Top 40 fast-casual chains

Sales at the major fast-casual restaurants are growing at nearly three times the rate for the industry as a whole, but that intake is not evenly distributed. Which fast-casual brands are at the front of that increasingly crowded pack?

Restaurant Business borrowed data from its research sister, Technomic, to rank the 40 largest fast-casual chains by systemwide sales. Here, in ascending order, are the sector’s largest chains by sales volumes.

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40. Newk's Eatery

2015 U.S. Sales: $183.2 million

2015 U.S. Units: 95

Newk’s Eatery was acquired in 2014 by Sentinel Capital Partners, so 2015 meant executive changes, including a new CFO and CMO, and brand tweaks—it debuted a new store prototype in Lafayette, La., with upscale elements like brickwork and pendant lights, a digital menu board and multiple dining areas with different seating including bar-height tables. Systemwide sales in 2015 were 29 percent higher than the prior year, a faster pace than even its healthy 27 percent five-year CAGR.

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39. Donatos Pizza

2015 U.S. Sales: $183.6 million

2015 U.S. Units: 153

Late in 2015, the family-owned pizza chain debuted a new look and menu at a restaurant in its hometown of Columbus, Ohio. New elements include a black brick bar, a stage for musical performances, local beers on tap and real silverware and plates. From the semi-open kitchen to the marketing message, Donatos is focusing on its use of fresh ingredients and its relationship with the community.

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38. Taco Bueno

2015 U.S. Sales: $185.0 million

2015 U.S. Units: 175

This fast-casual pioneer will be marking its 50th birthday next year. This year, it’s reveling in the fact that Market Force Information named it America’s favorite Mexican chain. Last year, Taco Bueno celebrated its acquisition by TPG Growth from Palladium Equity Partners, perhaps in the hopes that it would help it overcome its flat sales and unit growth.

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37. Café Rio Mexican Grill

2015 U.S. Sales: $196.2 million

2015 U.S. Units: 89

The announcement that Café Rio hired President and CFO Stephen C. Vaughan, who had been senior vice president of franchise operations, finance and planning at Sonic Corp., had some industry watchers expecting the IPO the company had floated in 2014. The Salt Lake City-based chain is still private, and still exhibiting healthy sales and store count growth.

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36. Shake Shack

2015 U.S. Sales: $199.4 million

2015 U.S. Units: 49

With 54 percent sales growth and 36 percent unit growth, Shake Shack seems out to prove that “better burgers” have not yet peaked. The chain doubled its share price in its stock market debut last summer and ended its first day of trading with a value of more than $1.6 billion. More recently, it credited the January 2016 rollout of the Chick’n Shack sandwich with helping boost same-store sales by 9.9 percent in the first quarter. And customers didn’t balk when Shake Shack increased menu prices to compensate for the increases in employee wages as it tries to stay ahead of minimum wage increases.

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35. Baja Fresh Mexican Grill

2015 U.S. Sales: $206.7 million

2015 U.S. Units: 166

Despite the fact that it has continued to open restaurants with an updated design of recycled wood, stone and warm colors, Baja Fresh’s total store count has declined 6 percent since the end of 2014. Positive signs include a new line of grilled soft tacos and limited-time rice-based Crave-a-Bowls.

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34. Bruegger's Bagels

2015 U.S. Sales: $209.0 million

2015 U.S. Units: 280

Early in 2015, Bruegger’s Bagels named Paul Carolan president; he had been chief development officer with parent company Le Duff America, which also owns la Madeleine and Mimi’s Cafe. Its New York-style bagels and tendency to promote seasonal LTOs haven’t changed. Its headquarters has (it moved to Dallas from Burlington, Vt.), as has its co-branding partner: Bruegger’s has begun co-locating with Jamba Juice, and will not open new stores with Caribou Coffee (who’s going with Einstein Bros. now).

