CHICAGO (WBBM NEWSRADIO) -- Inside a 38,000 square foot warehouse in Melrose Park, mask making is an art form.
"Each one is hand painted, hand assembled," said Tony Zagone, owner, Zagone Studios, 4533 W North Ave, Melrose Park, IL.
The Halloween rush is over, but three generations of Zagones are already planning for next year.
WBBM:What was your first mask, do you remember?
"Yes, it was a gorilla," Phil Zagone laughed.
Zagone's three sons Phil Jr, Tony, and Rich, and now their children design, create, cast, clean, cut, sew, and test hand made masks, hands, feet and costumes.
The company started at Belmont and Southport inside a four-story factory. Production moved into the Melrose Park space about five years ago. Tony Zagone said they produce about 100,000 masks and 50,000 pairs of hands and feet a year, through retail, online and walk-ins.
"Some of these molds go back to 1971. We start with a clay sculpt and then we put plaster on it. It takes about two hours to make a single mask. We use about 25 tons of plaster a year," Tony Zagone said. "We have lots of scary masks, but our character masks are the most popular."
Phil Zagone said what they do is unique in the United States.
"Our Christmas business is growing. Our customers ask for Santa Claus masks, elf costumes, you name it. Christmas bar crawls call for all kinds of holiday masks and costumes. Our Christmas business is supplementing Halloween now which is great," he said.
"I'm real proud my family has kept this company going. I really am. My sons have probably tripled my sales and we're in 31 countries," Phil Zagone said.
For more information, visit zagonestudios.com.
