Sandwich shops look simple: bread, protein, cheese, toppings.
In reality, a $0.20 portion change can destroy your margin.
This guide shows a real sandwich cost calculator workflow using U.S. city average price data, clear portion math, and pricing targets that deli operators actually use.
Quick Summary
- Convert $/lb to $/oz first, or your cost math will be wrong
- Bread looks cheap but multiplies fast across combos and catering trays
- Sandwich shops survive on portion control + upsell discipline, not only on “cheap ingredients”
- Retail price benchmarks help sanity-check distributor quotes (and catch menu creep)
Why Sandwich & Deli Costing Feels Harder Than It Should
Most sandwich businesses lose money for predictable reasons:
- Portion creep (extra 0.5–1 oz of meat across 200 sandwiches = real dollars)
- Bread + protein double-hit (both are in every SKU)
- Combo dilution (sides + drinks sold at a discount wipe out margin)
- Toppings waste (lettuce and tomato spoil faster than protein)
- Labor hides inside “simple food” (prep time for slicing, wrapping, and line setup)
If you price sandwiches like “fast food,” you will underprice your labor and packaging.
Baseline Ingredient Prices (U.S. City Average, Nov-Dec 2025)
Use this table to sanity-check your distributor quotes.
These are U.S. city average retail prices from BLS average price data (via FRED).
Retail prices are not the same as wholesale. But they are a reliable benchmark when distributor prices spike or shrink.
| Item | Price per lb | Price per oz | Why it matters |
|---|---|---|---|
| Bread, white, pan | $1.833 | $0.11 | Your base cost on every sandwich |
| Ham, boneless | $5.356 | $0.33 | Deli classic protein anchor |
| Cheddar cheese, natural | $5.789 | $0.36 | Cheese adds cost fast with double slices |
| Chicken breast, boneless | $4.153 | $0.26 | Core protein for clubs & wraps |
| Bacon, sliced | $6.760 | $0.42 | High-cost add-on, easy upsell |
| Lettuce, iceberg | $1.731 | $0.11 | Spoilage-heavy topping |
| Tomatoes, field grown | $1.840 | $0.12 | Seasonal swing item |
Conversion formula:
Price per oz = Price per lb ÷ 16Note: Lettuce is the latest available (Sep 2025). Most other items are Dec 2025.
Costing Card Example #1 — Ham & Cheddar Classic
Portion assumptions (adjust to your shop’s standard):
- Bread: 2 slices (2 oz)
- Ham: 3 oz
- Cheddar: 1 oz
- Lettuce: 0.5 oz
- Tomato: 1.5 oz
- Condiments: $0.12 (estimated)
Cost Breakdown
| Ingredient | Portion | Cost per oz | Cost |
|---|---|---|---|
| Bread | 2 oz | $0.11 | $0.23 |
| Ham | 3 oz | $0.33 | $1.00 |
| Cheddar | 1 oz | $0.36 | $0.36 |
| Lettuce | 0.5 oz | $0.11 | $0.06 |
| Tomato | 1.5 oz | $0.12 | $0.18 |
| Condiments | — | — | $0.12 |
| Total Food Cost | — | — | $1.95 |
Price Targets
| Target Food Cost % | Menu Price |
|---|---|
| 28% | $6.96 |
| 30% | $6.50 |
| 32% | $6.09 |
If you bundle this with chips + drink, calculate the combo food cost together.
Costing Card Example #2 — Grilled Chicken Club
Portion assumptions:
- Bread: 2 slices (2 oz)
- Chicken breast: 4 oz
- Bacon: 1 oz (about 2 slices)
- Cheddar: 1 oz
- Lettuce: 0.5 oz
- Tomato: 1.5 oz
- Condiments: $0.15 (estimated)
Cost Breakdown
| Ingredient | Portion | Cost per oz | Cost |
|---|---|---|---|
| Bread | 2 oz | $0.11 | $0.23 |
| Chicken breast | 4 oz | $0.26 | $1.04 |
| Bacon | 1 oz | $0.42 | $0.42 |
| Cheddar | 1 oz | $0.36 | $0.36 |
| Lettuce | 0.5 oz | $0.11 | $0.06 |
| Tomato | 1.5 oz | $0.12 | $0.18 |
| Condiments | — | — | $0.15 |
| Total Food Cost | — | — | $2.44 |
Price Targets
| Target Food Cost % | Menu Price |
|---|---|
| 28% | $8.71 |
| 30% | $8.13 |
| 32% | $7.63 |
If your market won’t accept $8–9 sandwiches, the portion size is the first lever to pull.
The 5 Levers That Move Sandwich Margin
-
Portion control (first priority)
- Use portion scoops or a scale for every protein
- Train staff on visual portion standards
-
Protein mix and menu engineering
- Anchor items (roast beef, turkey) attract traffic
- Margin items (ham, veggie, egg salad) protect profit
-
Bread spec choices
- Thicker bread increases portion cost silently
- Switching roll size can cut 5–10% off plate cost
-
Topping discipline
- Lettuce/tomato waste is high; trim and par levels matter
- Prepped toppings should match your daily volume, not your ideal volume
-
Add-on pricing
- Extra protein, bacon, and avocado must be priced for margin
- If add-ons are “cheap,” customers will overuse them
Combo Math: Why Deli Shops Leak Profit
Most sandwich shops use combos to raise average ticket size.
But if the drink + side margin is low, the combo reduces total margin.
Use this quick check:
Combo Food Cost % = (Sandwich Cost + Side Cost + Drink Cost) ÷ Combo PriceIf your combo cost % exceeds your standalone target by 3–5 points, you are discounting too heavily.
Catering Trays: The Hidden Margin Opportunity
Sandwich trays look expensive to customers but can be very profitable if portioned correctly.
Key rules:
- Use smaller meat portions per piece (but keep visual fullness)
- Use higher-margin sandwiches in catering mixes
- Price trays by per-piece food cost, not by “feels like a nice round number”
Delivery & Takeout Adjustments
Sandwiches travel well, which makes them popular on delivery apps.
But delivery fees and packaging can erase your margin fast.
- Add a delivery-only price if your platform allows it
- Track packaging cost per order (bags, wraps, utensils)
- Review your delivery profitability monthly, not yearly
If you want a full breakdown, see the Delivery App Profit Guide.
Costing Checklist (Use This Weekly)
- Update protein costs when invoices change
- Audit actual portion sizes during a rush
- Review combo profitability after menu or price changes
- Adjust add-on prices at least once per quarter
- Re-evaluate top 5 sellers every month
Related Guides
- Food Cost Ratio Guide
- Prime Cost Complete Guide
- Loss Rate Calculation Guide
- Burger Restaurant Cost Guide
- US Chicken Sandwich Cost Guide
- US Gyro & Falafel Cost Guide
- Menu Engineering Guide
- Price Increase Timing Guide
- Excel vs App Cost Management
- Chicken Restaurant Cost Guide
- Pizza Cost Calculator
- Home Baking Pricing Guide
- Bunsik Cost Guide
If you want a faster way to track sandwich costs, portion changes, and menu profitability, try KitchenCost.