U.S. dairy resilience, demand for protein spur ongoing expansion

Editor’s note: Plants in Progress is a special segment spotlighting new facilities and expansion in the U.S. dairy sector — from initial groundbreaking to full operation and everything in between.

By Alyssa Mitchell

MADISON, Wis. — The International Dairy Foods Association and Ever.Ag Insights recently reported that America’s dairy processors are responding to surging demand for their products by investing more than $11 billion in new and expanded manufacturing capacity across 19 states. With U.S. milk production expected to grow 15 billion pounds by the end of the decade and dairy consumption and export demand rising as consumers seek out wholesome protein and nourishment, dairy processors have undertaken more than 50 individual building projects between 2025 and early 2028. These new and upgraded facilities will add to the billions of dollars of new processing capacity that has come online in the past decade.

That’s great news in the midst of a volatile economic and political climate as U.S. dairy companies continue to grapple with rising costs, trade uncertainty and labor shortages. New developments in automation and artificial intelligence are boosting volume, quality and consistency as the nation’s farmers, processors and retailers work together to feed consumers’ ever-increasing appetite for dairy proteins. From artisanal cheeses to specialty proteins to beverage innovations, there is no shortage of ways consumers can choose dairy at any time of day, in any format, almost anywhere.

We’re pleased to bring you the latest updates on just some of the investments and innovations happening across the country in our biannual special feature.

Please read on for more on these Plants in Progress ...

• Associated Milk Producers Inc., Portage, Wisconsin

Associated Milk Producers Inc. (AMPI) is in the final phase of a rebuild of its cheese processing and packaging plant in Portage, Wisconsin, following a January 2023 fire. The team is ready to see production restored to pre-fire levels.

“While a portion of the plant resumed operations just six weeks following the fire, we’ve been limited in achieving full capacity until the impacted area could be rebuilt,” says Tyler Banks, AMPI Portage division manager. “We’re excited to be in this phase where new construction is happening and our visions are becoming reality.”

Final restoration of the plant includes improvements in design to increase production efficiencies, process flow and product quality. Key features include additional space for packaging and production, and upgrades to heating, ventilation, air conditioning and flooring.

“We took the opportunity following the fire to fully examine the plant layout,” notes Mike Wolkow, AMPI senior vice president of operations. “The rebuild plan better utilizes space within the building, focusing on those products in demand and incorporating new capabilities to innovate and grow with our customers.”

Fulfillment of customer orders is continuing throughout the rebuild process, AMPI says.

• Bel Brands, Nampa, Idaho; Brookings, South Dakota; and Little Chute, Wisconsin

Bel Brands is investing in several of its facilities across the United States. The company recently made an investment of approximately $130 million in Nampa, Idaho, to double production capacity of GoGo squeeZ products.

Last month, the South Dakota Board of Economic Development approved funding for an expansion at Bel Brands’ facility in Brookings, South Dakota. The company was approved for a REDI (Revolving Economic Development and Initiative) loan of up to $10 million to construct an additional 100,000 square feet of space, doubling its current production capacity at the Brookings plant. Earlier this year, Bel announced a $200 million factory expansion at the Brookings plant that would increase its Mini Babybel production capacity by 10,000 tons annually.

Meanwhile, the company also is investing nearly $20 million in a new production unit for The Laughing Cow in Little Chute, Wisconsin, and in Boursin production capabilities, enhancing operational flexibility and efficiency.

These investments are expected to create approximately 250 jobs across the United States.

“At this important time, Bel is growing its market share with its portion-sized products. Bel is innovating its portions to meet nutritional needs for the U.S. diet in support of healthier snacking habits” says Cécile Béliot, CEO of Bel Group.

• Byrne Dairy, Cortlandville, New York

Byrne Dairy in July officially broke ground on the Byrne Cortlandville (BVC) expansion. BCV employees, members of the Byrne family, and community and business partners gathered to celebrate the biggest project in the company’s history.

The $120 million expansion project will double the workforce and production capacity at BCV. It encompasses several phases. Byrne Dairy, based in Syracuse, New York, began expansion activities in Cortlandville in 2022, which the company considered Phase 1, according to documents provided to a Town of Cortlandville Planning Board meeting held earlier this year. Additional phases will add more than 200 new positions and will encompass expanded space, new equipment, improved traffic and product flow, and more.

Earlier this month, the company provided additional progress updates, including that traffic has been diverted on a new road, and basic signage and scale relocation are complete. Work continues on the foundation and walls, the steel erection, underground piping and electrical prep, the company says

• Cayuga Milk Ingredients, Auburn, New York

Cayuga Milk Ingredients this summer marked the grand opening of a two-phase, $270 million expansion project in the Town of Aurelius, Cayuga County, allowing the company to better assist its clients and create opportunities for New York State dairy farmers. The state-of-the-art facility also will allow the company to more than double its workforce, adding up to 150 new jobs to the existing workforce of 100 employees.

New York State is supporting this project through a $4 million capital grant and up to $4 million made available through the performance-based Excelsior Jobs Tax Credit Program in exchange for job creation commitments. Cayuga Milk Ingredients is a farmer-owned dairy processor, producing premium milk and innovative dairy ingredients for customers across the globe.

Phase one of the expansion included the purchase and installation of an ultra-high-temperature (UHT)/aseptic low-acid packaging system and a new reverse osmosis filtration system. The second phase included the addition of machinery and equipment, and the expansion of the facility’s wastewater treatment plant.

“Cayuga Milk Ingredients is proud to be a key player in New York’s dairy industry with the investment in our new aseptic and extended-shelf-life fluid dairy production facility driving long-term growth in our community,” says CEO Brian Linney. “We are grateful for the support of Gov. Hochul in this project expansion as we work to ensure the continued success and longevity of the agricultural industry in New York State.”

Cayuga Milk Ingredients is owned and operated by 22 farm families with 32 farm locations in the Finger Lakes region of New York State, with a dairy ingredients portfolio that includes milk powders, protein powders and fluid milk products. With the addition of its new consumer goods dairy plant, the company is positioning itself as a vertically integrated, premium contract manufacturing solution for fast-growing, value-added dairy products, with a commitment to maximizing its nutritional impact while minimizing environmental impact.