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33. Which Wich Superior Sandwiches

2015 U.S. Sales: $214.4 million

2015 U.S. Units: 375

2015 was another good year for Which Wich, whose systemwide sales grew 18 percent in 2014, and whose five-year CAGR is almost 25 percent. Recent highlights include the introduction of a kids menu (six varieties of “Kidswiches” with their own bag for scribbling on); a new online ordering program; breaking the Guinness World Record for most sandwiches made in an hour; and Chief Vibe Officer Jeff Sinelli’s acceptance of the Future 50 Award at the Restaurant Leadership Conference on behalf of the chain.

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32. Rubio's

2015 U.S. Sales: $222.0 million

2015 U.S. Units: 192

A fish taco specialist, Rubio’s has been updating units with an ocean-theme decor to accent a renewed focus on seafood. The update also includes a name change, to Rubio’s Coastal Grill—its fifth name since its founding as Rubio’s Fish Tacos in 1983. Its unit count will increase by at least eight this year, as it rebrands the Lime Fresh Mexican Grill stores it acquired from Ruby Tuesday. Those restaurants are in Florida, a new market for Rubio’s.

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31. Fazoli's

2015 U.S. Sales: $228.6 million

2015 U.S. Units: 214

Fazoli’s has debuted a new restaurant design with an updated color scheme and 35-foot tower. It’s recruited experienced executives. It’s invested $3 million in a new computer system to enable online ordering and a mobile app. And it’s updating drive-thru menu boards and operations to improve speed and accuracy. The pizza and pasta maker seems to be throwing a lot of business-improving methods at the wall to see what sticks. Evidence that something is working: Fazoli’s attracted the attention of a new owner, Sentinel Capital Partners, last July, and the chain just announced that it’s had six straight years of franchised and company-owned same-store sales increases.

Explore: Technomic

30. Zoës Kitchen

2015 U.S. Sales: $230.8 million

2015 U.S. Units: 166

While investors aren’t necessarily sold with Zoës overall profitability, the comps keep rising for this better-for-you Mediterranean chain that focuses on made-from-scratch meals prepared with fresh ingredients. Part of that can be attributed to the modern branding and constantly changing menu that helps give offerings a seasonal edge. And it also places an emphasis on its mobile app and digital loyalty program, using the data to better understand and resonate with its customers.

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29. The Habit Burger Grill

2015 U.S. Sales: $251.4 million

2015 U.S. Units: 142

Often cited as one of the leaders in the better-burger market, The Habit is known for its signature Charburgers made with premium ingredients, offered at a price point that’s on the lower end of the competition. To stay competitive, the chain uses social media and e-marketing to promote its “everyday value,” instead of going the discounting route of other chains. While the chain’s IPO went through in late 2014, a second offering has been postponed. But that hasn’t stopped the concept from growing. The Habit continues to steadily open units, emphasizing on site selection as a key differentiator.

Explore: Technomic

28. Fuddruckers

2015 U.S. Sales: $253.0 million

2015 U.S. Units: 173

One of the original fast-casual burger chains, Fuddruckers was on the customizable bandwagon long before DIY elements were driving restaurant sales. But its continued efforts to modernize still have the chain winning big: It was named as one of millennials’ favorite chains this year. To make sure it continues to resonate with and reach as many types of customers as possible, the chain has spent the past year experimenting with new formats; it launched its first taproom in Montana, opened a unit inside of a convenience store and debuted a new prototype that expanded the customization bar and implemented tech upgrades and communal seating in Maryland.

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27. Portillo's

2015 U.S. Sales: $275.3 million

2015 U.S. Units: 41

The Chicago concept known for hot dogs and Italian beef sandwiches is poised to grow—with a wide reach—thanks to private-equity firm Berkshire Partners acquiring the nearly 40-unit chain from its founder for an estimated $1 billion. Known for its extensive menu and fast drive-thru operations, newer Portillo units average about $8.5 million per store.

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26. Smashburger

2015 U.S. Sales: $306.5 million

2015 U.S. Units: 328

It’s all about the preparation method for the concept; burgers are made to order, then smashed onto the grill and seared. As it’s grown—and it plans to continue on a path of aggressive expansion—Smashburger has made sure to maintain its regional feel, setting itself apart from other brands by including locally specific menu items and regional craft beers that differ by location. To further win millennials, who want that local, small-brand feel, it’s aimed to also feel “cool,” using channels such as Snapchat to connect with the sought-after demo. Of late, the chain sold a minority stake to Phillipines-based Jollibee Foods Corp., filled the vacated CEO role and named co-founder and industry vet Tom Ryan as chief brand officer.

