Food Processing Companies in the US: How Many Are There and What Do They Do?

The food processing industry in the US is bigger than most people imagine. Just picture this: according to the US Census Bureau’s most recent data, there are over 36,000 food and beverage processing facilities scattered from California to Connecticut. They don’t just slap labels on cans—they’re behind almost everything from your frozen pizza to bagged salad and even pet food.

If you grab a snack at the gas station or cook a quick dinner from the freezer aisle, odds are it passed through some kind of processing plant. And the variety is wild. You’ve got massive nationwide giants and tiny, family-run businesses tucked away in small towns. Whether you want to partner with a contract manufacturer or you’re just curious about what’s fueling those grocery store shelves, understanding this industry can save you a lot of guesswork and help you make smarter choices—whether you’re shopping, investing, or trying to get your own product to market.

• How Many US Food Processing Companies Exist?
• What Types of Food Processing Units Are There?
• Big Names and Hidden Gems in the Industry
• Tips for Navigating the Food Processing Landscape

How Many US Food Processing Companies Exist?

If you’ve ever wondered just how many food processing companies there are in the US, the number may surprise you. The US Census Bureau clocked in over 36,000 registered food and beverage processing facilities across the country as of late 2023. These aren’t just mega-factories churning out soda or cereal—this count covers everything from bakery plants, dairy processors, and meat packers, to those making sauces, frozen dinners, and snacks. Even boutique chocolate makers and kombucha brewers add to these figures.

To get an idea of how this stacks up, check out the rough breakdown by type from recent industry surveys:

California, Texas, and New York lead in number of facilities, thanks to their huge populations and agricultural output. But every state has a slice of this pie—even the smallest ones host multiple operations. This broad spread means jobs, investments, and a huge mix of products in every part of the country.

Here’s the kicker: Most of these food processing units are small or midsize businesses, not the household brands you see on TV ads. A lot of them have less than 20 workers, but they’re cranking out essential stuff for restaurants, supermarkets, and export. If you’re into getting products manufactured—or just interested in where your lunch comes from—this massive network is what keeps shelves and kitchens stocked all year long.

What Types of Food Processing Units Are There?

Food processing in the US covers a ton of ground. If you hear "food processing," it isn't just about giant factories making packaged junk food. There are different types of units doing all sorts of stuff, and it’s helpful to know what each one does, whether you’re starting a business, picking suppliers, or just curious about the journey from farm to dinner plate.

Here’s a breakdown of common types of food processing companies:

• Primary Processors: These guys handle raw crops and livestock, turning them into something more usable. Think flour mills, meat packing plants, and vegetable canning operations. They’re the reason we have things like sugar in bags or chicken in trays at the store.
• Secondary Processors: After the basics, these companies take those ingredients and whip them into finished products. We’re talking bakeries, snack makers, dairy plants, frozen dinners, and bottled drinks. Most of what you see in grocery stores comes from these secondary units.
• Specialty and Niche Processors: Not everything comes from mega-factories. Small companies make gluten-free bread, ready-to-drink smoothies, organic salsas, or artisanal cheeses. They usually focus on health trends, diet needs, or local flavors.
• Co-packers and Private Label Manufacturers: Ever buy store brand chips or sauces? These are often made by co-packers—companies with the facilities and know-how to produce food for lots of different brands.
• Pet Food Manufacturers: Yep, it’s a huge part of American food processing. Some plants are dedicated just to pet food, and their output rivals what goes to human tables.

Here’s a practical look at how these types play out across different U.S. states:

Each type fills a specific role in the food chain. Knowing the difference can help you choose the right partner, job, or supplier. And if you’re an entrepreneur, picking the right kind of processing unit can make or break your business plan.

Big Names and Hidden Gems in the Industry

When you think about food processing in the US, mega-companies like Tyson Foods, PepsiCo, and Kraft Heinz probably pop into your head first. These big players basically help decide what lands in your grocery cart every week. To give you an idea, Tyson handles one out of every five pounds of chicken, beef, or pork sold in the country. PepsiCo isn’t just about soda—they own brands like Quaker, Frito-Lay, and Gatorade. Kraft Heinz, meanwhile, floods shelves with over 200 food products, from ketchup to ready meals.

But it’s not just about giant names. There’s a whole sea of smaller, often family-run food processing companies making everything from craft cheese to plant-based jerky. Some of these hidden gems get picked up by bigger companies because they’re so good or creative. Ever heard of Amy’s Kitchen? It started out as a tiny organic food company in California but now it’s shaking up the frozen foods market with vegetarian options. Applegate Farms has also carved a niche with its natural and organic meats. Then there are local stars—places like Vermont Creamery or S. Clyde Weaver in Pennsylvania—making waves with specialty cheeses and smoked meats.

Check out how the industry breaks down by type and total revenue:

If you’re hoping to work with an up-and-coming food processing unit or just want to try something off the beaten path, visiting local food expos or checking out regional specialty markets can reveal some surprisingly good and unique brands. Don’t overlook the little guys—they’re often faster to innovate and more flexible if you have a custom order or a special dietary need.

Tips for Navigating the Food Processing Landscape

Figuring out the US food processing scene can be a headache if you don’t have a game plan. There are thousands of companies, and they’re not all cut from the same cloth. Some handle massive quantities, others specialize in small batch or niche goods. So, how do you make sense of it all if you’re looking to work with a food processing company or just want to get deeper into this industry?

First up, know what you’re looking for. Are you after a co-packer for your new granola bar? Or maybe you want a private label maker for some salsa? Different food processing units focus on different things—some just do meat, others are all about beverages, and some are all-in-one shops. Start by narrowing it down so you don’t waste time talking to the wrong folks.

• Don’t skip online directories like Food Processing magazine’s supplier database, or even ThomasNet. These aren’t perfect, but they beat scrolling through endless Google results.
• Industry trade shows—like Process Expo or the annual IFT Food Expo—are places to meet company reps face-to-face. Even if you don’t have a booth, walking the floor can pay off big time with contacts and insights.
• Dig into reviews and references. It’s pretty common for small brands to swap notes on which food manufacturing partners deliver and which ones ghost you when things get tough. Don’t be afraid to ask hard questions.
• If you want data, the US Department of Agriculture (USDA) keeps updated statistics on food processing plants annually. Their database helps you filter companies by product type and region.

Here’s a quick example of company size and specialty, based on a recent industry survey:

Last thing—watch out for minimum order requirements. Even smaller companies often insist on a production minimum, since setting up a line takes time and money. Ask up front. And, always be clear about certifications like USDA Organic or non-GMO if that matters for your brand. Trying to fix that after the fact usually leads to a headache.