• Chobani LLC, Twin Falls, Idaho, and Rome, New York

Chobani LLC earlier this year announced its largest investment yet, a $500 million expansion of its Twin Falls, Idaho, plant. The project will increase production by 50% and add over 500,000 square feet of new space. The expansion, anticipated to be operational by early 2026, is expected to create a minimum of 160 new jobs, officials say.

Simultaneously, the City of Twin Falls, the Urban Renewal Agency of the City of Twin Falls (URA) and Chobani formalized an agreement outlining responsibilities, funding and commitments related to this expansion. The agreement builds upon the original 2011 Development Agreement and subsequent amendments, continuing the partnership that has made Chobani’s Twin Falls facility the largest natural food production facility in the country, Chobani says.

“This agreement demonstrates the strong partnership between Chobani and the City of Twin Falls,” says Shawn Barigar, City Economic Development director and executive director of the Urban Renewal Agency. “We’re committed to supporting Chobani’s continued growth and ensuring the necessary infrastructure is in place to accommodate this expansion.”

The expansion will bring the Twin Falls plant to 1.6 million square feet, featuring 24 production lines and employing over 1,200 people, earning wages almost 12% higher than the regional average. The expansion also requires significant infrastructure improvements, including upgrades to the city’s water, wastewater and power systems.

“Over a decade ago, this empty stretch of land in Twin Falls, Idaho, became the heartbeat of a food revolution. Today, that heart is growing even stronger,” Chobani says. “This isn’t just a place where yogurt, oatmilk and coffee creamers are made. It’s a place where in the Magic Valley farmers, engineers and dreamers come together to make food that nourishes millions.”

Meanwhile, Chobani in April broke ground on a new $1.2 billion, state-of-the-art plant in Rome, New York.

“New York is where Chobani’s journey began. It was the perfect spot to start Chobani 20 years ago, and it’s the perfect place to continue our story,” says Hamdi Ulukaya, founder and CEO of Chobani. “With our new plant in Rome and our original home in South Edmeston, we’re entering a new dimension, partnering with hard-working people across the heartland of New York to build an ecosystem of natural food production and nourish families throughout the country.”

Once home to the former Griffiss Air Force Base, the 150-acre stretch of land is being transformed into a thriving center of food production, enabling Chobani to keep up with soaring product demand and create a runway for new innovations. The 1.4-million-square-foot facility is expected to add over 1,000 full-time jobs with competitive wages, an attractive benefits package and access to a suite of on-site health and wellness amenities.

Rooted in the belief that business can be a force for good, the Rome plant is not a standalone operation — it’s designed to be a catalyst for an entire ecosystem of food innovation across the Mohawk Valley and beyond, Chobani says. The company will partner with local farmers, businesses, colleges, universities, government leaders, entrepreneurs and community organizations to drive new thinking, train the next generation of high-skilled labor and fuel economic opportunity in the region.

With capacity to produce over 1 billion pounds of high-quality dairy products per year, the new plant will house up to 28 production lines designed to process approximately 12 million pounds of milk per day.

Once the new plant reaches full capacity, Chobani will purchase an estimated 6 billion pounds per year, creating additional economic opportunity and strengthening the state’s dairy industry, officials say

• Dairy State Cheese LLC, Rudolph, Wisconsin

Dairy State Cheese now is running 100% 40-pound blocks of Parmesan, according to Doug Simon, president of external manufacturing for Cheese Merchants, which acquired Dairy State Cheese in January 2023. Since that time, Cheese Merchants has continuously invested in the facility to produce high-quality Parmesan. The plant currently is undergoing an expansion to double cheese and whey production by mid- to late-2026, according to Simon. The expansion includes a significant investment in wastewater handling to ensure the plant can effectively treat the additional wastewater from the expanded production.

• Daisy Brand LLC, Boone, Iowa

Daisy Brand LLC, manufacturer of one of the largest brands of sour cream and cottage cheese in the United States, held a ceremonial groundbreaking earlier this year in Boone, Iowa. Demand for the company’s products has created the need for an additional manufacturing facility, company officials say.
Daisy is investing nearly $700 million in a 750,000-square-foot facility, creating 106 new jobs to start, a number anticipated to grow to 255 as demand increases. The Iowa Economic Development Authority (IEDA) board approved $7 million in direct financial assistance as well as tax benefits for the company.
“Daisy Brand’s investment in Iowa further reinforces our standing as a manufacturing powerhouse and reputation for fostering an environment where businesses succeed and grow,” says Iowa Gov. Kim Reynolds. “With a third of the nation’s top food manufacturers located in Iowa and 26% of our manufacturing industry attributed to food processing, Iowa and Daisy are a perfect fit. From our dairy industry and farmers to our skilled workforce, there is no better place for Daisy to expand, and I am confident the company will continue to flourish in our great state.”

Headquartered in Dallas, Daisy Brand is a fifth-generation family-owned company with existing operations in Texas, Arizona and Ohio. The decision to expand into Iowa was driven by several factors, including Iowa’s agricultural resources and strengths, favorable business environment and strategic location, officials say.

Company officials say Daisy Brand hopes to have the new plant up and running by 2028.

• Danone North America, Jacksonville, Florida, and Minster, Ohio

Danone U.S. this summer announced the opening of a new $65 million production line in Jacksonville, Florida. The expansion of this 115,025-square-foot facility, which has been a cornerstone of the Jacksonville community since 1948, supports the continued growth of Danone’s coffee and creamer portfolio, including high-performing brands such as International Delight creamers and STōK Cold Brew Coffee.

Danone also is investing in a new regional distribution center in the Jacksonville area as part of a streamlined, high-capacity distribution network rooted in regional infrastructure. This investment will allow the company to enhance its supply chain efficiency and deliver products at peak freshness across the Southeastern United States. Between the manufacturing plant and distribution center, Danone is creating nearly 200 new direct and indirect jobs in the Jacksonville community. Through this investment, Danone’s aim is to increase product availability on shelves nationwide and shorten the path from production to customer delivery.

