LEYDEN — The Our Family Farms dairy cooperative has opened a $1.8 million plant to process its milk and stay competitive in a notoriously difficult industry.

Construction on the 4,500-square-foot facility started in November 2021 but completion was delayed significantly due to ongoing challenges, including cost overruns, unexpectedly shifting processors mid-construction and supply chain issues related to the pandemic. Our Family Farms consists of Bree-Z-Knoll Farm in Leyden and Gould Maple Farm in Shelburne.

“Milk is a lot different than any other commodity, because it has to be processed and packaged for the end user,” said co-owner Angie Facey, who co-owns Bree-Z-Knoll Farm with husband Randy and father-in-law Warren. “It’s not like we grow apples and we sell retail, and then what we can’t sell we sell wholesale somewhere else.”

The processing plant, a former maternity barn, was largely financed by $1 million that was awarded to the farm through a state Food Security Infrastructure Grant. However, Angie Facey said, the project went $800,000 over budget, resulting in the Faceys taking out a loan to cover the difference.

“So we really need to sell a lot of milk,” she said.

Nevertheless, she and Randy said the facility was necessary to save the Our Family Farms brand and stay in business.

“We would have gone out in five years, probably,” Randy Facey projected.

Though only Bree-Z-Knoll and Gould Maple farms remain in the cooperative, Our Family Farms was founded by eight local dairy farmers in 1997. Until the processing facility opened in April, the co-op had relied on outside processors to convert raw milk into a marketable product. Having its own processing plant has enabled the farms to expand its product line. Whereas only half-gallons and gallons were available previously, the dairy farmers can now produce quarts and pints as well as heavy cream and half-and-half. The next objective on the agenda is flavored milks (chocolate, strawberry, coffee and maple) and, eventually, ice cream mixes, drinkable yogurt and soft cheeses.

“The Faceys have overcome inordinate challenges in building this plant over the past 18 months,” Karen and Larry Gould, owners of Gould Maple Farm, said in a statement. “Their hard work and diligence have paid off in a dream long come true — to expand the Our Family Farm brand, and ensure the future of craft dairy production in our local community.”

Angie Facey noted milk was first processed in the new plant on April 5, and the products were shipped out to stores the following day.

“That first night we worked until … almost midnight, and then we celebrated with a bowl of cereal,” she said. “One of our friends brought a bunch of cereal and bowls and stuff.”

Reach Domenic Poli at: dpoli@recorder.com or 413-930-4120.

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