Explore: Technomic

25. Schlotzsky’s

2015 U.S. Sales: $319.6 million

2015 U.S. Units: 350

Schlotzsky’s has been all about modernization to keep up with consumer demand of late. Much of that has been led by executive changes throughout 2015, with a new group president overseeing the chain and the announcement of a new VP of global marketing. It also added wireless charging stations at its units, and along with the other five brands under parent Focus Brands’ umbrella, Schlotzsky’s began testing delivery of its sandwiches and other offerings through third-party deliverer Postmates. But it’s not just resting on these tech initiatives to boost sales; the chain has revamped its kids’ menu and added a line of more-premium specialty sandwiches.

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24. Taco Cabana

2015 U.S. Sales: $331.4 million

2015 U.S. Units: 166

Despite an increase in AUV, the Mexican chain known for housemade tortillas and salsa closed a number of units in the past year. It also ran into trouble as a result of the ongoing egg shortage, which led to decreased breakfast transactions—though those reduced visits didn’t cause comps to fall into the negatives. Still, the chain pushed forward with initiatives such as rolling out a mobile ordering app and online ordering in select cities. And the news came from parent Fiesta Restaurant Group: It’ll split into two companies in the coming years, dividing Taco Cabana and sister brand Pollo Tropical.

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23. Pei Wei Asian Diner

2015 U.S. Sales: $350.3 million

2015 U.S. Units: 213

The fast-casual sibling of P.F. Chang’s hit its 200th unit late last year, and the growth hasn’t slowed. Notably, it opened its first unit on a college campus last year. And as it expands, Pei Wei is embracing a new, lighter look that was rolled out in 2015—with all existing restaurants expected to be remodeled over the next few years. To go along with the sleeker design, the chain rolled out new in-house tech to streamline order taking, added Apple Pay and debuted a digital customer loyalty program. But one thing that won’t go away with the new design and modernization: ample seating—Pei Wei is one of the few fast casuals that sees more dinner business than lunch.

Explore: Technomic

22. Au Bon Pain

2015 U.S. Sales: $363.3 million

2015 U.S. Units: 207

While sales grew slightly, thanks to a touch higher AUV than the previous year, Au Bon Pain’s unit count went down in 2015. The bakery-cafe competitor has maintained its emphasis on a lighter, nutritious menu, with the new corporate chef it brought in last January sticking to seasonal menu items that deliver on the better-for-you promise. In an attempt to engage today’s younger diners, Au Bon Pain is using social platforms—notably contests on Instagram—to reach out.

Explore: Technomic

21. Pollo Tropical

2015 U.S. Sales: $368.2 million

2015 U.S. Units: 160

To stand out in the growing chicken segment, Pollo Tropical adds an island twist to the traditional chicken chain, both with a laid-back vibe and called-out flavors such as citrus and guava. Since being spun off from former owner Carrols Restaurant Group in 2012, the chain, now operated by Fiesta Restaurant Group, has been in growth mode. But it doesn’t just let the menu twists drive its forward mentality. In 2015, the chain jumped onto the better-for-you trend and added a five-item Lite Bites menu, and it’s launched a more modern store design that it plans to have rolled out by the end of 2018. To boot, it’s keeping up with tech trends with the addition of an online ordering platform.

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20. Potbelly Sandwich Shop

2015 U.S. Sales: $379.8 million

2015 U.S. Units: 396

What started as a Chicago antique shop that also served lunch has spawned a national brand with sales nearing $380 million in 2015. While the chain’s founder, Bryant Keil, discontinued his involvement with the brand last year, Potbelly leaned into expansion efforts. The chain also joined the Starbucks-led 100,000 Opportunities Initiative, a coalition with the goal to hire and train youth who face barriers to employment.