The new Jacksonville line features cutting-edge technology — including a unique bottle-molding process that will increase production capacity and deliver efficiency and sustainability benefits. Leveraging this new technology will result in a 30% reduction in bottle loss and reduced water usage to create Danone’s new recyclable bottles, officials note.

Also this summer, Danone U.S. announced the expansion of its Minster, Ohio, yogurt facility, which produces brands such as Oikos, Activia, Dannon and Danimals. The multimillion-dollar investment includes an approximately 48,000-square-foot facility expansion as well as a new production line and upgrades to existing lines, bringing 30 new full-time jobs to the region.

“Our commitment to American manufacturing runs deep, with 90% of our ingredients and packaging materials bought here,” says Dan Magliocco, president, Danone North America. “Fulfilling our mission to bring health through food to as many people as possible means producing nutrient-rich foods with U.S. ingredients in American factories that are benefiting local communities.”

Danone officials note the yogurt category is experiencing explosive growth driven by consumers seeking more nutrient-dense foods that are high in protein and rich in nutrients and probiotic benefits. This investment in the Minster yogurt facility offers expanded capacity to address that consumer demand. Danone will purchase 60% more milk for the Minster yogurt facility over the next couple years, which will include working with existing producer partners to increase their production and onboarding new local farms into the Danone family. For nearly a decade, Danone has partnered with dozens of farmers across the United States to source the ingredients that go into its products.

Danone’s enhanced facility will also create approximately 30 new, full-time jobs in Ohio’s Golden Triangle region — a hub of American manufacturing strength — with competitive wages and comprehensive benefits.

“We are excited to continue growing our team and presence in Minster, Ohio. This is the latest example of our 80-plus years of investments in American food, its economy and the farming partners that sustain our food systems — and this closely follows our recent investment in Jacksonville, Florida,” says Heiko Gerling, COO for Danone North America.

• Dari Processing LLC, Seward, Nebraska

Nebraska Gov. Jim Pillen, state and local leaders, and Nebraska’s dairy industry this summer celebrated the groundbreaking of a milk processing plant at the Seward Rail Campus. The facility is being built by Dari Processing LLC — a fourth-generation dairy company run by the Tuls family in Rising City, Nebraska.

Dari Processing expects the new facility to process 1.8 million pounds of milk per day when it reaches full capacity in the coming years. The company anticipates hiring the equivalent of 70 full-time positions at the dairy plant. Combining multiple stages of production in Nebraska at a strategic location along Interstate 80 will allow the company to maximize its resources.

“Dairies in Nebraska, including ours, have been shipping more and more milk out of state,” says TJ Tuls, co-owner and CEO of Dari Processing.

“We are excited to build this plant adding new processing capacity. This will help keep 30% of the state’s milk here — saving hundreds of thousands of miles on trucks, reducing emissions and making dairy more sustainable.

“We vetted two states for this project, and Nebraska wanted it significantly more (than the other option),” he adds. “We’ve received a warm welcome from Seward. The city and state have been great partners in setting up the power, water and gas for the facility.”

The state of Nebraska is helping to fund the extension of Worthman Boulevard, as well as sewer and water/wastewater extensions, to support the new dairy plant. The Nebraska Department of Economic
Development (DED) is providing $1 million of funding through the Community Development Block Grant Program for the infrastructure project, which the city of Seward is matching. The Nebraska Department of Transportation is awarding $583,000 for the infrastructure improvements through its Economic Opportunity Program. Additionally, DED is awarding $500,000 of Site and Building Development Funds for the project to support construction of the facility.

Dari Processing’s facility in Seward will process raw milk at ultra-high temperatures (UHT pasteurization) to eliminate bacteria. Milk products then will be packaged immediately in airtight bottles/containers within a sterile environment. This process, known as aseptic production, results in fresh milk and cream that can go up to 12 months without refrigeration. The longer shelf life will expand opportunities for Dari Processing to ship Nebraska dairy across the country and potentially around the world.

• Darigold Inc., Pasco, Washington

Darigold Inc., the Seattle-based processing and marketing arm of the Northwest Dairy Association (NDA) and one of the nation’s largest dairy producers, has officially begun receiving and processing milk at its new facility in Pasco, Washington. The new plant will process up to 8 million pounds of milk per day from more than 100 regional farms, producing butter and powdered milk products for customers across the United States and in some 30 countries worldwide.

The Pasco project represents more than $1 billion in investment in Washington’s dairy sector, including both construction and on-farm expansion. It is expected to employ nearly 200 people directly and support up to 1,000 jobs in total through transportation, warehousing and farm workers.

“Dairy demand continues to grow, both here at home and abroad,” says Allan Huttema, president and CEO of Darigold and a third-generation dairy farmer in Parma, Idaho. “Our new Pasco facility solidifies the Northwest as a global dairy leader and reflects our farmer-owners’ long-term commitment to good stewardship, high-quality production and maintaining dairy farming as a way of life.”

Darigold’s farmer-owners in 2021 approved the Pasco project to expand and modernize the company’s production capability, create growth opportunities for member farms and strengthen the co-op’s ability to serve global markets. Pasco was selected for its proximity to a large number of NDA member farms, access to a robust workforce in the Pasco/Tri-Cities area and access to key transportation infrastructure — including highways, rail lines and ports.

Construction began in 2022. While the facility now is receiving and processing milk, Darigold will continue to finalize work on production equipment over the coming months. The company expects to begin producing powdered milk from the first of two milk dryers, and butter by early August. A second dryer is slated to come online by year’s end.

The new Pasco facility also is central to Darigold’s alignment with U.S. Dairy’s 2050 stewardship goals.

The Pasco project was developed in partnership with the Port of Pasco, designed by architectural firm E.A. Bonelli & Associates and built by Miron Construction.

