Continued Investment Is
'Key' For RI Boxmaker

by Jim Curley

While it is undeniable that New England manufacturing has declined in recent decades, it is not fair to conclude that there is a shortage of opportunities for boxmakers in that region who are willing to invest to sharpen their processes and improve their products.

Key's vaue-added production is growing says Telmo da Silva

In its fifth decade of operation in Pawtucket, Rhode Island, just outside Providence, Key Container has invested heavily in equipment in recent years, most notably at the corrugator.

"Our focus has been on bringing our corrugator into the 21st century, both in technology and size," explains Key's Vice President Telmo da Silva.

Most recently, the investment included three heavy duty roll stands and two automatic splicers, all manufactured by M.Torres and sold by Dallas, North Carolina based Profero systems.

"The Torres products have done a good job for us," da Silva notes. He adds that there were three factors that helped Key decide to opt for Torres: "trust in the people at Profero who stand behind their product, the simplicity of the product, and cost.

"The automatic splicers enable us to increase the speed of the corrugator, which means less waste and fewer roll breaks," da Silva adds. "We can run the corrugator unattended and with our 'tail grabber,' we can run our paper to the core. In addition, we can now run doublewall with two workers rather than three."

Other upgrades to the corrugator, originally an S&S unit installed in 1965, within the last two years include two MHI 60G singlefacers and an Agnati IM-90 double glue machine. The plant's output is about 85 percent C-flute; nearly 10 percent doublewall (mostly BC-, with some CE-); and the rest B- and E-flute.

Completing The Picture

With sophisticated singlefacers and a renovated dry-end section, all that remains to get 98-inch boardmaking capabilities is a wider doublefacer. A new doublefacer unit is expected to be installed next spring.

Key's continued investment in its corrugator (A United-VortX starch unit was being installed while I visited.) has reaped dividends for the plant, da Silva says. He estimates that the plant has seen an increase in output of 35-40 percent in the last six years, due to increased operator training and HRMS's MatchMaker corrugator scheduling link-up with the plant's Harry Rohde business system as well as the improvements in corrugator components.

Improved board quality has helped the plant as it moves to more high graphics and provides a better product for area sheet plants (da Sliva estimates that 25 to 30 percent of the corrugator's output goes to area sheet plants.).

Converting equipment at the plant includes four two-color flexos, including a 50- inch by 115-inch Hooper/ Swift, a 35-inch by 85-inch Koppers, a 38-inch by 90-inch Ward and a 66-inch by 190-inch McKinley, purchased in 2001.Both the Ward and the McKinley unit possess die cutting capabilities. The plant also utilizes a two-color 66-inch by 80-inch Staley rotary die cutter and another multi-color rotary die cutter is on the plant's "wish list" in the next year or two. About 20 percent of the plant's output is die cut, da Silva estimates.

Recent improvements to the corrugator includes Torres roll stands, above and splicers as well as MHI Paser singlefactors.

There are three designers at Key, including a graphics designer. The company utilizes a Kongsberg sample table with Artios CAD Software.

The plant employs about 125 people, including 80 hourly workers in its two-shift operation. It utilizes a staff of a dozen salespersons to serve customers within a 110-mile radius of Providence. An alliance with Mt. Tom Box, a sheet plant in western Massachusetts, has allowed Key to extend its sales area into New York.

Born In The Sixties

Key Container began operations at another site in Pawtucket in November 1960. Two years later, it moved to its present location. After several additions in the 1980s and 1990s, the building currently encompasses 150,000 square feet, including 30,000 square feet of warehouse space.

The company, started by Jack Sundel, is presently in its third generation of family ownership, represented by company President David Strauss. In its forty years, Key has had to adapt to the changing New England converting landscape. Long-time customers such as Hasbro and American Tourister have left for warmer pastures; da Silva notes that Key used to send 10 truckloads of product each day just to those two customers.

'The Whole Package'

Key Container's motto, "The Whole Package" gives a clue as to how the company survived difficult times. Key has clearly branched out to provide multi-color printing, and displays as well as foam-enhanced boxes and wood crating to customers. " We have a more diverse customer base today," da Silva explains. "Along with traditional manufactures, we service the auto industry, food processors, retailers, and mail order houses."

Service is an important component of the firm's success, says da Silva. Key provides warehousing of customer boxes and overnight delivery among its service options. "About 10 years ago, we got serious about customer service," he notes. Lead times, once around 17 days, had been reduced to 4 days or less. A stable, experienced workforce has also been important in providing top-notch customer service, says da Silva. He adds that he is proud of the company's safety and training efforts.

In 2000, the plant achieved ISO-2000:1994 registration, an undertaking that has made Key " a little sharper in our processes," says da Silva. He remains quietly confident about Key and its future. The company, which posts its annual sales of more than $25 million, has seen business pick up since late summer, and daSilva says, "2002 overall will be a very good year."

Clearly, Key's investments in processes, people, and equipment have helped the company remain competitive in a changing converting environment.