In last year’s Top 150 Frozen Foods Processors report, we discussed how the industry overcame consumers’ negative perception of frozen foods.

Fast forward to today, and it’s clear that shoppers are gravitating more and more to the freezercases. That’s because according to our most recent poll, 41% of readers surveyed eat frozen foods of some kind (whether it be frozen vegetables, pizza, breakfast items, soups or ice cream) more than once a week, followed by 18% eat frozen foods every day and 17% eat frozen foods once a week. 

Likewise, cold food manufacturers are certainly doing their part to grow the frozen foods industry by building, expanding and developing new products.

For example, Inventure Foods, Inc., Phoenix, Ariz., announced plans to add a second manufacturing site to its existing individually-quick frozen (IQF) berry processing and packaging facility in Lynden, Wash.

The Schwan Food Co., Marshall, Minn., formed the Schwan’s Chef Collective, a team of up-and-coming U.S. chefs who will assist in developing the next generation of Schwan-branded frozen foods.

Houston, Texas-based Ajinomoto Windsor, formerly known as Windsor Foods, announced plans to add a new production line at its Oakland, Miss., facility.

AdvancePierre Foods, Cincinnati, opened a customer innovation and research center, a combination of lab space and meeting rooms that brings the R&D food labs and test kitchens to customers. These are just to name a few.

Welcome to Refrigerated & Frozen Foods’ annual Top 150 Frozen Foods Processors report, which breaks down the Top 25 frozen food processors in each of the six sectors. Processors are ranked by annual net sales and listings. 

Twenty-four companies appear in more than one category, and are marked with an asterisk (*) by the company name. For those companies that didn’t respond or declined to release figures, estimated sales numbers, which are marked with an asterisk (*), are based on company reports, news releases, market analysts’ reports, industry media and more. This report represents Refrigerated & Frozen Foods’ best efforts to reflect pertinent sales from all channels. 

Thank you to all of the respondents for taking the time to update their company information and providing the industry with the most up-to-date data possible.

WHY FROZEN MEALS DOMINATE
According to a study conducted by Harris Poll, Rochester, N.Y., 15% slice of Americans hail frozen pizza as their No. 1 choice for comfort food. 

Here’s a snapshot of why the Top 25 players in this category continue to dominate.

Changes from last year’s report:

• Added BEF Foods, Inc.
• Added P.F. Chang’s.
• Added On-Cor Frozen Foods.
• Removed John Soules Foods, Inc.
• Removed Hanover Foods Corp.
• Removed Flying Food Group.
• Windsor Foods became Ajinomoto Windsor, Inc.
• Heinz North America became The Kraft Heinz Co. (see below)

Significant events in 2015

• Rich Products celebrated its 70th anniversary.
• Ruiz Foods completed a new state-of-the-art culinary center at its Dinbua, Calif., headquarters, and added on to its Florence, S.C., distribution center. Ruiz Foods also received Refrigerated & Frozen Foods’ 2015 Frozen Foods Processor of the Year award.
• Ajinomoto Inc. restructured its subsidiary Ajinomoto North America, Inc. (AJINA), changing its name to Ajinomoto Windsor, Inc.
• ConAgra Foods acquired Blake’s All Natural Foods. It also established a Chicago headquarters, effective late 2016, and announced plans to separate the company into two independent public companies—consumer portfolio of leading brands and a foodservice portfolio comprised of frozen potato specialties operating under ConAgra Foods Lamb Weston. ConAgra Foods also sold its private label operations, consisting of frozen pasta, to TreeHouse Foods.
• AdvancePierre Foods acquired Landshire, Inc. and Better Bakery. It also opened a customer innovation and research center at its Cincinnati headquarters.
• H.J. Heinz Co. and Kraft Foods Group, Inc. merged to create The Kraft Heinz Co.
• The Schwan Food Co. formed the Schwan’s Chef Collective, a team of up-and-coming U.S. chefs who will assist in developing the next generation of Schwan-branded frozen foods. Also, Refrigerated & Frozen Foods named Schwan’s as its 2015 Sustainable Processor of the Year.
• Nestlé opened the doors to its new research and development center at its Solon, Ohio, headquarters. And, in April, it announced that all 23 factories—dairy, frozen meals, ice cream and more—are now landfill-free, contributing zero waste for disposal.
• Kellogg Co. closed its Clearfield, Utah, frozen foods plant.