• Fairlife LLC, Webster, New York

Project completion is near for Fairlife’s new 760,000-square-foot state-of-the-art facility in Webster, New York. The company will begin production testing before the end of the year, with sellable cases coming in the first quarter of 2026, officials say.

Fairlife has held two job fairs locally — one in August attended by more than 500 applicants and another in September with a similar turnout.

“We are aiming to hire more than 300 roles initially and have filled about half of those to date,” says Lisa Lecas, strategic communications leader at Fairlife.

The Town of Webster was strategically chosen by parent company The Coca‑Cola Co. and Fairlife teams for its proximity to the state’s best-in-class dairy cooperatives in the Rochester and Niagara regions, officials add.

The new facility will serve as Fairlife’s flagship Northeast location.

• Freshpack, Monticello, Wisconsin

Freshpack, a leader in cheese packaging and processing, marked a major milestone this summer by officially opening a 50,000-square-foot expansion of its South Plant facility in Monticello, Wisconsin. The ribbon-cutting ceremony celebrated more than just the extra square footage — it helped begin a new era of growth, innovation and investment in the future of Freshpack’s cheese processing.

The project more than tripled the size of the original building, now totaling 70,000 square feet, and was a massive leap forward for Freshpack’s operation and continued growth. The expanded facility features state-of-the-art equipment upgrades, including advanced cheese spread and dip production capabilities that will double production capacity. The modernization of the production lines will allow for the creation of exciting new whipped products, continuing Freshpack’s tradition of delivering industry-leading solutions, says Freshpack President and CEO Todd Kriebs.

Over the next five years, Freshpack anticipates adding 50 new jobs in Monticello, Wisconsin, and processing an additional 11 million pounds of cheese annually including millions of pounds sourced from Wisconsin cheesemakers.

• Grande Cheese, Chilton, Wisconsin

Progress continues on an expansion of Grande Cheese’s Chilton, Wisconsin, facility that it acquired from Foremost Farms in 2023. Grande Cheese, located in Southeastern Wisconsin, serves as a premier manufacturer of fine Italian cheeses and specialty whey and lactose products.

Company officials say the company expects to be making cheese in Chilton by mid-2026.

“Construction has gone well. We are currently hiring for first-shift production associates and support roles. We have many contractors on-site daily who are dedicated to keeping the project on time,” the company says.

Construction will include approximately 20,000 square feet of renovations and 60,000 square feet of new construction. The facility will be the third largest in Grande’s network and primarily produce Mozzarella.

• Hiland Dairy Foods Co., Tyler, Texas

Hiland Dairy’s new expansion project in Tyler, Texas, continues to advance on schedule, marking another milestone in the company’s ongoing investment in regional growth and product distribution, the company says. The state-of-the-art facility is designed to increase production capacity and improve logistics for customers across East Texas and surrounding markets.

The investment will add 90,000 square feet to the existing facility at 200 Fuller Ave., which will include state-of-the-art processing, filling, casing, palletizing, load-out, storage areas and a new laboratory. The expansion is expected to be complete by the first quarter of 2026.

Recent progress includes the installation of major utility systems and continued interior and exterior construction work. Crews are completing interior finishes, mechanical and electrical systems, and site paving in preparation for the final stages of build-out. The project has now surpassed 128,000 work hours with zero lost-time or recordable accidents, reflecting Hiland’s commitment to safety and quality performance on every job site, officials say.

The expansion, designed by E.A. Bonelli Architects + Engineers and constructed by Big-D Construction, remains on track for completion as scheduled.

• Hilmar Cheese Co., Dodge City, Kansas

Hilmar Cheese Co., Inc., one of the world’s largest cheese manufacturers and a global supplier of high-quality whey ingredients, this spring held a ribbon-cutting at its new facility in Dodge City, Kansas. The company was joined by federal, state and local officials at the event.

“We are grateful to the state and local officials who supported this project and thrilled to celebrate with them,” said David Ahlem, Hilmar’s former president and CEO, at the event. “We chose to build in Dodge City because of the local and skilled labor force, supportive and expanding agricultural region and excellent transportation network. The superior collaboration with local, regional and state leaders in Kansas has further confirmed that we made the right choice.”

Hilmar’s Dodge City facility makes American style cheese in commercial 40-pound blocks that are then sold wholesale to customers and used in a variety of nutritious foods. The site also produces a wide range of high-quality innovative proteins to meet the needs of customers worldwide.

“We appreciate everyone who has helped bring us to this point,” said Ahlem. “Thank you to our internal teams, some of whom moved here, and the hundreds of contractors and suppliers who partnered with us to ensure the facility was built and operational on schedule. We are also grateful to the dairy farm families in Southwest Kansas for their investment to supply us milk.”

The Dodge City manufacturing site incorporates the latest technology in sustainability and conservation. The advanced instrumentation and automated control systems minimize the water needed to keep the plant clean and reduces energy use. Recycled water is used further to process protein, clean the facility and equipment and reclaim heat. Upgraded spray nozzles were installed for more efficient cleaning. The cleaning process also reuses rinse water.

The sustainability effort continues throughout the site with efficient pumps and equipment. These features will decrease the plant’s greenhouse gas intensity and minimize water use. Hilmar is part of the U.S. Dairy Stewardship Commitment to achieve a carbon neutral dairy industry by 2050. The advancements in Dodge City will help Hilmar meet this goal.

Hilmar’s Dodge City site now employs nearly 250 people and represents more than $600 million in capital investment.

• HP Hood, Winchester, Virginia, and Batavia, New York

An expansion at HP Hood’s Winchester, Virginia, manufacturing facility is nearly complete. A new filler was installed and went into production late last year, and the new, expanded warehouse and processing room were in service starting in the first quarter of this year, officials say. The plant will encompass 442,000 square feet when the expansion is complete.

HP Hood previously announced it will invest more than $83.5 million in the project, which includes upgrades to production and packaging equipment as well as construction of additional warehouse and cooler space. HP Hood’s expansion will provide increased production capacity that will fund technology allowing Hood to offer new products, the company says.

