Gelato Tubs Manufacturing Plant

Gelato Tubs Manufacturing Plant Project Report (DPR) Summary:

IMARC Group's comprehensive DPR report, titled "Gelato Tubs 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 gelato tubs manufacturing unit. The global gelato tubs market is primarily driven by the expanding premium frozen dessert segment, increasing consumption of artisanal gelato through organized retail and foodservice channels, and the rising demand for hygienic, food-safe packaging solutions. Europe hold the largest share in the market, accounting for 38.5%.

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 gelato tubs 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.

What are Gelato Tubs?

Gelato tubs are container made of either rigid or semi-rigid food-grade with quality that are primarily meant for to preserve, show and serve gelato and premium frozen desserts. The materials used would be a coated paperboard, polypropylene (PP), polyethylene (PE), or biodegradable materials with linings to resist moisture and grease to guarantee quality at sub-zero temperatures. These tubs are designed for thermal stability, structural strength and condensation resistance which means that they keep the product fresh for a long time and also look appealing in freezer displays. Both gelaterias and ice cream manufacturers, and coffee shops and retail chains use gelato tubs; thus, they cater the purposes of bulk storage and consumer presentation at the same time.

Key Investment Highlights

• Process Used: Sheet forming or molding, coating/lamination, die cutting, printing, and finishing.
• End-use Industries: Foodservice, frozen desserts, hospitality, retail, and cloud kitchens.
• Applications: Used for storage, display, transportation, and retail serving of gelato and premium ice cream products.

Gelato Tubs Plant Capacity:

The proposed manufacturing facility is designed with an annual production capacity ranging between 40–60 million tubs, enabling economies of scale while maintaining operational flexibility.

Gelato Tubs Plant Profit Margins:

The project demonstrates healthy profitability potential under normal operating conditions. Gross profit margins typically range between 30-40%, supported by stable demand and value-added applications.

• Gross Profit: 30-40%
• Net Profit: 12-18%

Gelato Tubs Plant Cost Analysis:

The operating cost structure of a gelato tubs manufacturing plant is primarily driven by raw material consumption, particularly plastic (PP/PET), which accounts for approximately 50-60% of total operating expenses (OpEx).

• Raw Materials: 50-60% of OpEx
• Utilities: 8-12% 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:

• Gelaterias and ice cream parlors (used for in-store storage and front-end display of gelato flavors while maintaining hygiene and visual appeal)
• Foodservice and HoReCa (enables bulk storage and portion-controlled serving for hotels, restaurants, and catering services)
• Retail and supermarkets (support branded frozen dessert sales with enhanced shelf presence and temperature stability)
• Online and cloud kitchens (ensure safe transportation and temperature retention for home-delivered frozen desserts)

Why Gelato Tubs Manufacturing?

✓ Essential Packaging for Premium Desserts: Gelato tubs are crucial for protecting the ice cream's quality and for maintaining hygiene, thus being a must-have core necessity for both artisanal and industrial gelato producers.

✓ Alignment with Premiumization Trends: The consumers' growing inclination towards handmade, organic, and luxury frozen desserts is increasing the demand for high-quality and aesthetically pleasing tubs.

✓ Supportive Food Safety Regulations: The strict global standards for packaging and hygiene are driving food manufacturers towards high-performance packaging solutions that are certified and reliable.

✓ Localization and Short Lead-Time Benefits: By producing gelato locally, manufacturers are able to cut down on the logistics costs, make sure that the product is always available more quickly, and also, change the product design to be in line with the local market preferences.

Transforming Vision into Reality:

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

Gelato Tubs Industry Outlook 2026:

The gelato tubs market is witnessing steady expansion due to the global growth of premium frozen desserts and the increasing popularity of artisanal gelato across urban markets. In addition, consumers are showing a strong preference for high-quality presentation and hygienic packaging, pushing manufacturers to invest in durable, food-safe, and aesthetically refined tubs. Moreover, brands in the frozen dessert space are increasingly expanding their premium offerings to cater to evolving consumer preferences for indulgent and differentiated experiences. For instance, in April 2025, Baskin Robbins launched its new Italian Gelato range for the summer, reinforcing its push toward premium desserts in India. The range features rich gelato flavours such as chocolate and roasted hazelnut, mango and cream, and blueberry cheesecake, along with new indulgent sundaes. Such innovations in gelato market are expected to support the growing demand for gelato tubs, particularly among urban consumers seeking restaurant-style desserts at home. Besides, sustainability is becoming a major industry trend, with widespread adoption of recyclable paper-based tubs and bio-coated materials to comply with environmental regulations and consumer expectations. Furthermore, advances in coating technologies are enabling improved moisture resistance without compromising recyclability, thus contributing to the market growth.

Leading Gelato Tubs Manufacturers:

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

• Amorino
• Uli's Gelato
• Unilever PLC
• Gelatissimo
• Crosta Mollica
• Hackney Gelato
• Baskin-Robbins, Inc.
• Righteous Gelato Ltd.
• G.S. Gelato & Desserts, Inc.
• SAMMONTANA Italia S.p.A.

all of which serve end-use sectors such as foodservice, frozen desserts, hospitality, retail, and cloud kitchens.

How to Setup a Gelato Tubs Manufacturing Plant?

Setting up a gelato tubs 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 gelato tubs 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 plastic (PP/PET), lids and seals, labels, insulation materials, printing inks, and packaging materials. 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 gelato tubs production must be selected. Essential equipment includes thermoforming units, coating and lamination lines, printing presses, die-cutting machines, and finishing systems. All machinery must comply with industry standards for safety, efficiency, and reliability.​
   
• Raw Material Sourcing: Reliable suppliers must be secured for raw materials like plastic (PP/PET), lids and seals, labels, insulation materials, printing inks, and packaging materials 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 gelato tubs. 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 gelato tubs 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 thermoforming units, coating and lamination lines, printing presses, die-cutting machines, and finishing systems, 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 plastic (PP/PET), lids and seals, labels, insulation materials, printing inks, and packaging materials, 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 gelato tubs 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:

• June 2025: Italian gelato maker Sammontana Italia, home to brands such as Bindi, Tre Marie, La Rocca, and Sammontana Gelati all’Italiana, entered the U.S. market. The company is debuting in New York City with summer brand activations, including a gelato kiosk at Eataly Flatiron and community pop-ups in partnership with Madison Square Park Conservancy.
   
• September 2025: Peters Ice Cream’s Connoisseur brand launched two Mediterranean-inspired gelato flavours in Australia including Pistachio Gelato and Almond Biscotti Gelato Sticks. Drawing on Italian dessert traditions, the new range aims to deliver a premium, escape-inspired experience and is now available nationwide from $12 RRP.

Report Coverage:

Report Customization

While we have aimed to create an all-encompassing gelato tubs 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.
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• 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.