Significant events still to come in 2016

• ConAgra Foods will move its Omaha, Neb., headquarters to Chicago. It also announced plans to work toward a supply of 100% cage-free eggs in its U.S. operations by 2025.
• Tyson Foods announced plans to discontinue operations at its pepperoni plant in Jefferson, Wis., and the Chicago facility, which makes prepared foods for the hospitality industry.
• General Mills announced a commitment to reduce absolute greenhouse gas emissions by 28% across its full value chain—from farm to fork to landfill—over the next 10 years.
• Kellogg Co. announced plans to cut greenhouse gas emissions by 65% across its own operations, and work with suppliers to help reduce their emissions by 50% by 2050.
• Ajinomoto Windsor announced plans to add a new production line at its Oakland, Miss., facility.

BEEFING UP THE COMPETITION
For frozen meat, poultry and seafood processors, it’s the best of times and the worst of times. Strict food safety regulations place hesitation in a category that’s already been knocked down by massive recalls. Yet, processors still build, expand and develop.

And, after U.S. chicken production increased 4% in 2015, according to Rabobank, New York, per capita chicken rose to an all-time high as well.

Meanwhile, the rebound in hog herd in 2016 pushed U.S. packing capacity to the limit in Q4, driving margins to favorable levels, Rabobank says in its latest agribusiness review.

Here’s how the Top 25 processors in this category are beefing up the competition.

Significant events in 2015

• Tyson Fresh Meats, Inc., a subsidiary of Tyson Foods, added new lines for production of pork chops and roasts at its Council Bluffs, Iowa, plant, and announced plans to invest $47 million in a new boxed beef warehouse. Tyson Fresh Meats also ceased operations at its Denison, Iowa, beef plant.
• Meanwhile, Tyson Foods expanded its Robards, Ky., poultry plant to include a new freezer and additional workstations, but discontinued operations at its Buena Vista, Ga., poultry plant and will no longer run a third shift at its Dawson, Ga., facility. Tyson Foods also made major improvements to its Vienna, Ga., tray pack chicken plant, adding about 100,000 square feet, including new equipment and production lines, as well as processes and technology designed to benefit food safety, quality and workplace safety.
• AdvancePierre Foods opened a customer innovation and research center at its Cincinnati headquarters.
• JBS acquired Cargill’s U.S.-based pork business.
• Cargill opened a nearly $50 million distribution center at its Dodge City, Kan., beef processing facility.
• Hormel’s Progressive Processing facility in Dubuque, Iowa; Golden State Foods’ McCook, Ill., distribution center; and OSI Group’s Ostróda, Poland, and Alpenrind, Austria, plants were named Plants of the Future in Refrigerated & Frozen Foods’ December 2015 issue. Meanwhile, Golden State Foods built a new state-of-the-art meat processing facility in Opelika, Ala. Hormel Foods also acquired Applegate Farms, LLC.
• Butterball purchased a further processing facility in Raeford, N.C.
• Perdue purchased Natural Food Holdings and its Niman Ranch brand.
• West Liberty Foods installed an additional high-pressure processing (HPP) system in its Bolingbrook, Ill., facility. It also opened the doors to Liberty Cold, the company’s new cold storage complex.

Significant events still to come in 2016

• Greater Omaha Packing is building a new portion cutting and a ground beef plant.
• Tyson Foods announced plans to discontinue operations at its pepperoni plant in Jefferson, Wis., and the Chicago facility, which makes prepared foods for the hospitality industry.
• JBS announced a $75 million expansion project at its Hyrum, Utah, beef processing complex.
• Sanderson Farms announced that a site located in St. Pauls and Robeson County, N.C., was selected for construction of a new hatchery, poultry processing and wastewater treatment facility.
• Wayne Farms announced plans to expand its Dothan, Ala., fresh processing facility.
• High Liner Foods announced plans to cease value-added fish operations at its New Bedford, Mass., production facility.
• Seaboard Foods formed a joint venture with Triumph Foods to construct a new pork processing facility in Sioux City, Iowa, with construction completed by July 2017.

DAIRY PROCESSORS REMAIN STEADFAST
A majority of U.S. ice cream and frozen dessert manufacturers have been in business for more than 50 years, and in fact, many are still family-owned businesses, according to the International Dairy Foods Association, Washington, D.C. 

In fact, the global imbalance of growth in dairy consumption leaves U.S. dairy manufacturers with the option of chasing international opportunities or competing for share in the increasingly competitive home market, says Paul Carbonneau, partner, and Ludovic Meilhac, an associate partner, for McKinsey & Co., a New York-based consulting firm. 

Some manufacturers, Carbonneau and Meilhac say, will grow by capturing share in the global market and employing “best-in-class” international export and local production capabilities. Other companies will succeed by redefining their businesses and broadening their consumer bases beyond traditional dairy.

