Frozen Green Peas Manufacturing Plant Setup Cost

Frozen Green Peas Manufacturing Plant Project Report (DPR) Summary:

IMARC Group's comprehensive DPR report, titled "Frozen Green Peas Manufacturing Plant Project Report 2026: Industry Trends, Plant Setup, Machinery, Raw Materials, Investment Opportunities, Cost and Revenue," provides a complete roadmap for setting up a frozen green peas manufacturing unit. The frozen green peas market is driven by the increasing consumer demand for convenient and nutritious food options, coupled with the rising popularity of frozen food due to longer shelf life and ease of storage. The global frozen green peas market size was valued at USD 19.35 Million in 2025. According to IMARC Group estimates, the market is expected to reach USD 26.38 Million by 2034, exhibiting a CAGR of 3.5% from 2026 to 2034.

This feasibility report covers a comprehensive market overview to micro-level information such as unit operations involved, raw material requirements, utility requirements, infrastructure requirements, machinery and technology requirements, manpower requirements, packaging requirements, transportation requirements, etc.

The frozen green peas manufacturing plant setup cost is provided in detail covering project economics, capital investments (CapEx), project funding, operating expenses (OpEx), income and expenditure projections, fixed costs vs. variable costs, direct and indirect costs, expected ROI and net present value (NPV), profit and loss account, financial analysis, etc.

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What are Frozen Green Peas?

Frozen green peas are peas that have been harvested at the height of their maturity; they are washed, blanched, and frozen right away in order to retain their flavor, texture, and possible health benefits. The benefits of freezing the peas ensure that they retain their bright green color, are tender in nature, and have the highest sugar content at the time of consumption. The frozen green peas are often packed in bags or containers of varying capacities for commercial as well as industrial use. The benefits of frozen green peas include their long shelf life without any deterioration in their health benefits.

Key Investment Highlights

• Process Used: Blanching, individual quick freezing (IQF), and packaging.
• End-use Industries: Retail grocery, food service, prepared food manufacturing, and institutional food supply.
• Applications: Used for frozen vegetable medleys, side dishes, prepared meals, soups, stewas, and as a direct ingredient for foodservice operations.

Frozen Green Peas Plant Capacity:

The proposed manufacturing facility is designed with an annual production capacity ranging between 10,000 - 20,000 MT, enabling economies of scale while maintaining operational flexibility.

Frozen Green Peas Plant Profit Margins:

The project demonstrates healthy profitability potential under normal operating conditions. Gross profit margins typically range between 25-35%, supported by stable demand and value-added applications.

• Gross Profit: 25-35%
• Net Profit: 10-15%

Frozen Green Peas Plant Cost Analysis:

The operating cost structure of a frozen green peas manufacturing plant is primarily driven by raw material consumption, particularly fresh peas, which accounts for approximately 65-75% of total operating expenses (OpEx).

• Raw Materials: 65-75% of OpEx
• Utilities: 15-20% of OpEx

Financial Projection:

The financial projections for the proposed project have been developed based on realistic assumptions related to capital investment, operating costs, production capacity utilization, pricing trends, and demand outlook. These projections provide a comprehensive view of the project’s financial viability, ROI, profitability, and long-term sustainability.

Major Applications:

• Raw Material Handling (receiving, cleaning, and sorting of green peas)
• Processing (blanching, cooling, and quality control operations)
• Freezing (IQF systems, spiral freezers, and temperature-controlled handling)
• Packaging & Storage (weighing, packing, cold storage, and distribution logistics)

Why Frozen Green Peas Manufacturing?

✓ Essential Food Supply Component: Frozen green peas are a common ingredient found in food service and processing applications as well as consumer households for their year-round availability and retention of nutritional properties of frozen green peas.

✓ Moderate but Defensible Entry Barriers: Though less capital-intensive than heavy industries, frozen green pea production is a sector that involves capex in cold chain, IQF freezers, food safety, and sourcing of green peas. This is a hindrance to new entrants as it requires experienced and quality-conscious players.

