In order to succeed in today’s converting industry, a company must develop an edge over its competition. A. J. Schrafel Paper Corporation has identified their competitive edge as providing the highest quality paperboard in a timely manner. For 56 years, dedication to this basic mission has given this New York-based business a reputation as a quality source for paperboard of all grades and quantities.
The company was the brain child of Alfred J. Schrafel, who started out in the paper business as a broker for a New York paper company. In 1941, he decided to branch out on his own and established A. J. Schrafel Paper Corporation in the Manhattan area. In spite of the uncertain basis of the country’s wartime economy, the company did well and eventually grew into a multi-faceted business. Today Alfred Schrafel, Jr. and Edward Case run the company, both of whom boast more than 70 years of combined experience between them.
In the mid-1970’s, A. J. Schrafel honed its competitive edge by expanding its services to Customers through a close working relationship with Accurate Paperboard Converters. This union allowed Schrafel to convert its orders in a timely manner. The company’s converting arm now serves box makers, printers, and mills located in the Northeastern area, with some customers as far as California and the Caribbean.
Schrafel Paper’s typical order size ranges from one to five tons. They also run specialty work which can vary in size from very small to moderate. Focusing on these order sizes offers the company the opportunity to fill their customers’ needs very quickly. Most importantly, Schrafel Paper’s customers can depend on receiving quality work on demand.
The bulk of the company’s converting lays in boxboard grades, and they deal in first quality SBS and recycled grades in thicknesses ranging from .008 inches to .034 inches. “Our boxboard customers require high quality work, as they produce items such as boxes for games, cosmetics, or pharmaceuticals,” Schrafel notes, “The printers we service have upgraded their equipment and thus require a squarely cut, dust-free sheet.”
Sharpening the Edge
In 1996, Schrafel Paper Converting Corporation (SPC) was formed by the third generation of Schrafels, Richard, Robert, and Thomas. They saw that in order to better serve their customers, it was time for changes to be made in the areas of order turnaround time and increased quality. These changes involved relocating the converting facility from Beacon Falls, Connecticut to West Haven, Connecticut and updating the converting equipment.
SPC’s facility in West Haven added convenience and additional warehouse space. Situated close by Interstate 95 with convenient rail service, the company is now in a position to offer easier access to and from their facility. “This is a very convenient location for many of our customers,” notes Schrafel, “Our New York and Boston shipments are easier, and we have trucks going to New York and New Jersey every day.” Customers also benefit from the 74,000 square foot facility. This added space has eliminated the company’s need for outside warehousing of inventory, and 200,000 square feet of adjacent warehouse facilities provide an overflow option. The company maintains an inventory of 10 – 24 point SBS on hand for immediate conversion, and proudly notes that they are able to extend a helping hand to mills needing supplemental roll inventory in a pinch.
SPC also took cost, sheet quality, and customer service issues into consideration during their restructure. These issues became important when they began the process of updating their equipment needs. Their purchase of the Maxson DFK Sheeter and the upgrading of one of their two existing Maxson sheeters with a dual motor drive retrofit was the answer. “We needed to make changes that would allow us to keep up with technology and production rates,” Richard Schrafel comments.
Reportedly, the Maxson DFK Sheeter can accommodate sheet lengths of 17 inches to 65 inches and can run at speeds up to 1,300 fpm. According to the manufacturer, sheet length accuracy is +/- 0.015 on all cutoffs at all speeds. The DFK has a specially-designed cross cutting knife system that accepts webs up to 60 inches wide. Because of the synchronous speed of the knives and web at the moment of cut, reportedly no adjustment for sheet squareness is required. The two pivot arm shaftless roll stands accept rolls up to 84″ in diameter. This reportedly provides the company with the flexibility to sheet oversized rolls, run two smaller rolls side by side, or sheet two superimposed webs. “With lighter calipers, we’ve seen substantially increased productivity. Maxson worked with us to design elements of the machine to suit our needs.” Schrafel comments. The web carrier roll, dual double direction decurler for heavy caliper board grades, reject gate, and extending grid also increase productivity and provide a faster turnaround time. Another upgrade was Maxson’s installation of a dual motor drive retrofit on Schrafel Paper’s existing 65″ Maxson MSH Sheeter.
Committing to Quality
Currently, this family-run company is hard at work utilizing all three sheeters to keep up with production schedules. Orders are now more readily expedited, and quality is job one. The Schrafel family has been able to enhance their well-established position within the paper industry, as well as their many long-standing business relationships.
As Schrafel Paper looks ahead, they see future growth in converting specialty grades of paper and paperboard such as foil laminate and pasted board. The Schrafels believe that their basic mission, providing the best possible paperboard in a timely manner, is what will set them ahead of their competition. If its past success is any indication, it looks as if these core values will indeed carry Schrafel’s accomplishments into the 21st century.
Reprinted from Boxboard Containers, September 1997