Growth opportunities are also available to companies that heighten their efforts on operation and performance excellence, the consultants say. Dairy processors will need additional emphasis on network optimization, manufacturing and procurement efficiencies, supply chain and logistics and in-store execution in order to remain competitive.

Here’s a rundown of the Top 25 ice cream and frozen dessert processors in the industry:

Significant events in 2015

• Smith Dairy Products Co. became SmithFoods Inc.
• Rich Products celebrated its 70th anniversary.
• ConAgra Foods established a Chicago headquarters, effective late 2016, and announced plans to separate the company into two independent public companies—consumer portfolio of leading brands and a foodservice portfolio comprised of frozen potato specialties operating under ConAgra Foods Lamb Weston.
• Blue Bell Ice Cream products returned to stores in select areas after issuing a voluntary recall and shutting down operations due to the potential of being contaminated with Listeria monocytogenes.
• Nestlé’s Bakersfield, Calif., Dreyer’s plant was named a Plant of the Future in Refrigerated & Frozen Foods’ December 2015 issue. It also opened the doors to a new research and development center at its Solon, Ohio, headquarters. And, in April, Nestlé announced that all 23 factories—dairy, frozen meals, ice cream and more—are now landfill-free, contributing zero waste for disposal.
• Mars opened a Global Food Safety Center, what is said to be a first-of-its-kind facility for pre-competitive research and training.

Significant events still to come in 2016

• ConAgra Foods will move its Omaha, Neb., headquarters to Chicago. It also announced plans to work toward a supply of 100% cage-free eggs in its U.S. operations by 2025.
• General Mills announced a commitment to reduce absolute greenhouse gas emissions by 28% across its full value chain—from farm to fork to landfill—over the next 10 years.

MAINTAINING PRIME POSITIONING ON THE MENU
Not only do appetizers come first in menu positioning, but often this meal part is also the place where new flavor and ingredients get a start, according to US Foods, Rosemont, Ill. 

And, smaller portions mean that strongly flavored or premium ingredients can star. 

That being said, appetizers are gaining prominence as consumers’ notions about dining occasions evolve, US Foods says. Starters allow consumers to downsize portions and prices, share and sample and experience on-the-go eating and around-the-clock grazing.

Chef-inspired innovations and foodservice-to-retail positioning help this category maintain prime positioning. 

Learn how the Top 25 processors of frozen snacks, appetizers and side dishes keep consumers coming back for more.

Changes from last year’s report

• Removed Old Fashioned Kitchen.
• Windsor Foods became Ajinomoto Windsor, Inc.
• Heinz North America became The Kraft Heinz Co. (see below)
• Golden County Foods became Monogram Appetizers (see below).
• Moved Boboli International to frozen bakery.
• Added P.F. Chang’s.

Significant events in 2015

• Rich Products celebrated its 70th anniversary.
• Ajinomoto Inc. restructured its subsidiary Ajinomoto North America, Inc. (AJINA), changing its name to Ajinomoto Windsor, Inc.
• ConAgra Foods acquired Blake’s All Natural Foods. It also established a Chicago headquarters, effective late 2016, and announced plans to separate the company into two independent public companies—consumer portfolio of leading brands and a foodservice portfolio comprised of frozen potato specialties operating under ConAgra Foods Lamb Weston.
• H.J. Heinz Co. and Kraft Foods Group, Inc. merged to create The Kraft Heinz Co.
• The Schwan Food Co. formed the Schwan’s Chef Collective, a team of up-and-coming U.S. chefs who will assist in developing the next generation of Schwan-branded frozen foods. Also, Refrigerated & Frozen Foods named Schwan’s as its 2015 Sustainable Processor of the Year.
• Nestlé opened the doors to a new research and development center at its Solon, Ohio, headquarters. And, in April, it announced that all 23 factories—dairy, frozen meals, ice cream and more—are now landfill-free, contributing zero waste for disposal.
• Bob Evans Farms completed a sale-leaseback transaction of its BEF Foods industrial properties located in Lima, Ohio, and Sulphur Springs, Texas.
• Monogram Foods acquired Golden County Foods, and re-named it Monogram Appetizers.
• A newly created entity, Cuisine Innovations Unlimited, acquired Cuisine Innovations.

Significant events still to come in 2016

• ConAgra Foods will move its Omaha, Neb., headquarters to Chicago.
• General Mills announced a commitment to reduce absolute greenhouse gas emissions.
• Anijomoto Windsor announced plans to add a new production line at its Oakland, Miss., facility.

READY-TO-BAKE, READY-TO-THAW KEEPS FROZEN BAKED GOODS ALIVE
The frozen bakery products market is projected to reach $21.2 billion by 2020, growing at a CAGR of 8.5% from 2015-2020, according to Markets and Markets, Dallas, Texas, and is considered to be one of the fastest-growing segments of frozen foods due to the increased demand in ready-to-bake and ready-to-thaw frozen products.