Meanwhile, Hood’s Batavia, New York, manufacturing plant this summer was approved for a $25 million expansion to its milk receiving bay. The 7,772-square-foot expansion will improve the processing capabilities of the Batavia plant and increase the overall fluid capacity of the facility. The improvements include a two-bay raw milk silo alcove and room for four silos, along with additional facility upgrades.

The Batavia plant currently processes more than 175 million gallons of fluid dairy each year and employs around 450 people from the nearby community. The plant produces extended-shelf-life (ESL) products — both dairy and non-dairy.

• Ice Cream Factory, Lebanon, Missouri

PNC Brands Group, parent company of Pivot North Consulting Group and PNC Specialty Foods, has acquired a majority interest in Ice Cream Factory, a family-owned ice cream company based in Lebanon, Missouri. The company operates from a restored 90,000-square-foot historic dairy plant in Lebanon, originally built in the 1940s and listed on the National Register of Historic Places. The facility will remain the brand’s headquarters and manufacturing hub as it enters a new stage of modernization and expansion.

Under PNC’s leadership, Ice Cream Factory will undergo targeted upgrades to maximize efficiency and capacity, including updated processing lines, expanded frozen storage and a new savory production line to broaden co-manufacturing capabilities. These improvements will strengthen Ice Cream Factory’s position as both a premium producer and a trusted partner for emerging food brands seeking scalable production support, officials say.

The company will retain all current employees and expects to add 12-15 new jobs in production, research and development, and client support. The expansion also will stimulate local economic activity through suppliers, packaging vendors and logistics partners.

• Lactalis USA, Tulare, California; and Buffalo and Walton, New York

Lactalis USA late last year announced a $55 million investment in its Tulare, California, facility that will allow the company to significantly increase the volume of Président Feta cheese produced in the United States.

The new 38,000-square-foot manufacturing line will bring additional capacity for Lactalis USA Feta production in the United States at its facilities in Tulare and Belmont, Wisconsin. The project creates 20 full-time positions at Tulare along with 100 temporary or contract positions during construction. The construction timeline spans from 2023-2027; when completed in 2027, Lactalis USA will have increased its U.S. Feta production capacity to address current and future customer and consumer demand.

The new production line at the Tulare facility is being outfitted based on a complete 3D ergonomic analysis to support worker well-being and safety, in addition to automated air flow control and in-line production.

Meanwhile, Lactalis USA also has announced improvement projects at facilities in Buffalo and Walton, New York.

Lactalis has committed to invest $123 million in its Buffalo plant from the beginning of 2020 through the end of 2027. This includes a $60 million project to expand its Ricotta capacity, which encompasses the installation of six 50,000-pound vats, an advanced cheese belt, separators, silos and a robotic palletizer.

Lactalis has invested $15 million to modernize its Walton facility to expand its cottage cheese and sour cream production lines. Market demand for nutritious, high-protein foods is increasing, and this will enhance the company’s efficiency, capacity and sustainability, officials say. The project will include new fillers, HEPA air filtration, advanced lab equipment, new roofing and boiler upgrades.

The Walton plant produces Breakstone’s sour cream and cottage cheese.

In addition to creating jobs, both New York plants support the region’s agricultural economy by processing more than 800 million pounds of milk annually from 236 local dairy farmers, officials say.

• Lifeway Foods, Waukesha, Wisconsin

Lifeway Foods Inc., a leading U.S. supplier of kefir and fermented probiotic dairy products, has completed the first stage of a multimillion-dollar expansion at its facility in Waukesha, Wisconsin.

The project, which will roughly double production capacity by the third quarter of 2026, includes adding fermentation tanks to increase output of kefir, a fermented milk beverage made with probiotic cultures. Lifeway currently processes nearly 100 million pounds of Wisconsin milk annually into kefir.

“We’re not just growing; we’re accelerating,” says Julie Smolyansky, CEO of Lifeway Foods. “With record-breaking results across Q1 and Q2 and blistering momentum already in Q3, Lifeway is charting a new growth frontier. Our Waukesha expansion ensures we scale smart, invest in community and remain at the vanguard of functional dairy innovation.”

• Miceli Dairy Products, Cleveland

Earlier this year, Miceli Dairy Products, a family-owned Cleveland-based cheese manufacturer, held a groundbreaking ceremony to kick off a $12 million cold storage expansion that will create 50 new jobs and revitalize the Buckeye Woodland neighborhood, company officials say.

The project will increase the company’s production capacity and include the redevelopment of the former Gray Barrel site into a dry storage facility. The Miceli family was joined at the event in May by community leaders and officials from First National Bank, which provided financing for the project.

Founded in 1949, Miceli Dairy Products produces a wide variety of Italian cheeses sold nationwide. The company continues to invest in Cleveland’s future and support local communities through ongoing charitable contributions, officials say.

• Miller Family Dairy, Montgomery, Alabama

The Alabama Department of Agriculture and Industries recently awarded Miller Family Dairy $1.9 million through the USDA Resilient Food Systems Infrastructure (RFSI) program to support a major expansion of its Colbert County operation.

The first-generation farm, which opened in 2020 as a raw milk operation, currently milks eight cows and plans to grow its herd to about 100. The grant will allow the family to add pasteurization and begin producing value-added dairy products including butter and cheese.

“This grant opportunity completely changed everything for us,” says owner Jennilee Miller. “We saw an opportunity to not only expand into value-added dairy but also to support other dairy farmers in the area. According to the Dairy Alliance, only 16 dairy farms remain in Alabama. With our new facility, we hope to be able to change this.”

The project also will provide space and resources for future growth, including sourcing milk from additional dairies, creating jobs and offering educational opportunities to promote Alabama’s dairy industry.

“We are incredibly proud of the RFSI program and the positive impact it’s having on Alabama’s farmers like Miller Family Dairy,” says Alabama Agriculture and Industries Commissioner Rick Pate. “Programs like RFSI help ensure our farmers have the resources they need to grow and thrive while connecting more Alabamians with fresh, locally produced products like milk, butter and cheese.”

