Spirits were high last Tuesday at Joy Cone Flagstaff as a ribbon-cutting ceremony marked the opening of the plant鈥檚 expansion. Attended by company employees and the architects who worked on the project, the event was, for many, the first glimpse into the new 81,800-square-foot warehouse.
鈥淚t鈥檚 the first one in the Joy company. It was fun to show it off,鈥� said Joe Pozar, general manager of Joy Cone Flagstaff.
Joy Baking Group has seen extraordinary growth since its humble beginnings in 1918 as George and Thomas Cone Company. Headquartered in its origin city of Hermitage, Pennsylvania, the company looked to expand westward in the mid-1990s.
Demand for the cones had increased in the West. The cones, known for being both fragile and bulky despite their low weight, were expensive to ship across the country. The company selected Flagstaff after finding it checked the essential boxes: a high enough population to staff the factory聽fully聽and a prime location on Interstate 40. The parcel of land was purchased in 1995, with the building being fully opened for production in 2000.
鈥淲e knew then we would eventually be able to have over 300,000 square feet under-roof. We鈥檝e always had that target in the background,鈥� said David George, CEO of Joy Baking Group. 鈥淲ith this expansion, we鈥檝e hit that number.鈥�
As for Flagstaff鈥檚 tricky elevation, the initial baking process was trial and error.
鈥淚鈥檝e learned from my wife and family members that trying to bake here is almost impossible,鈥� Pozar said.
Especially challenging were the company鈥檚 cake cones, which need to rise in the mold before baking.
鈥淲e struggled with that for a couple of years,鈥� George said.
After a great deal of experimentation with the formula, Pozar and George found the magic solution: the same flour used at the Hermitage plant. With the flour shipped in from Pennsylvania, baking goes off without a hitch.
Joy Cone Flagstaff has seen substantial growth in the past five years alone. The number of employees has more than doubled, adding over 150 new jobs to the community. As production continues to expand, the facility has struggled to accommodate the inventory required to meet demand.
The new expansion, in addition to a massive increase in storage volume, includes an 1,800-square-foot administrative office, a tractor trailer parking area and a larger employee parking lot. It also opens the door for continuing growth and job advancement in the coming years.
As of 2016, Joy Baking Group is a 100% employee-owned business. The individual ownership of each employee increases in value along with the company.
The group also takes pride in contributing to Flagstaff. It is a supporter of local organizations big and small, such as United Way of Northern Arizona, Toys for Tots and even Little Leagues and high schools.
鈥淲e try to do our part in being active in the community,鈥� said Michelle Raban, human resources manager at Joy Cone Flagstaff.
While the company has a history of offering public tours, the COVID-19 pandemic and the construction of the warehouse rendered them infeasible. Tours have not resumed due to changes in food safety regulations.
鈥淲e have to reconsider what that will look like in the future,鈥� Raban said. 鈥淲e need to be thoughtful about how we鈥檙e going to go forward with tours.鈥�
On a national level, Joy Baking Group has progressed into baking not only cones, but also cookies and graham cracker crusts. While the Flagstaff facility is not currently equipped to step into production of these assets, it is not off the table for future consideration.
鈥淚 could see it happening here,鈥� George said. 鈥淚f we do it out West, we鈥檙e going to do it in Flagstaff.鈥�
George, who had a hand in starting up the Western wing of the company, is a third-generation descendant of Albert George, one of the original founders of the George and Thomas Cone Company.
Growing up, taking part in the family business was something he always dreamed of, and he has certainly fulfilled the legacy. Throughout the years, he has been fully hands-on within the company, taking part in everything from operations to sales.
鈥淚t鈥檚 fortunate that I had the opportunity and really fortunate that it鈥檚 something I was looking forward to,鈥� George said. 鈥淪o far, so good.鈥