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19. Corner Bakery Cafe

2015 U.S. Sales: $381.0 million

2015 U.S. Units: 197

This 190-unit bakery-cafe looks poised for changes, as it last year named two new occupants of its C-suite. As speed of service continues to be a consumer selling point, the Roark Capital-owned venture—whose locations are largely concentrated in urban areas—has been testing quick-cooking ovens in an effort to hasten throughput and improve consistency across the chain.

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18. Einstein Bros. Bagels

2015 U.S. Sales: $511.9 million

2015 U.S. Units: 742

Not long after announcing a nationwide restructuring last year, the bagel chain teamed up with Caribou Coffee to launch a scalable concept that brought together the two brands’ breakfast products in a single unit—a bid for each chain to enter new markets. At 742 units, Einstein Bros. is the largest bagel brand owned by its private-equity parent, JAB Holding Co., which has been acquiring breakfast companies at a rapid clip.

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17. Noodles & Company

2015 U.S. Sales: $517.9 million

2015 U.S. Units: 491

Seeking to jump-start growth, Noodles & Company has recently doubled down on its efforts to appeal to millennial families, debuting a customizable kids’ meal and emphasizing the wholesomeness of its ingredients. The chain was dogged by slowing sales last year, having lost momentum in three markets in particular. It closed 17 underperforming restaurants as part of its plan to boost future metrics.

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16. Dickey’s Barbecue Pit

2015 U.S. Sales: $519.6 million

2015 U.S. Units: 530

Though a leader in the barbecue category (having raked in $519.6 million in 2015), 74-year-old Dickey’s isn’t sitting back on its success. It recently debuted its fourth-generation restaurant design, with changes spanning both the atmosphere and menu. Following trends toward transparency, the smaller-footprint prototype features upgraded tech and an open kitchen with the barbecue pit on full display.

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15. McAlister’s Deli

2015 U.S. Sales: $547.7 million

2015 U.S. Units: 361

Staying abreast of consumer demand for off-premise eats has paid off for McAlister’s Deli, as its sales grew 8.7 percent last year. As of now, it’s unclear who will take helm at the chain, which was recently left without a president when Carin Stutz departed to lead operations at Red Robin. Still, the chain, known for its sweet tea and made-to-order sandwiches, is ramping up its Midwest expansion, eyeing Wisconsin in particular.

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14. Raising Cane’s Chicken Fingers

2015 U.S. Sales: $567.3 million

2015 U.S. Units: 249

With year-over-year sales growth that topped 26 percent in 2015, the chain’s brand of made-to-order chicken tenders and signature dipping sauce is clearly making waves with customers. The chain last year announced plans to bring its brand abroad, debuting its first international unit in Kuwait City.

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13. Boston Market

2015 U.S. Sales: $610.0 million

2015 U.S. Units: 452

Boston Market last year sought a fresh look as it looked to expand its unit count. Leaning into consumer preferences for fresh, healthy menu items, the chain made a significant shift from a value-focused strategy to a health-centered one, even hiring several new executives to support its new positioning. Its new messaging debuted with the launch of its “All Good” campaign, which urged customers to “take a side against fried” chicken.

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12. Moe’s Southwest Grill

2015 U.S. Sales: $638.1 million

2015 U.S. Units: 637

As rival Chipotle contends with its food safety recovery plan, this Mexican chain has aimed to snare market share by leaning into its “irreverent” persona (its name is an acronym for Musicians-Outlaws-Entertainers, after all). Thanks to revamped efforts from a new head of global marketing, Moe’s has recently become more purposeful with brand communication, seeing social media as a key piece of the mix. U.S. sales at the chain grew 12 percent in 2015.

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11. Firehouse Subs

2015 U.S. Sales: $648.5 million

2015 U.S. Units: 943

This firehouse-themed brand prides itself on appealing to customers’ growing desire for healthy ingredients and convenient technology. The steamed-sub chain last year further invested in tech, adding mobile pay and a loyalty program to the enhanced app it launched in August. It’s also firing up international expansion efforts, recently announcing that it would open 90-plus locations in Ontario, Canada.

