SunOpta adds 10% capacity with US$35 million Texas beverage expansion

SunOpta has completed a US$35 million expansion of its manufacturing facility in Midlothian, Texas, adding a fourth production line that is expected to increase capacity across its network by 10%.

The company, which is now part of beverage solutions provider Refresco, said the investment responds to growing customer demand for plant-based milks and creamers, tea and broths, while providing additional flexibility across packaging formats.

• SunOpta has invested US$35 million in a fourth production line at its Midlothian, Texas, manufacturing facility.
• The expansion is expected to increase capacity across the company's production network by 10% and bring manufacturing closer to customer distribution.
• The new line adds half-gallon and 32-ounce Edge-style packaging alongside existing formats for plant-based milks, creamers, tea and broths.

“Demand for plant-based milks and creamers, tea and broths in various formats is increasing, and the Midlothian expansion positions us to meet that momentum head-on,” said Brian Kocher, CEO of SunOpta. “By investing in our existing footprint and capabilities, we’re strengthening our ability to support customers with the scale, flexibility and reliability they need today and well into the future.”

SunOpta opened the Midlothian plant in winter 2023 as a manufacturing base for plant-based beverages, including milks and creamers, as well as tea and broths.

The original 285,000-square-foot facility was designed to handle a range of packaging sizes and configurations for foodservice, shelf-stable retail and e-commerce. Expansion was part of the plans from the outset, with the site designed to accommodate up to 400,000 square feet.

The newly commissioned fourth line increases capacity for existing customers while giving SunOpta room to add new business. The company said locating additional production in Texas would also bring manufacturing closer to distribution for some customers and strengthen supply chain resilience.

Packaging flexibility is another focus of the investment. Alongside 16-ounce, 32-ounce and 330-ml packages, the new line enables the Midlothian site to manufacture 32-ounce Edge-style packaging and half-gallon formats.

The expansion comes following SunOpta's acquisition by Refresco, giving the business a new parent as it continues to build its US manufacturing operations. SunOpta operates seven manufacturing facilities across six markets and provides manufacturing and supply chain services to brands, retailers and foodservice customers.

More than 220 people are employed at the Midlothian site.

“At Midlothian, we take pride in turning growth opportunities into results,” said Plant Director Nick Muzzin. “This expansion reflects the dedication of our team and our ability to deliver high-quality plant-based milks and creamers, tea and broths at scale. We’re excited to support our customers as they grow and to help bring more of these products to consumers every day.”

SunOpta also designed the Texas facility to reduce resource use during production. Its water reuse equipment has the capacity to save up to 20 million gallons annually, according to the company, while an energy-efficient HVAC system is designed to cut energy consumption by 45%.

The plant also uses LED lighting and water heaters that SunOpta said reduce power usage by 95%, while its offices and laboratories were constructed using at least 40% recyclable materials.

The latest investment builds on the manufacturing capacity SunOpta established when it opened Midlothian three years ago, with the additional line allowing the company to use more of the expansion potential designed into the site from the beginning.

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