Kettle Heroes Announces Construction of New Food Processing and Distribution Facility in Chandler, Arizona

Phoenix East Valley Kettle Popcorn Brand Expands Manufacturing Footprint to Support National Retail and Distribution Growth

TEMPE, AZ — May 14, 2026 — Kettle Heroes LLC, the Tempe-based kettle popcorn company dedicated to celebrating everyday heroes, today announced the construction of a new state-of-the-art food processing and distribution facility in Chandler, Arizona. The investment marks a significant milestone in the company’s mission to scale premium, mission-driven snacking nationally while deepening its roots in the Phoenix East Valley community it has called home since its founding.

The approximately 21,000 square-foot Chandler facility — just eight minutes from Kettle Heroes’ current Tempe base of operations — represents a total capital investment of approximately $3.2 million across two phases and is expected to be fully operational in Q3 2026. The facility will house the company’s fully vertically integrated manufacturing operation, enabling a dramatic expansion of production capacity as Kettle Heroes grows its retail footprint across the United States.

FROM FOOD TRUCK TO FOOD FACILITY: A DISTINCTLY ARIZONA STORY

What began in 2013 as a food truck popping kettle corn at local farmers' markets and Arizona Cardinals football games has grown into one of Arizona’s most recognizable better-for-you snack brands. More than a decade later, Kettle Heroes’ expansion into a purpose-built manufacturing and distribution facility reflects both the loyalty of its community following and the strength of its national distribution momentum.

“We started by popping corn one batch at a time and handing bags directly to Arizona Cardinals fans and farmers market families. This new facility is the next chapter of that same story — built in the community that believed in us from the beginning, and designed to bring the Kettle Heroes mission to snack lovers everywhere.”

— Rudi Sinykin, CEO and Co-Founder of Kettle Heroes

A NEW STANDARD FOR CRAFT SNACK MANUFACTURING

At the heart of the new facility is a Syntegon SVX Agile automated packaging line, which will deliver a 10x production capacity expansion over the company’s current throughput. Phase 1 of the project, representing a $2.2 million investment in facility infrastructure and the Syntegon line, is targeted for completion in Q3 2026. Beyond volume, the new line will enable a complete refresh of Kettle Heroes’ packaging across its product lineup, bringing a bold new visual identity to retail shelves that better reflects the brand’s mission and premium quality. The facility is designed to SQF Code Edition 9 food safety standards and will support the company’s GFCO-certified gluten-free product line.

Phase 2 of the facility buildout — representing an additional ~$1 million investment — will include installation of additional commercial popping and seasoning lines, completing a fully balanced upstream and downstream production system, and enabling Kettle Heroes to pursue co-manufacturing partnerships as additional revenue channels.

BUILT ON A MISSION TO HONOR HEROES

Since its founding, Kettle Heroes has built its brand around a simple but powerful belief: that heroes deserve to be celebrated. The company is a proud partner of the Pat Tillman Foundation, featuring Tillman Scholars on every bag through its “This Bag Honors” program. But the mission extends further — Kettle Heroes is equally committed to honoring the everyday heroes who show up in communities across the country: healthcare workers, teachers, first responders, and military veterans.

“Every bag we make is a small act of recognition. The nurses pulling double shifts, the teachers staying late, the firefighters and veterans who serve without fanfare — they’re the reason this brand exists. Growing our capacity means we can tell more of those stories, on more shelves, in more communities across the country. And doing it right here in the Phoenix East Valley, where we got our start, makes it that much more meaningful.”

— Aaron Sinykin, Co-Founder of Kettle Heroes

“Our dad, Daniel Sinykin, served as a U.S. Army Captain and raised three sons on the belief that hard work and service to others are the foundations of a life well lived. We lost him in May 2023, and not a day goes by that we don’t feel his presence in what we’re building. Our partnership with the Pat Tillman Foundation isn’t just a program on a bag — it’s our way of honoring him, and every veteran who served with the same quiet dedication he did. Dad would have loved seeing this facility go up. This one’s for him.”

— Josh Sinykin, Kettle Heroes

FUELING NATIONAL DISTRIBUTION MOMENTUM

The new facility comes as Kettle Heroes accelerates growth across multiple distribution channels. The brand got its start in premium natural grocery with Whole Foods Market and AJ’s Fine Foods in Arizona and has since expanded its retail footprint to Central Market in Texas through KeHE Distributors and regional Costco runs in San Diego. Regional retail partnerships through UNFI — spanning Bristol Farms, Metropolitan Markets, and Erewhon — further anchor the brand’s presence in the better-for-you grocery channel. A growing network of over 300 independent retailers across 45 states via Faire and active regional foodservice accounts round out a distribution portfolio that is both broad and deeply rooted in premium positioning. The company has also expanded its direct-to-consumer and Amazon presence, driving an annualized alternative channel run rate approaching $1.1 million.

ABOUT KETTLE HEROES LLC

Founded in 2013 by brothers Rudi and Aaron Sinykin, Kettle Heroes is a self-manufacturing kettle-cooked popcorn company based in Tempe, Arizona. In 2025, the founding team welcomed a third Sinykin brother, Josh, to the company. Kettle Heroes produces premium, small-batch style kettle-cooked popcorn in a growing lineup of flavors — including fan favorites like Hatch Green Chile Cheddar — and is available through national and regional grocery, foodservice, and online channels. Kettle Heroes is dedicated to celebrating heroes of all kinds: from Pat Tillman Scholars honored on every bag, to the healthcare workers, teachers, first responders, and military veterans who make their communities stronger every day.

To learn more, visit kettleheroes.com.