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10. Jason’s Deli

2015 U.S. Sales: $654.3 million

2015 U.S. Units: 262

Long before the removal of artificial ingredients became a trend loudly applauded by consumers and practitioners, Jason’s Deli decided to yank preservatives from its food because the team decided it was the right thing to do. The brand never came up with a catchy slogan about the integrity of its food (uh, Chipotle?), nor any sound bites about serving food as it should be (ahem, Panera). Instead, the privately held chain just chugged along, striving to provide healthful, less-processed food while growing at a decidedly controlled rate (the 40-year-old concept had 262 stores opened as of Jan. 1).

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9. Jersey Mike’s Subs

2015 U.S. Sales: $675.0 million

2015 U.S. Units: 1,046

The premium-sandwich chain may soon rival Bruce Springsteen as the Garden State’s best-known export, having expanded far from a single shop in Point Pleasant, N.J., to more than a thousand stores across the continent. Technomic has cited the chain’s expansion and sales strengths as some of the reasons Subway recently has struggled. Mike’s is not without considerable direct competition, but Jimmy John’s is the only rival to beat it in the sales rankings.

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8. Qdoba Mexican Eats

2015 U.S. Sales: $744.9 million

2015 U.S. Units: 670

Outfitted with a new name, look and pricing model, the Mexican sister of Jack in the Box outperformed its traditional-QSR sibling last year. A major reason, says management, was the switch to all-inclusive pricing, instead of charging a la carte for guacamole, as Chipotle does. Whatever the brand lost in immediate revenues was made up in simpler operations, a boost in perceived value and a far better guest experience, according to the concept’s parent company. Now it remains to be seen if momentum can be retained after the departure next month of President Tim Casey, the architect of the changes.

Explore: Technomic

7. Wingstop

2015 U.S. Sales: $768.6 million

2015 U.S. Units: 786

Let’s forget the ROI on Wingstop’s stores for a minute ($1.1 million in average sales from a building that typically costs $370,000) to focus on the top line, or, more specifically, how the chicken wings chain plans to snag more business. Online orders are usually $4 higher than the typical tab, so management is pushing for more digital preordering by takeout customers, who account for 75 percent of sales. Mobile devices and desktops now generate 15.8 percent of intake—a four-point jump from a year ago. And franchisees have greenlighted a national advertising campaign one year earlier than the strategic plan had specified.

Explore: Technomic

6. Five Guys Burgers and Fries

2015 U.S. Sales: $1.3 billion

2015 U.S. Units: 1,215

By the standards of Five Guys, the burger chain that makes Hot ‘n Now seem like a slave to the latest menu fad, it was ground-shaking: Selected stores added milkshakes last year. That’s as close as the retro concept is likely to come to a change in its purist formula: Burgers, fries, hot dogs and a few sandwiches. The focus on execution kept the fast-casual pioneer in the Top 10, even with far more heat from new competitors.

Explore: Technomic

5. Zaxby’s

2015 U.S. Sales: $1.5 billion

2015 U.S. Units: 748

The millennials on our editorial staff give older co-workers an indulgent you’re-so-clueless eye roll when there’s a suggestion that chicken fingers are for kids. Chicken fingers, the oldsters are told, are loved just as much by millennials, who see them as an easier-to-eat alternative to chicken wings. Zaxby’s, the highest-finishing chicken fingers specialist among the 250 fast-casual concepts ranked by Technomic, likely wouldn’t argue.

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4. Jimmy John’s Gourmet Sandwiches

2015 U.S. Sales: $2.0 billion

2015 U.S. Units: 2,450

According to the lore Jimmy Liautaud has yet to contradict, he was a buzz-loving teenaged slacker until his father gave him an ultimatum: Either make some money or report for military service. He decided to open a knockoff of Portillo’s, his favorite fast-food joint, but couldn’t afford the equipment needed to cook hot dogs. Instead, he made cold subs. Thirty-four years later, Liautaud oversees the industry’s largest fast-casual chain in terms of unit count, with some 2,450 branches. He could have sold the brand to the public last summer, but acknowledged he got cold feet. Now he’s likely keeping an eye on all the third-party services that have enabled competitors to add delivery, a major distinction of his venture.

