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Kerry has opened a new coffee extraction facility in Bethlehem, Pennsylvania, expanding its capacity to produce coffee ingredients for beverage, dairy, foodservice and other food and beverage applications.
The site, Kerry’s first manufacturing facility in Pennsylvania, officially opened on 30 September with a ribbon-cutting ceremony attended by customers, industry partners, government representatives, and community leaders.
First announced in September 2025, the facility is designed to develop natural coffee taste and flavour profiles using extraction and concentration technologies. Kerry said the site will produce tailored coffee solutions for applications including ready-to-drink (RTD) coffee, alcoholic beverages, ice cream and savoury sauces.
The facility includes separate hot and cold brew extraction lines and has been designed with additional capacity to allow production to scale as demand increases.
John Cahalane, president and CEO of Kerry North America, said the investment would increase coffee production capacity closer to customers on the US East Coast and provide greater flexibility in responding to changing consumer preferences.
The company also expects the site to help reduce supply chain complexity and associated environmental impacts.
The opening comes as demand for premium and speciality coffee continues to increase in the US.
According to data cited by Kerry from the National Coffee Association, 48% of American adults drank speciality coffee in the past day, compared with 39% for traditional coffee – a record level for speciality coffee consumption.
Kerry also points to growing demand for higher-quality coffee across formats such as RTD beverages, despite continued price pressures.
The company is positioning its Bethlehem operation to support manufacturers and foodservice operators looking to replicate fresh-brewed and craft coffee experiences in products with longer shelf lives.
Its technologies combine roasting, extraction, concentration and thermal processing to create coffee ingredients tailored to individual formulations while maintaining what Kerry describes as consistent, true-to-bean flavour and aroma.
For foodservice customers, the ingredients can also be used to develop products such as iced lattes, espresso-style beverages, cold brew and functional drinks without requiring specialist barista skills or significant investment in coffee equipment.
Sustainability is another focus of the new facility, with Kerry highlighting the potential environmental benefits of concentrated coffee products.
The company said its high-Brix coffee concentrates, at between 23 and 30 Brix, can reduce the amount of water that needs to be transported and can be shipped at ambient temperatures rather than requiring refrigeration.
According to Kerry's calculations, its Direct Concentrated Fresh (DCF) bean solution can deliver a 61% lower carbon footprint, while its conventional coffee offering has a 40% lower carbon footprint compared with competitor conventional coffee products. Kerry also claims a 34% reduction compared with refrigerated Brix products.
The facility will use naturally sourced ingredients aligned with certification standards including USDA Organic, Fairtrade, Rainforest Alliance and Café Femenino.
The investment forms part of Kerry’s wider sustainability strategy, which includes commitments around responsible sourcing and reducing environmental impacts across its operations and supply chain.