The Miller Family Dairy facility is expected to open later this year. Once operational, milk, butter and cheese will be available in local grocery stores and directly from the farm.

• Nasonville Dairy, Marshfield, Wisconsin

As Nasonville Dairy continues to grow, it is expanding its main plant in Marshfield, Wisconsin, upgrading lines to add more packaging capability and allow for new product innovations, as well as expanding its milk receiving bays to increase capacity.

The company broke ground this past spring on its intake expansion, and the entire project is expected to be complete by early next year.

“Our milk receiving bays have been tied up virtually 24 hours a day, and our new milk intakes will allow for us to look into the future and do things we’re not capable of now,” says Ken Heiman, CEO of Nasonville Dairy. “It gives us a better avenue for handling our regular milk, but also the capacity to handle organic and kosher.”

The new packaging lines were delivered earlier this year, Heiman adds, and these also will added capabilities to Nasonville’s portfolio of cheeses.

“There will be different packaging that will be offered in crumbled Fetas and other cheeses. We’ll have a lot of different capabilities, whether chunks in brine, different cubes, crumbles and other things we do,” he says. “And not only in Feta, but also in our Montereys, flavored cheeses or Parmesans, we will be able to do a number of different things.”

• Nelson-Jameson, Fairview, Pennsylvania

This fall, Nelson-Jameson held a grand opening for its new distribution center located in Northwest Pennsylvania. The 45,000-square-foot warehouse in Fairview, Pennsylvania, located just 12 miles from Erie, marks a significant step in enhancing Nelson-Jameson’s capabilities and more efficiently serving customers and partners in the Northeastern United States, company officials say.

“The new distribution center will be another key building block in delivering exceptional service while prioritizing food safety for our customers and partners in the Northeast and beyond,”says Mike Rindy, president of Nelson-Jameson.

Scott Sasse, vice president of strategic initiatives at Nelson-Jameson, notes one of the business’ strategic objectives is to be able to deliver a consistent customer experience in all regions of the country where it is operating.

As the company has expanded from its Wisconsin roots, it has looked for strategic locations to serve customers across the United States. In the past couple of years, Nelson-Jameson completed construction of a new facility in Jerome, Idaho, to bring that experience to its customers in the Northwest United States.

“That was very well received and improved services that we were seeking to bring to that area,” Sasse says. “It inspired us to do the same in the Northeast region.”

Nelson-Jameson determined the Fairview location was the perfect fit for this endeavor, undertaking the renovation and retrofitting of an existing facility. The Fairview distribution center, initially built in 2004 and fully remodeled in 2025, sits on an 8.4-acre lot with an adjacent 20-acre parcel reserved for future expansion. The building’s 45,000-square-foot footprint is complemented by an additional 16,000-square-foot second-floor mezzanine and underwent significant renovations to enhance functionality, capacity and the employee experience.

Key upgrades at the new distribution center include a refreshed exterior featuring newly paved employee and visitor parking lots. The climate-controlled warehouse will provide 1.1 million cubic feet of storage capacity and accommodate more than 3,800 pallet positions. Approximately 8,000 square feet of space will be allocated in the future for a new service and repair center. The facility also features 12 truck bays for its transportation and delivery fleet.

The renovation also includes substantial employee-focused improvements, including a new visitor reception area, employee break room, locker room and lavatory to enhance the work environment.

Additionally, a new warehouse transition corridor will be designed to meet Safe Quality Food certification standards.

Nelson-Jameson began its first shipments out of the facility Aug. 4.

• Oregon State University Extension, Corvallis, Oregon

More than 1,500 people came out for the grand opening celebration in April of a new dairy pilot plant and creamery at Oregon State University (OSU) Extension in Corvallis, Oregon. The project included the renovation of a former school theater to accommodate the dairy pilot plant and creamery.

“We’d like the pilot plant to be a showcase for the next generation in manufacturing,” says Lisbeth Goddik, OSU Dairy Processing Extension specialist.

Total area of the creamery itself is approximately 4,500 square feet, with the addition of a quality control lab as well as a teaching lab for students not included in that estimate. The Beaver Classic Creamery ice cream scoop shop is selling ice cream, cheese and other products produced by students of the College of Agricultural Sciences.

Officials say the creamery is a big hit on campus and already is becoming a community hub.

“Our creamery is off to a great start with ice cream and cheese production,” Goddik says. “We just used the facility for our first cheese short course and will start using it for OSU student classes in January. The inauguration was a huge party for all of campus.”

• Renard’s Cheese, Algoma, Wisconsin

Phases 1 and 2 of expansion at Renard’s Cheese, a fourth-generation, family-owned and operated cheesemaking business in Door County, Wisconsin, are now complete, says Ann Renard, owner and president of Renard’s Cheese.

“Although the completion came two years later than expected, we are happy to move forward with our growth plans,” she says. “We are currently focusing on filling our additional manufacturing capacity. Our SQF certification and the implementation of our new inventory management system to enhance food safety and traceability are also complete. We will continue to focus on employee training to ensure the sustainability of our company and to support our future growth.”

Renard’s Cheese broke ground on the 50,000-square-foot expansion in 2023, which includes a new production facility as well as an on-site exact-weight cut-and-wrap operation and warehouse.

Renard notes phase 3 is expected to begin in the spring of 2027.

• Saputo Inc., Caledonia, Wisconsin

Saputo Cheese USA Inc. this summer celebrated the grand opening of its new 311,000-square-foot cold storage distribution facility in Caledonia, Wisconsin. The state-of-the-art facility, located within Caledonia
Corporate Park, will strengthen Saputo’s distribution network and support the company’s continued growth. Local officials, project partners and community leaders joined Saputo and Zilber Property Group representatives to commemorate the milestone and recognize the project’s positive economic impact on the region.

Saputo has a long-standing presence in Wisconsin, with multiple facilities across the state. Most recently, in 2023, the company opened a new cheese packaging and distribution facility in Franklin, Wisconsin, creating over 650 jobs. This new cold storage facility in Caledonia builds on that investment and is expected to generate approximately 160 additional jobs over the next three years in skilled trades, logistics and management.