Explore: Technomic

3. Panda Express

2015 U.S. Sales: $2.6 billion

2015 U.S. Units: 1,790

Long before the fast-casual market was where everyone wanted to be, Panda Express was quietly mining demand at the high end of limited service for better, more authentic food. Its Asian outlets sprouted quickly in nontraditional sites such as shopping malls, airports and colleges and universities. The rest of the industry would eventually get wise, but Panda enjoyed an enviable lead it still holds today. Now its founders are looking at such other fast-casual growth projects as Pieology and Just Salad, but their 33-year-old workhorse is still a pacesetter.

Explore: Technomic

2. Chipotle Mexican Grill

2015 U.S. Sales: $4.4 billion

2015 U.S. Units: 1,987

Forgive the leadership of Chipotle for looking back at 2015 with nostalgia. The food safety problems that pushed sales off a cliff didn’t begin until mid-October. The crises failed to negate results from a solid first nine months, letting the concept stay near the top of the sales ranking. Now it’s in courtship mode, trying to woo back a public that abandoned the chain. The major efforts will include the chain’s first-ever loyalty program and significant menu changes, including a possible remix of the beverage lineup.

Explore: Technomic

1. Panera Bread/Saint Louis Bread Co.

2015 U.S. Sales: $4.8 billion

2015 U.S. Units: 1,955

Executives coined “Panera 2.0” as a label for the chain’s suite of tech initiatives, but the term could just as readily signify the reinvented bakery-cafe chain in its entirety—if the tag weren’t as stale as yesterday’s muffins. Something like “Panera 2.8” might be a more accurate way of capturing the changes that range from stripping recipes of additives to adding a big-time executive in the form of president Drew Madsen, formerly the No. 2 guy at Darden. The setup took four years; now, says CEO Ron Shaich, it’s payoff time. He cites the examples of Charlotte, N.C., stores that were collecting $33,000 in weekly sales pre-Panera 2.0, about $45,000 afterward, and roughly $55,000 today with the addition of delivery, the chain’s next big initiative.

Explore: Technomic

Methodology

The Top 40 Fast-Casual Chains ranking is a measure of the largest concepts by U.S. systemwide sales, based on results from the 2015 calendar year. Relevant information is accrued using a combination of public company financial filings, direct operator surveying, franchise disclosure documents and propriety valuation algorithms.

You can get the complete Top 250 Fast-Casual Chain Restaurant Report here.

Technomic Inc. believes that its sources of information are reliable but does not assume any liability for the accuracy or comprehensiveness of the information published.

Explore: Technomic

40. Newk's Eatery

39. Donatos Pizza

38. Taco Bueno

37. Café Rio Mexican Grill

36. Shake Shack

35. Baja Fresh Mexican Grill

34. Bruegger's Bagels

33. Which Wich Superior Sandwiches

32. Rubio's

31. Fazoli's

30. Zoës Kitchen

29. The Habit Burger Grill

28. Fuddruckers

27. Portillo's

26. Smashburger

25. Schlotzsky’s

24. Taco Cabana

23. Pei Wei Asian Diner

22. Au Bon Pain

21. Pollo Tropical

20. Potbelly Sandwich Shop

19. Corner Bakery Cafe

18. Einstein Bros. Bagels

17. Noodles & Company

16. Dickey’s Barbecue Pit

15. McAlister’s Deli

14. Raising Cane’s Chicken Fingers

13. Boston Market

12. Moe’s Southwest Grill

11. Firehouse Subs

10. Jason’s Deli

9. Jersey Mike’s Subs

8. Qdoba Mexican Eats

7. Wingstop

6. Five Guys Burgers and Fries

5. Zaxby’s

4. Jimmy John’s Gourmet Sandwiches

3. Panda Express

2. Chipotle Mexican Grill

1. Panera Bread/Saint Louis Bread Co.

Methodology

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