Alamance Foods has launched AFI Labs, a dedicated research, development, and commercialisation centre designed to help food companies bring innovative products to market faster.
The facility includes specialised capabilities for developing and scaling aerosol dairy and dairy alternative products.
AFI Labs brings together product development, process engineering, pilot-scale manufacturing, and commercialisation support in a single facility.
For aerosol manufacturers and food brands, the centre offers capabilities specifically tailored to aerosol whipped toppings and aerosol cold foams – categories where innovation and consumer demand for convenience continue to drive growth.
Bridging the gap between concept and commercial scale
The facility addresses a core challenge in food product development: the transition from laboratory formulation to commercial-scale manufacturing.
AFI Labs integrates product development directly with Alamance Foods' manufacturing expertise, allowing teams to test products under authentic operating conditions before committing to full production.
The development process encompasses five stages: exploration of consumer trends and market opportunities; formulation and prototype development; performance testing and evaluation; pilot-scale validation; and commercial scale-up preparation.
For aerosol products, this integrated approach is particularly valuable. Aerosol dispensing systems place specific requirements on product formulation – viscosity, stability, foam structure, and propellant compatibility all affect performance.
Testing formulations at pilot scale, rather than only at bench level, allows developers to validate how aerosol products will perform in real dispensing conditions before investing in commercial production.
Capabilities for aerosol product categories
AFI Labs specialises in several food and beverage categories, including:
- Dairy and dairy alternative aerosol whipped toppings
- Dairy and dairy alternative aerosol cold foams
- Ready-to-drink (RTD) beverage applications
- Freezer pops
- Drinkable yogurt
The facility combines laboratory, culinary, and pilot plant resources, with capabilities including bench-scale product development, pilot-scale processing equipment, product performance evaluation, manufacturing validation, and sensory testing.
The centre also includes specialised resources such as small commercial bakery equipment and modular, plug-and-play kitchens.
Supporting foodservice and retail innovation
The facility is designed to support foodservice operators, quick-service restaurants, retailers, convenience retailers, consumer packaged goods companies, and private label partners.
Each customer engagement is customised based on project goals, ranging from one-off innovation workshops and rapid prototyping to long-term co-development partnerships.
For aerosol manufacturers and brand owners, AFI Labs offers the ability to explore new product concepts – whether entirely new product platforms or improvements to existing formulations – with technical support and manufacturing validation built into the development process.
The shift toward convenience products and premium foodservice applications continues to drive demand for aerosol-dispensed toppings and foams. AFI Labs' integration of commercialisation planning into early-stage development helps reduce the time and risk associated with bringing new aerosol products to market.
"The real magic happens when you can turn an idea into a product that works, tastes great, can be manufactured at scale, and is ready for the market," Alamance Foods states in describing the facility's purpose.
