SunOpta, a subsidiary of Refresco, has commissioned a fourth production line at its manufacturing plant in Midlothian, Texas.
The $35 million capital project increases SunOpta's total manufacturing network capacity by 10%, while situating processing capacity closer to key regional customer distribution channels across North America.
The expansion increases output for plant-based milks, creamers, ready-to-drink teas, and liquid culinary broths, meeting growing contract manufacturing demand from retail brand owners and commercial foodservice operators.
"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, Chief Executive Officer 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."
Packaging Capabilities and Technical Infrastructure
The installation of the fourth high-speed line expands the plant's operational flexibility and packaging formats.
While the Midlothian facility previously focused on 16-ounce, 32-ounce, and 330ml aseptic configurations, the new production equipment introduces:
Half-Gallon Formats: Multi-serve liquid cartons configured for domestic chilled and ambient household use.
32-Ounce "Edge" Packaging: Modernised, pour-friendly carton architecture designed for premium ambient retail and barista-blend foodservice channels.
The technological additions allow the business to support order volumes from existing retail and foodservice partners while creating processing capacity to onboard new co-manufacturing accounts.
Site Development and Sustainability
SunOpta originally opened the 285,000-square-foot Midlothian manufacturing facility in winter 2023, engineering the industrial footprint with the structural potential to expand to 400,000 square feet. The site currently employs more than 220 staff across production, engineering, quality assurance, and operations.
The plant incorporates resource-efficiency systems to limit utility consumption across high-volume liquid processing:
Water Conservation: Closed-loop water reuse equipment engineered to recycle up to 20 million gallons of water annually.
Thermal and HVAC Efficiency: Low-energy climate and ventilation systems delivering a 45% reduction in baseline energy consumption.
Power Reduction: Facility-wide LED lighting arrays and high-efficiency water heating systems reducing power demand by up to 95%.
Recycled Building Inputs: Administrative offices and on-site testing laboratories constructed with at least 40% recyclable materials.
"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."
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