Frozen bakery products help industrial consumers in in-store bakeries, coffee chains, gas stations and quick-service restaurants offer quick and convenient baked goods. Prolonged shelf life enables operators to secure stocks at times of seasonal variations.

However, manufacturers of frozen bakery products face intense competition from inter- and intra-industry peers in sourcing raw material, ultimately restraining the market growth to a significant extent.

Find out how the Top 25 players in this category experienced growth.

Changes from last year’s report

• Removed Aunt Millies Bakeries.
• Added Boboli International.
• Weston Foods became Maplehurst Bakeries.

Significant events in 2015

• Gonnella Baking Co. opened a new cold storage and distribution center in Schaumburg, Ill. Gonnella also completed a 70,000-square-foot expansion to its Aurora, Ill., facility.
• Rich Products celebrated its 70th anniversary.
• ConAgra Foods established a Chicago headquarters, effective late 2016, and announced plans to separate the company into two independent public companies—consumer portfolio of leading brands and a foodservice portfolio comprised of frozen potato specialties operating under ConAgra Foods Lamb Weston.
• Maplehurst Bakeries purchased Creative Occasions Inc. and Starr Culinary Delights.
• The Schwan Food Co. formed the Schwan’s Chef Collective, a team of up-and-coming U.S. chefs who will assist in developing the next generation of Schwan-branded frozen foods. Also, Refrigerated & Frozen Foods named Schwan’s as its 2015 Sustainable Processor of the Year.
• Dianne’s Fine Desserts acquired retail desserts creator Daystar Desserts.

Significant events sill to come in 2016

• ConAgra Foods will move its Omaha, Neb., headquarters to Chicago. It also announced plans to work toward a supply of 100% cage-free eggs in its U.S. operations by 2025.
• Maplehurst Bakeries announced plans to build a commercial bakery in Nashville, Tenn.
• The Hillshire Brands Co., a subsidiary of Tyson Foods, is making major improvements to its Tarboro, N.C., bakery plant, which produces croissants, biscuits, layer cakes, sheet cakes, muffins, pound cakes and cobblers.
• General Mills announced a commitment to reduce absolute greenhouse gas emissions by 28% across its full value chain—from farm to fork to landfill—over the next 10 years.

INNOVATION IN FREEZING TECHNOLOGIES HELP GROW THE FROZEN FRUITS, VEGETABLES CATEGORY
A growing demand for easy-to-prepare foods continues to drive the global frozen fruits and vegetables market, according to a report published by Global Industry Analysts, Inc., San Jose, Calif.

Other factors driving growth include continuous innovation in freezing technologies, development of cold chain logistics, enhancements to post-harvest handling, storage and transportation and the growing demand for fresh-picked fruits and vegetables in extended shelf-life format.

Furthermore, the introduction of new products and development of nutrient-sealing packages will help drive growth in the market in the coming years.

Read on to find out how today’s Top 25 frozen fruit and vegetable processors fare in the industry.

Changes from last year’s report

• Removed Seapoint Farms.
• Removed Stahlbush Island Farms.
• Added Ajinomoto Windsor, Inc.
• Added back McCain Foods USA.

Significant events in 2015

• SunOpta acquired Sunrise Growers-Frozsun Foods.
• Ajinomoto Inc. announced plans to restructure its subsidiary Ajinomoto North America, Inc. (AJINA), changing its name to Ajinomoto Windsor, Inc. It also announced plans to add a new production line at its Oakland, Miss., facility.
• General Mills sold its Green Giant and Le Sueur frozen vegetables businesses to B&G Foods, Inc.
• ConAgra Foods established a Chicago headquarters, effective late 2016, and announced plans to separate the company into two independent public companies—consumer portfolio of leading brands and a foodservice portfolio comprised of frozen potato specialties operating under ConAgra Foods Lamb Weston.
• Bonduelle opened an innovation center in France to bring consumers into the heart of its product creation and improvement process.

Significant events still to come in 2016

• ConAgra Foods will move its Omaha, Neb., headquarters to Chicago. It also announced plans to work toward a supply of 100% cage-free eggs in its U.S. operations by 2025.
• General Mills announced a commitment to reduce absolute greenhouse gas emissions by 28% across its full value chain—from farm to fork to landfill—over the next 10 years.
• Inventure Foods announced plans to add a second manufacturing site to its existing company-owned individually-quick frozen (IQF) berry processing and packaging facility in Lynden, Wash. (see right)