✓ Megatrend Alignment: The increasing rate of urbanization, rise in the number of quick service restaurants, preference for easy-to-eat and ready-to-cook meals, and consumption of frozen foods, particularly in emerging markets, drive demand.

✓ Policy & Agricultural Support: The measures taken by the government that have had an overall positive effect on the frozen vegetable, particularly green peas, industry include food processing, cold storage, linking farmer organizations, and agri-export promotion.

✓ Localization and Supply Chain Reliability: A growing measure for food retailers and institutional purchasers is to prefer local or regional frozen food makers to guarantee freshness, facilitate logistics, address crop variability, and develop unbroken supply chords, presenting an immense opportunity for responsible local producers.

Transforming Vision into Reality:

This report provides the comprehensive blueprint needed to transform your frozen green peas manufacturing vision into a technologically advanced and highly profitable reality.

Frozen Green Peas Industry Outlook 2026:

The demand for frozen green peas is driven by the growing preference for convenient, nutritious, and cost-effective food options among consumers worldwide. Increasing adoption of frozen foods is also supported by improved cold storage and distribution networks, making these products more accessible. The Ministry of Food Processing Industries revealed that the share of processed food exports in agri-food exports has increased substantially from 13.7% in 2014-15 to 20.4% in 2024-25. Additionally, the rise in the number of working individuals and busy lifestyles contributes to the increased consumption of frozen vegetables, including green peas. With a longer shelf life compared to fresh peas, frozen peas provide convenience without sacrificing nutritional value, making them an attractive choice for households, foodservice providers, and the food processing industry. Furthermore, the rising health-conscious trend and growing interest in plant-based diets are expected to fuel the demand for frozen green peas.

Leading Frozen Green Peas Manufacturers:

Leading manufacturers in the global frozen green peas industry include several multinational companies with extensive production capacities and diverse application portfolios. Key players include:

• Green Giant (General Mills)
• McCain Foods
• The Birds Eye
• Farm Fresh
• Bonduelle

all of which serve end-use sectors such as retail grocery, food service, prepared food manufacturing, and institutional food supply.

How to Setup a Frozen Green Peas Manufacturing Plant?

Setting up a frozen green peas manufacturing plant requires evaluating several key factors, including technological requirements and quality assurance.

Some of the critical considerations include:

• Detailed Process Flow: The manufacturing process is a multi-step operation that involves several unit operations, material handling, and quality checks. Below are the main stages involved in the frozen green peas manufacturing process flow:
  • Unit Operations Involved
  • Mass Balance and Raw Material Requirements
  • Quality Assurance Criteria
  • Technical Tests
     
• Site Selection: The location must offer easy access to key raw materials such as fresh peas, water, blanching equipment, freezing tunnels, packaging. Proximity to target markets will help minimize distribution costs. The site must have robust infrastructure, including reliable transportation, utilities, and waste management systems. Compliance with local zoning laws and environmental regulations must also be ensured.​
   
• Plant Layout Optimization: The layout should be optimized to enhance workflow efficiency, safety, and minimize material handling. Separate areas for raw material storage, production, quality control, and finished goods storage must be designated. Space for future expansion should be incorporated to accommodate business growth.​
   
• Equipment Selection: High-quality, corrosion-resistant machinery tailored for frozen green peas production must be selected. Essential equipment includes pea hullers, vibratory sorting tables, blanchers, industrial freezers (IQF tunnels), packaging systems, and cold storage units. All machinery must comply with industry standards for safety, efficiency, and reliability.​
   
• Raw Material Sourcing: Reliable suppliers must be secured for raw materials like fresh peas, water, blanching equipment, freezing tunnels, packaging to ensure consistent production quality. Minimizing transportation costs by selecting nearby suppliers is essential. Sustainability and supply chain risks must be assessed, and long-term contracts should be negotiated to stabilize pricing and ensure a steady supply.
   
• Safety and Environmental Compliance: Safety protocols must be implemented throughout the manufacturing process of frozen green peas. Advanced monitoring systems should be installed to detect leaks or deviations in the process. Effluent treatment systems are necessary to minimize environmental impact and ensure compliance with emission standards.​
   
• Quality Assurance Systems: A comprehensive quality control system should be established throughout production. Analytical instruments must be used to monitor product concentration, purity, and stability. Documentation for traceability and regulatory compliance must be maintained.

