Mannkraft makeover: this independent corrugated box plant reinvigorates itself with Arrow's displays

Paperboard Packaging, Nov, 2004 by Mark Arzoumanian

"These displays are a tremendous calling card," he says. "Customers are getting to know us better as an industrial packaging company that offers other products." The displays can be shipped flat to anywhere in the country. Because they ship flat clients can save on freight costs, and shipping distances can expand.

Some major consumer companies have concerns about working with niche companies like Arrow. But when Mannkraft bought the company's assets most of these concerns evaporated.

Four years ago one giant food and soap products company that had been Arrow's biggest customer cited a lack of critical mass as a major factor behind dropping it. At that time it consolidated suppliers and conducted Internet auctions for its point-of-purchase display business, most of which went to major integrated companies. But today some of its divisions are again turning to Arrow for certain display projects. With Mannkraft's marketing and financial support, Mehiel sees Arrow getting all that business back and more in the years ahead.

Equipment Roundup

For the past 15 years Mannkraft's 98-inch MHI/Marquip corrugator has been the cornerstone of the plant's box making operation. It produces C-, B- and E-flute singlewall board, as well as CB and EB doublewall, at an average running speed of more 600 feet per minute. In 2001 the corrugator was upgraded with a Marquip knife and stacker to increase speed and meet the demand for more order changes per shift. The plant runs two shifts of eight to 12 hours, with 40 to 50 slitter changes per shift.

Its four flexo folder-gluers have three-color and diecutting capability. It also operates three rotary diecutters, including a four-color United with vacuum transfer, infrared dryers and automatic plate cleaners that are used for many of the plant's high-end graphics jobs; two Post folder-gluers; two litho laminators; a flatbed diecutter; and a five-color printing press.

DeRosas Stick Together

Meeting someone who has worked at the same box plant for more than 30 years is the exception nowadays, but by no means shocking. But what about meeting three brothers who have worked at the same box plant for decades? That's the special story with the DeRosas at Mannkraft, which employs 160. Frank started working at the company in 1968; today he earns his paycheck in the maintenance department. Tony began his career at Mannkraft in 1967 and today is the lead man in the diecutting specialty department, while Peter, the youngest, started in 1971 and is now a plant superintendent.

"Today this plant has less than 2 percent turnover," General Manager Bob O'Connell says. "Not one person has left us that we didn't want to see go, whether salaried or hourly. We have sophisticated, experienced and highly trained people. Many people working here are second generation: fathers and sons, uncles, aunts."