablet lines utilize 0.2–0.5% colloidal silica or magnesium stearate. This ensures optimal flowability, allowing presses to achieve an impressive rate of 12,000 units per hour. These high-purity agents are pivotal for efficient production, especially with the increasing volumes of nutraceuticals and generic drugs. While the beauty and personal care sector is moving away from talc in favor of higher-loading kaolin substitutes, the pharmaceutical industry's stringent precision requirements underscore its leadership in growth. Additionally, the "Other" category sees fertilizer conditioning bolstered by low-cost clays and lignosulfonates, ensuring 18-month humidity resistance.

Note: Segment shares of all individual segments available upon report purchase

Geography Analysis

Manufacturing clusters, humidity profiles, and regulatory climates shape regional consumption patterns. In the Midwest, states like Illinois, Ohio, Wisconsin, and Indiana account for nearly 40% of the nation's volume. This is largely due to mega-plants operated by Kraft Heinz, Conagra, and General Mills, producing everything from soup mixes to bakery premixes. With Midwestern summers boasting 60-75% relative humidity, these companies are compelled to increase their use of silica and calcium silicate to ensure smooth operations. Meanwhile, California stands at the forefront of clean-label experimentation. Here, supplement giants in Orange County and organic brands in the Sacramento Valley opt for rice hull and bamboo fiber, even at a premium price. 

The Southeast has emerged as a hub for pharmaceuticals and over-the-counter products. Notable companies like Patheon, Catalent, and Thermo Fisher are setting the standard, often specifying USP-grade colloidal silica. In North Carolina’s Research Triangle Park, nutraceutical research and development labs are making strides, refining direct-compression blends that can reduce cycle times by 30-40%. Over in the Gulf Coast, fertilizer granulation plants in Texas and Louisiana are applying kaolin-polymer coatings to withstand tropical moisture. This practice bolsters a consistent demand for clay-based anti-caking agents throughout the year. 

On the East Coast, New Jersey's pharmaceutical corridor has a high demand for top-tier glidants. Meanwhile, distributor warehouses in Pennsylvania, such as Brenntag, Univar, and IMC, are streamlining just-in-time deliveries for small-batch food producers. In the Pacific Northwest, organic processors, spearheaded by Bob’s Red Mill, are opting for powdered cellulose or rice concentrate to uphold their USDA Organic credentials. States like California and Washington, known for their stringent combustible-dust codes, are witnessing a swift shift towards liquid anti-caking slurries or enclosed transfer systems. This transition, while beneficial, comes with added capital costs, posing a challenge for smaller firms who either have to absorb these expenses or consider exiting the market.