Project Economics:

​Establishing and operating a frozen green peas manufacturing plant involves various cost components, including:​

• Capital Investment: The total capital investment depends on plant capacity, technology, and location. This investment covers land acquisition, site preparation, and necessary infrastructure.
   
• Equipment Costs: Equipment costs, such as those for pea hullers, vibratory sorting tables, blanchers, industrial freezers (IQF tunnels), packaging systems, and cold storage units, represent a significant portion of capital expenditure. The scale of production and automation level will determine the total cost of machinery.​
   
• Raw Material Expenses: Raw materials, including fresh peas, water, blanching equipment, freezing tunnels, packaging, are a major part of operating costs. Long-term contracts with reliable suppliers will help mitigate price volatility and ensure a consistent supply of materials.​
   
• Infrastructure and Utilities: Costs associated with land acquisition, construction, and utilities (electricity, water, steam) must be considered in the financial plan.
   
• Operational Costs: Ongoing expenses for labor, maintenance, quality control, and environmental compliance must be accounted for. Optimizing processes and providing staff training can help control these operational costs.​
   
• Financial Planning: A detailed financial analysis, including income projections, expenditures, and break-even points, must be conducted. This analysis aids in securing funding and formulating a clear financial strategy. 

Capital Expenditure (CapEx) and Operational Expenditure (OpEx) Analysis:

Capital Investment (CapEx): Machinery costs account for the largest portion of the total capital expenditure. The cost of land and site development, including charges for land registration, boundary development, and other related expenses, forms a substantial part of the overall investment. This allocation ensures a solid foundation for safe and efficient plant operations.

Operating Expenditure (OpEx): In the first year of operations, the operating cost for the frozen green peas manufacturing plant is projected to be significant, covering raw materials, utilities, depreciation, taxes, packing, transportation, and repairs and maintenance. By the fifth year, the total operational cost is expected to increase substantially due to factors such as inflation, market fluctuations, and potential rises in the cost of key materials. Additional factors, including supply chain disruptions, rising consumer demand, and shifts in the global economy, are expected to contribute to this increase.

Capital Expenditure Breakdown:

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Operational Expenditure Breakdown:

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Profitability Analysis: 

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Latest Industry Developments:

• Nov 2025: A leader in organic produce, Natural Grocers expands its 100% USDA-certified organic selection with 10 new frozen vegetables (including green peas) under its house brand.

Report Coverage:

Report Customization

While we have aimed to create an all-encompassing frozen green peas plant project report, we acknowledge that individual stakeholders may have unique demands. Thus, we offer customized report options that cater to your specific requirements. Our consultants are available to discuss your business requirements, and we can tailor the report's scope accordingly. Some of the common customizations that we are frequently requested to make by our clients include:

• The report can be customized based on the location (country/region) of your plant.
• The plant’s capacity can be customized based on your requirements.
• Plant machinery and costs can be customized based on your requirements.
• Any additions to the current scope can also be provided based on your requirements.

Why Buy IMARC Reports?

• The insights provided in our reports enable stakeholders to make informed business decisions by assessing the feasibility of a business venture.
• Our extensive network of consultants, raw material suppliers, machinery suppliers and subject matter experts spans over 100+ countries across North America, Europe, Asia Pacific, South America, Africa, and the Middle East.
• Our cost modeling team can assist you in understanding the most complex materials. With domain experts across numerous categories, we can assist you in determining how sensitive each component of the cost model is and how it can affect the final cost and prices.
• We keep a constant track of land costs, construction costs, utility costs, and labor costs across 100+ countries and update them regularly.
• Our client base consists of over 3000 organizations, including prominent corporations, governments, and institutions, who rely on us as their trusted business partners. Our clientele varies from small and start-up businesses to Fortune 500 companies.
• Our strong in-house team of engineers, statisticians, modeling experts, chartered accountants, architects, etc. has played a crucial role in constructing, expanding, and optimizing sustainable manufacturing plants worldwide.