U.S. Processed Food Market Size, Growth, and Trends 2025 to 2035

U.S. Processed Food Market Size 2025 to 2035

The U.S. processed food market size reached at USD 204.44 billion in 2025 and is expected to grow steadily from USD 219.98 billion in 2026 to reach nearly USD 425.29 billion by 2034, with a CAGR of 7.6% during the forecast period from 2026 to 2035. Rising demand for convenience and ready-to-consume foods along with increasing health awareness significantly boosting the market.

Key Highlights

• By type, secondary processed foods segment dominated the U.S. processed food market with the largest share in 2025. The secondary processed demand is experiencing prominent increase in recent years due to the rising demand for convenience foods, risen consumer interest in processed food. 
• By type, ultra-processed foods segment is observed to grow at the fastest rate during the forecast period. Swift urban growth and increasing net income are fueling the need for easy and ready-to-eat food. Intense promotion and marketing of ultra-processed food items are fueling market expansion. 
• By technology, the freezing segment held the largest share of the market in 2025. Surge in the demand of the frozen food advancing the freezing technology.
• By technology, the extrusion segment is seen to grow at a notable rate during the predicted timeframe. Extrusion technology exceeding in adaptability, quickly responding to consumer demand by adjusting ingredients and conditions. 
• By product type, the grains & cereals segment led the U.S. processed food market in 2025. Rising health awareness among individuals has surged demand for whole grains and healthy cereals, as they are considered as nutritious food choices.
• By product type, the meat & poultry segment is expected to grow at the fastest rate in the market during the forecast period. Increasing demand for the protein diets among consumers boosting the meat and poultry products demand.

U.S. Processed Food Industry Coverage

Increase in the Changing and Busy Lifestyle

Convenience food options such as pre-packaged, simple-to-prepare meals and ready-to-eat items are becoming more popular as consumer lifestyles become faster. Due to hectic schedules, long work hours, and active family engagements, people are looking for time-saving solutions and requesting convenient food options. The U.S. processed food market is expanding because of this shift, adjusting to fulfill consumer demands for convenience while preserving taste and quality. With shifting household dynamics and busy lifestyles, today’s consumers seek to acquire almost all their daily nutrition in an instant. Individuals are eating prepackaged and ready-made meals, leading to a rise in demand as numerous people in developing areas relocate to cities, earning higher incomes and having the capacity to purchase processed foods. International trade systems enable food producers to reach a larger variety of markets, allowing them to offer a more extensive array of products. 

What are the Trends in U.S. Processed Food Market?

• Health and wellness trend: As of today’s consumers, are becoming more knowledgeable about their health and wellness, they are seeking processed foods that are not only quick to prepare but also provide nutritional advantages. Therefore, there is rising demand for products free from artificial additives and preservatives. Now, around 82% of the U.S. consumers are considering wellness as their top priority and opting for the products offering nutritional value. 
• Demand for sustainable and ethically sourced food: In recent days demand for the sustainable, eco-friendly and ethically produced increasing among consumers. These consumers are also focusing on the transparency and traceability. Therefore, by promoting renewable energy, lowering waste, and supporting rural communities, manufactures are producing processed foods to meet the consumer’s demand and therefore expanding the U.S. processed food market. 
• Consumer preference for organic and clean label food: Because people now realize how important food is to be maintaining a healthy lifestyle, consumers are become more aware of what they eat.  Therefore, clean eaters look for "clean label" items, albeit it's unclear exactly what that means. Food items that are packed using organic materials and go through organic processing are known as organic processed foods. GMOs, additives, and other artificial substances that could cause health problems are not present in these food products.  
• Innovation in packaging: Currently, consumers show greater interest in food packaging that is biodegradable, microwave-safe, and self-heating or cooling. They are also keen to learn about the quality of packaged food during its transport and storage. Packaging technologies have grown increasingly intricate, leading to the development of various food packaging solutions that significantly aid in creating a safe and high-quality food product. These include controlled-release packaging, antimicrobial packaging, nanotechnology, and biosensors. These technologies can help manage not just spoilage microorganisms that render the food product unappealing, but also harmful pathogens.