“The opening of the Caledonia facility underscores our ongoing commitment to Wisconsin and marks a key step in strengthening our supply chain across the United States. By expanding our distribution capabilities, we’re better positioned to meet the evolving needs of our customers and deliver the high-quality products they expect from Saputo,” says Darren Richter, senior vice president, supply chain, Dairy Division (USA), Saputo Inc.

• Sargento Foods, Plymouth, Wisconsin

Sargento this spring announced it is planning to build a new manufacturing facility, marking the largest investment in the company’s history to accommodate its ambitious growth plans.

Sargento purchased 66 acres of land on Highway 57 and County Road PP in Sheboygan County, Wisconsin, where the new plant will be located. The initial plan is to relocate manufacturing operations from its current Plymouth campus to this new 384,000-square-foot facility. Construction set to begin spring of 2026. Completion of the project and phased occupancy is anticipated to begin in 2027.

The company says with a vision to be the most innovative, best-loved real food company, this investment also demonstrates its commitment to the community and the future.

“We take great pride in our community and Wisconsin — our home. This investment represents our commitment in Plymouth and our long-held belief of sharing our success with our stakeholders,” says third-generation Sargento Chairman and CEO Louie Gentine. “We’re excited for this new chapter for the Sargento family. We look forward to continuing our track record of industry-leading innovation in our hometown.”

This new facility will have the latest manufacturing technology and offer enhanced employee ergonomics. While the company does not anticipate new jobs to be created right away, this state-of-the-art facility will have more room to grow in the future.

• SOMIC Packaging, Inver Grove Heights, Minnesota

SOMIC Packaging Inc. welcomed more than 120 guests from around the world when it held an open house this fall at its new North American corporate headquarters in suburban Minneapolis, which opened one year earlier.

One of the machines featured was the new 434 SuperFlex. SOMIC’s most revolutionary end-of-line packaging machine. Guests were provided with an early preview before the machine was formally introduced days later at Pack Expo Las Vegas. In addition to the 434 SuperFlex, visitors saw demonstrations of various machines, including the 434 with CORAS collating and grouping technology.

SOMIC Packaging Inc. late last year completed the purchase and renovation of a 48,000-square-foot building at the InverPoint Business Park in Inver Grove Heights, Minnesota. The site now serves as the company’s new headquarters as it recently marked 10 years since beginning operations.

SOMIC Packaging CEO Peter Fox notes that in addition to now having the ability to assemble all new North American machines and with room for future growth, the move retains accessibility to several major highways and close proximity to nearby Minneapolis International Airport.

In addition to the expansive manufacturing floor and larger inventory area for the warehousing of critical parts and consumables, the building includes more than 10,000 square feet of administrative space and 8,000 additional square feet on the second floor for future office requirements.

• Tillamook County Creamery Association, Decatur, Illinois

Tillamook County Creamery Association (TCCA) this summer held a grand opening celebration of its newly opened ice cream manufacturing facility in Decatur, Illinois. The production facility opening marks a key milestone in the 116-year-old farmer-owned co-op’s national expansion.

“Our Decatur plant is expected to deliver 15.5 million gallons of ice cream as production scales,” says Mike Bever, executive vice president and chief supply chain officer of TCCA. “The Decatur plant is well equipped to serve our valued customers with increased production capacity, while driving supply chain efficiency from the plant to a growing footprint of national and regional retail outlets.

”Upon opening, the new Tillamook production facility has created 50 new jobs in the Decatur area, with plans to expand the workforce as production scales. TCCA also is actively engaging with the Decatur community through local philanthropy with recent commitments, including a $25,000 donation that was matched by JP Cullen — the general contractor on the TCCA plant project — to deliver a total of $50,000 to support local Decatur initiatives.

The Decatur facility is TCCA’s first owned and operated manufacturing facility outside of Oregon and is the only facility solely dedicated to ice cream production. It previously was owned by Prairie Farms, which also used it for ice cream production until it was closed in early 2022. The plant manufactures Tillamook family-size (48-ounce) ice cream as well as Tillamook foodservice (3-gallon) ice cream.

• United Dairy, Martins Ferry, Ohio

United Dairy, in collaboration with JobsOhio, Ohio Southeast Economic Development (OhioSE) and the Belmont County Port Authority, this summer announced an investment of over $2.3 million to expand its operations in Martins Ferry, Ohio, creating seven new jobs.

“United Dairy is an Ohio-founded company that continues to invest, grow and create jobs throughout the state,” says JobsOhio President and CEO J.P. Nauseef. “The expansion at the Martins Ferry facility strengthens United Dairy’s footprint in the state while ensuring schools and hospitals throughout the region continue to be supplied with its nutritious, high-quality products.”

Founded in 1954, United Dairy produces dairy and ice cream products with a commitment to excellence from sourcing at local family farms to delivering fresh, trusted products to customers’ refrigerators.

“At United Dairy, we take great pride in producing fresh, high-quality dairy products and supporting the local farmers and families who make it all possible,” says Doug Longenette, director of human resources at United Dairy. “This expansion strengthens our ability to serve key customers like schools and hospitals while deepening our roots here in Martins Ferry. We’re grateful for the collaboration and support from JobsOhio, OhioSE and the Belmont County Port Authority, who helped make this investment and our continued growth in Belmont County a reality.”

With this investment, United Dairy will expand its production capacity and upgrade its equipment. This upgrade will improve the efficiency and flexibility of packaging to meet growing demand from schools and hospitals.

The project is supported by a $200,000 JobsOhio Grant, which promotes economic development, business expansion and job creation by funding eligible projects. OhioSE helped the company through the process necessary to obtain assistance.

• University of Idaho CAFE, Rupert, Idaho

Innovation and efficiency will be the hallmarks of the Idaho Center for Agriculture, Food and the Environment (Idaho CAFE), a University of Idaho-led facility under construction in the Magic Valley that will include the nation’s largest research dairy. The project’s first phase, which includes major earth work and construction of a milking barn with a modern rotary parlor, has been completed, and the next phase of construction — which will include maternity and commodity barns and classrooms — is underway.

This spring, the University of Idaho (U of I) led a tour of lawmakers, local officials and members of the state’s Permanent Building Fund Advisory Council to showcase the return on the considerable investment they’ve made in CAFE.

As part of the tour showcasing CAFE’s innovations, visitors learned about the water reuse system incorporated into the dairy. With the support of automation, the milking parlor can be efficiently operated by a team of just three employees per shift, who can accommodate the entire CAFE herd in under three hours.

Robots will spray cows’ teats with sanitizer prior to each milking — a task typically done manually by dairy workers. A separate robotic system will sanitize teats again following milking, and milking units automatically will be sanitized and flushed between milking each cow.

The facility will achieve additional labor efficiencies through an automated crowd gate with a bar that will lower behind cows within the holding pen, slowly moving forward and guiding them through the parlor entrance.

Tour groups will be able to observe dairy operations through a window from atop a catwalk, maintaining a quiet atmosphere for cows.

The facility will provide research into challenges affecting Idaho dairies at an industry scale, making findings more applicable to their operations. The dairy industry collaborated closely with U of I in designing CAFE.

The classroom space now under construction will include an advanced distance-learning facility, where U of I will host classes for graduate and undergraduate students, extension courses, workforce development instruction and collaborative classes with community colleges.

The final phase will add shaded pens, concrete lanes for cows and a manure processing facility for testing and evaluating manure treatment and nutrient separation technologies.

• Upstate Niagara Cooperative/UNC Dairy, West Seneca, New York

Upstate Niagara Cooperative Inc./UNC Dairy is working on plans for a multimillion-dollar project that will significantly increase the size and capacity of its West Seneca, New York, operations hub.

Upstate Niagara, headquartered in Lancaster, New York, has proposed a 165,000-square-foot addition to its existing 222,851-square-foot facility at 3300 North America Drive in West Seneca. Upstate Niagara is one of the anchor tenants of West Seneca’s North America Center corporate and industrial park.

Officials say the expansion will result in Upstate Niagara increasing its employment at the West Seneca site. The project will “add significant manufacturing capacity and storage of finished products,” the company says.

Upstate Niagara is working with the Erie County Industrial Development Agency on a series of tax breaks and incentives to help finance the project.

Within the expanded area, capacity will be devoted to manufacturing such products as milk, yogurt, sour cream and cottage cheese.

Officials say the expansion project should be completed by late 2026.

• Valley Natural Beverages, Bakersfield, California

California Dairies Inc. (CDI), the largest dairy farmer-owned cooperative in California, this spring celebrated the grand opening of its new, state-of-the-art manufacturing plant, Valley Natural Beverages (VNB), in Bakersfield, California.

The 200,000-square-foot greenfield facility represents a transformational investment by CDI’s member-owners, demonstrating their commitment to meeting the growing demand for innovative fluid milk products in both the United States and international markets. The vertically integrated plant is processing an estimated 116,000 gallons of local dairy milk, showcasing the local nature of California’s dairy industry.

“We are thrilled to officially open this cutting-edge facility,” says Brad Anderson, president and CEO of CDI. “This investment underscores our commitment to innovation and sustainability. The new plant will allow us to increase production capacity, expand our product offerings, improve efficiency and create next-generation jobs for the local community.”

The state-of-the-art shelf-stable milk manufacturing facility features advanced robotics, energy-efficient technologies, and a commitment to environmental sustainability incorporating renewal energy sources and waste conservation. The plant is opening with three processing lines to produce conventional extended-shelf-life (ESL) and ultra-high-temperature (UHT) dairy beverages and products. VNB’s strategic growth plan includes multiple phases to expand to 10-12 processing and filling production lines in the future, tripling the facility’s current capacity. When all phases are completed, the facility will be 400,000 square feet, processing up to 600,000 gallons per day of fresh, local milk.

The project is located in northern Kern County, a region with significant milk production but no local processing facilities. Not only will this investment significantly reduce the transportation distances of milk produced in Kern County, it also will further demonstrate CDI’s commitment to sustainable solutions by incorporating renewable energy sources and waste conservation as key priorities in the facility and operational design, company officials say.

• Westby Cooperative Creamery, Westby, Wisconsin

Westby Cooperative Creamery this summer announced a $14.1 million investment to modernize the co-op’s manufacturing facility. The expansion project, which will be complete in the fall of 2026, includes a new food-grade room within the existing facility, the installation of four fully enclosed cottage cheese vats, two cream tanks, a new 30,000-gallon milk silo and upgraded refrigeration, sanitation and auxiliary equipment. It will increase cottage cheese production capacity by 50%.

The plant will maintain its current staffing levels, but the upgraded equipment will transform the nature of the jobs at the facility, offering less labor-intensive roles, officials say.

“By modernizing and investing in the plant, the creamery is protecting current jobs and ensuring long-term stability for our farmer-owners,” says Westby President and CEO JD Greenwalt.

Westby Cooperative Creamery, founded in 1903, is known for its award-winning cottage cheese, sour cream and cultured dairy products, and it is the only cottage cheese manufacturer in Wisconsin.
Not only will the expansion help increase efficiency and cottage cheese sales, it also will help to ensure that future generations of farmers will be able to continue their families’ business and legacies, according to Westby Cooperative Creamery Board President Ben Klinker.

“We thank our patrons, who have been with us for multiple generations, many of them, wanting to see what’s going to happen next, and how do we keep these doors open for our families,” said Klinker at a press event in August. “I consider this co-op a legacy. Many have been shipping milk for more than one generation, and at least one farm has been shipping milk here for more than 50 years.”

CMN

© 2026 Cheese Market News • Quarne Publishing, LLC • Legal Information • Online Privacy Policy • Terms and Conditions
Cheese Market News • Business/Advertising Office: P.O. Box 24 • Sun Prairie, WI 53590 • 608/831-6002
Cheese Market News • Editorial Office: 5315 Wall Street, Suite 100 • Madison, WI 53718 • 608/288-9090