Market Opportunity 

Technological Development in Food Processing Accelerating the U.S. Processed Food Market

Food processing technologies are essential for guaranteeing the safety, quality, and sustainability of the worldwide food supply. Embracing innovations in food processing technologies can enhance consumer trust, minimize waste, and establish a sustainable food supply chain. The incorporation of advanced technologies like high-pressure processing, pulsed electric fields, microwave heating, nanotechnology, ultrasonication, and smart packaging systems has transformed the food processing industry. There is an increasing shift toward automation and technology integration in food processing, where producer’s proficiency in crafting tailored lines for various products such as chips, frozen french fries, and diverse fruit processing applications can significantly enhance value.

Market Challenge 

Rising Health Awareness and Alternative Options Hampering the U.S. Processed Food Market

Since processed foods have become essential in American diets, they’ve permanently altered physical well-being. Processed foods play a role in the obesity crisis and long-term health issues like type 2 diabetes, increasing awareness of synthetic preservatives and additives. Shoppers are increasingly aware of health issues and are on the lookout for substitutes to heavily processed items. Consumers are opting for the minimally processed or unprocessed food because of rising health concerns. 

Trade of Processed Food in United States 

U.S. exports of processed food items and the sales from foreign branches of U.S. firms in the sector have been increasing swiftly. Canada and Mexico are the two primary trading partners of the United States in the Western Hemisphere, while limited amounts of processed food items are sent to various other countries in the region. U.S. Foreign Direct Investment (FDI), like exports, is primarily focused on Canada and Mexico, though noteworthy FDI also exists in South American nations like Brazil and Argentina's processed food sector. U.S. foreign direct investment, indicated by sales from overseas affiliates, is considerably higher than U.S. processed food exports. (Source: Ag Econ search)

The food processing industry in the United States consists of 1.95K firms, which includes 602 funded entities that have together secured $10.9B in venture capital and private equity investments. Among these, 436 have received Series A+ funding, and 1 has attained unicorn status. By April 2025, there were 8 acquisitions in the food processing industry in the United States. In 2024, a total of 44 acquisitions occurred in the Food Processing industry in the United States last year. As of February 2025, food processing firms in the United States have secured $32.5M in equity financing through 7 rounds. Most food processing startups in the United States have been established by graduates from Harvard University, Stanford University, and the Massachusetts Institute of Technology. (Source: Tracxn)

• In the U.S., 19-39 age of adults are consuming 54.4% of calories from ultra-processed foods, while adults 60 and older consumed 51.7% and adult ages 40–59 consumed 52.6%.

Value Chain Analysis of U.S. Processed Food Market

Raw Material Procurement

• In the U.S. processed food industry, the raw material procurement deals with strategic procedure of purchasing, evaluating, processing, sourcing and packaging of label and frozen food products from the various natural, plant-based, natural and clean-label food products in the U.S.
• Market Players: Danone S.A., General Mills Inc., Organic Valley

Packaging and Branding

• Branding and Packaging for U.S. processed food market focuses on creating packaging which may ensures remain stable, safe and fresh by protecting them from contamination, light and moisture.
• Key Players: PepsiCo, Kraft Heinz, General Mills and Nestle

Waste Management and Recycling

• The waste management and recycling of processed food market in the U.S. are significantly related to the food manufacturing packaging, process and general corporate sustainability initiatives of the various major players.
• Market Players: Suez, Veolia, Republic Services and Waste Management

Global Processed Food Market Size and Growth 2025 to 2034

The global processed food market was valued at USD 2.09 trillion in 2024 and is expected to grow from USD 2.18 trillion in 2025 to approximately USD 3.23 trillion by 2034, reflecting a compound annual growth rate (CAGR) of 4.48% during the forecast period. This growth is primarily driven by the rising demand for convenience food products.

U.S. Processed Food Market Segmental Insights

Type Insights

Secondary Processed Foods Segment Dominated the U.S. Processed Food Market With the Largest Share in 2025

The secondary processed demand is experiencing prominent increase in recent years due to the rising demand for convenience foods, risen consumer interest in processed food, and the surge of various health-conscious trends. Secondary processing is widely utilized for variety of products such as snack foods, bakery products, beers and porridges, each having fascinating texture, flavour and colour. Increasing demand for the snack food. bakery and convenience foods increasing the demand for secondary processed food.

Ultra-Processed Foods Segment is Observed to Grow at the Fastest rate in the U.S. Processed Food Market During the Forecast Period

Swift urban growth and increasing net income are fueling the need for easy and ready-to-eat food. Intense promotion and marketing of ultra-processed food items are fueling market expansion, accompanied by a trend toward increasing interest in plant-based and clean eating. The rapidly increasing population has resulted in a rise in ultra processed food consumption, as these products are less expensive to manufacture and can yield more food than conventional food production methods. An additional factor in the increase of UPFs is industrialization, as it facilitated the development of food processing technology and significantly influences the types of foods accessible to consumers. The United States ranks as the top nation in the consumption of ultra-processed foods, as UPFs make up roughly 60% of the overall daily calorie intake. 

Technology Insights

The Freezing Segment Held the Largest Share of the U.S. Processed Food Market in 2025

Rising income and busy lifestyle increasing the demand for the frozen ready-to-cook food and product life is also extended because of freezing. Surge in the demand of the frozen food advancing the freezing technology. Technological innovation in freezing techniques keep revolutionizing the food sector, as these developments help to reduce producing times and rise energy efficiency but also improve the quality of frozen goods.   

The Extrusion Segment is Seen to Grow at a Notable Rate in the U.S. Processed Food Market During the Predicted Timeframe

Extrusion technology exceeding in adaptability, quickly responding to consumer demand by adjusting ingredients and conditions. It offers variety of items with distinctive attributes, meeting varied market preferences. Extrusion technology is largely applicable food processing sector for the formulation of variety of snacks, supplementary foods, breakfast cereals, pasta, pet food, and other textured foods. It is an efficient technology for integrating food processing by-products and residue back into the food stream.

Product Insights

The Grains & Cereals Segment Led the U.S. Processed Food Market in 2025

Rising health awareness among individuals has surged demand for whole grains and healthy cereals, as they are considered as nutritious food choices. Furthermore, the increasing population and dietary shift in consumer’s habits are contributing to an enhancement in cereal consumption. The increasing trend of plant-based food creates an opportunity for industries to invest in alternative grains that are rich in proteins and other nutrients. Rise in the demand of convenience foods is promoting producers to formulate ready-to-eat cereal items, which can capture a wide consumer base looking quick meal solutions.

The Meat & Poultry Segment is Expected to Grow at the Fastest Rate in the U.S. Processed Food Market During the Forecast Period

Increasing demand for the protein diets among consumers boosting the meat and poultry products demand. There is extended business of products in the presentation of cured, smoked, canned meat and frozen products with rising consumption and utilization by household individuals, foodservice firms and retail establishments present in the industry. 

Recent Developments in the U.S. Processed Food Market

TiNDLE Foods

• Market Expansion: In April 2025, TiNDLE Foods expanded its portfolio in U.S. retail store with the introduction of its plant-based chicken items at 500 newer grocery stores across the nation. Product is launched in various location in the US such as the Kroger-backed Fred Meyer, Smith’s, and Ralphs, this brought TiNDLE to stores on the West Coast and Mountain Region of the US. This growth brought TiNDLE’s total volume of retail stockists to more than 1,300. (Source: Plant Based News)

Delimex

• Launch: In October 2024, Delimex introduced Crispy Quesadillas, a new product line expanding beyond their traditional taquitos. Delimex Crispy Quesadillas offered a choice of Char-Grilled or Chipotle Chicken, featuring juicy, flavorful chicken and melted cheese in a crispy tortilla. (Source: Businesswire)

General Mills

• Launch: In March 2025, General Mills has launched its first ramen noodle product. This new item is being spearheaded by two surprising companies, both owned by the same parent company. A major food company has partnered with Old El Paso and Totino's to introduce instant ramen noodles. To increase visibility and stand out from the competition, the companies joined forces for this strategic partnership. (Source: Generalmills)

U.S. Processed Food Market Leading Companies

• Tyson Foods
• PepsiCo
• Cargill Foods
• Archer Daniels Midland (ADM)
• JBS USA
• Smithfield Foods
• Kraft Heinz Company
• Conagra Brands
• Hormel Foods
• General Mills

Segments Covered in the Report

By Type

• Secondary Processed Food
• Ultra-Processed Food
• By Technology
• Drying
• Extrusion
• Freezing
• Grinding
• Others

By Product Type 

• Fruits & Vegetables
• Grains & Cereals
• Dairy
• Meat & Poultry
• Others