What To Do When A Superstorm Strikes? Says The Wall Street Group: “We Never Really Asked the Question”

Partners Philip J. McGee (left) and Alfred J. Basile in the pressroom of The Wall Street Group.

Imagine everything in ruins.

Not some of it. All of it: production equipment. Paper. Press bays and workspaces. Lights and HVAC. Telephones and computers. Jobs in progress. Literally every material item housed within a printing plant either damaged beyond repair or knocked completely out of commission.

Now, try to imagine surveying this overwhelming devastation and vowing—without knowing how or even if the vow can be fulfilled—to re-emerge from the dead zone into which a vast wall of black water has brutally shoved your printing business.

The Wall Street Group of Jersey City, NJ, recently reported exactly this kind of phoenix-like rise—not from ashes, but from the waterlogged detritus that its plant and equipment had been turned into by superstorm Sandy on October 29, 2012.  Metro Graphics Reporter visited the company this week to hear first-hand what one of the owners described as “more a story of survival than of disaster.”

Outwardly, there’s nothing to indicate that the printing building at 1 Edward Hart Drive had been lying squarely in the path of one of the worst natural disasters to strike the NY-NJ metro region in a generation. Inside, fresh slabs of sheetrock and the smell of new paint speak of a cleanup—but not of the gigantic task confronting partners Alfred J. Basile and Philip J. McGee as they began to comprehend the full extent of the harm that the killer storm had done.

What they did when they were able to regain access to the darkened, still partially flooded plant a few days later was simply to tackle whatever was in front of them.

The owners and their 30 employees immediately pitched into the bailing, hauling, salvaging, and scraping with no more guidance than the knowledge that these things desperately needed to be done. Moving just as quickly, Basile and McGee brokered out whatever work was ready for production or had to be rerun. Having satisfied themselves that obligations to customers wouldn’t be compromised, they then turned the somber job of inventorying damaged equipment and determining what could be saved and what would have to be replaced.

Basile and McGee aren’t the only printers in the metro area to have taken a body blow from Sandy, but we don’t know of any others who have faced up to a greater loss with more resilience and perseverance. Those virtues are the products of a decades-long partnership between two print professionals who epitomize all the qualities of endurance associated with the printing industry in this region.

On October 29, 2012, water surging from superstorm Sandy breached the plant’s front doors and destroyed or damaged nearly everything inside the building.

The story of The Wall Street Group begins with the small Multilith shop that Basile started at 27 Whitehall Street  in Lower Manhattan in 1966. About four years later, he moved the business to 11 Broadway where McGee, a former print buyer for Western Electric and sales manager for Xerox, was working for another printing firm. Joining forces, the two men went on to acquire a Mountainside, NJ, printing company that had offset presses larger than the small-format Multis they were running.

They moved the Broadway and Mountainside operations to Harborside, NJ, in 1981. Five years later, everything was consolidated in the Jersey City plant near Liberty State Park that The Wall Street Group now occupies. After refurbishing the building—a former metalworking plant—the partners installed 40” presses, a full bindery, and, eventually, digital presses and mailing equipment.

As the name suggests, printing for investment houses and financial institutions has been the traditional mainstay of the company since the days when Basile began producing buy-sell pads for stock market traders. Because documents such as research reports for equity firms have shifted from printed form to electronic distribution, some of this traditional volume has declined. The partners make up the difference with work for medical, educational, and not-for-profit customers and, as McGee says, for “anyone else who wants ink put on paper.”

Now that the company is just a few years shy of the 50th anniversary of the founding of the seminal business on Whitehall Street, the partners are clear about what has been most responsible for carrying them toward the golden milestone: their absolute commitment to customer service and to meeting what others might regard as impossible deadlines.

“We try not to have one-shot customers,” says McGee of his and Basile’s belief in making all customer relationships last. This they accomplish primarily by refusing to say no. They refrained from saying it, for example, in the case of the customer who one afternoon sent in an order for 50 Wire-O bound booklets with UV-coated covers that had to be in someone’s hands in Boston the next morning.

Thanks to vertically integrated production assets that included digital presses for the inside pages, an offline UV coater for the cover, and a Wire-O machine for the binding, The Wall Street Group was able to turn around in hours what might have taken another printer days.

“Nobody wants to wait for anything today,” says McGee, adding that being equipped for same-day production gives The Wall Street Group a significant edge over rivals lacking the capabilities it has. Another key to longevity, he says, is the fact that the company doesn’t do and thus has never had to depend on low-end commodity work.

It also pledges to optimize for printing everything its customers send it, correcting errors and doing whatever else it takes to make the job run problem-free. This is a habit developed in the old days, says McGee, when “customers used to give us a bag of paragraphs” and expect the hodgepodge to be turned into crisp, coherent documents.

The plant typically operates on two shifts, five days a week. Nowadays its output is about half digital print and half conventional offset. Such was the state of affairs last October 29, when Basile, McGee, and their staff battened down the plant for the bad weather they knew was on the way.

But, like nearly everyone else in the storm’s path, they had no idea of how bad it would turn out to be. Basile and McGee sandbagged the loading dock doors, double-skidded the paper in the storage area behind them, sent everyone home, and hoped to avoid the worst.

That night, storm surge in Upper New York Bay reportedly lifted the sea level high enough to obscure the pedestal of the Statue of Liberty. Some of it swelled into the inlet facing Edward Hart Drive, leaping over the low pier of the marina there and pouring straight up the street toward the plant, only a few hundred yards from the water’s edge.

The misplaced curtain of water struck the building with so much force that it literally tore the massive loading dock doors from their frames. Their wreckage, along with tons of spoiled paper, lay strewn across the parking lot outside. Within the plant, a flight of stairs leads from the mezzanine to the ground-floor pressroom. A faint stain just below the level of the fifth step from the bottom indicates the depth of the inundation that occurred when the water boiled through.

Located a few hundred yards below the plant, this shoreline scene looks peaceful now—but on the night of the storm, it turned into a floodgate of devastation.

Before it receded, the water had crested at a point where it submerged press motors and flooded nearly every other piece of equipment in the production area. Basile and McGee were able to recover and rebuild the press motors—about 50 of them—but what had happened to many of the other machines was much worse.

Now junk and in dire need of replacement were the plant’s digital presses, its CtP platemaker, its paper cutters, and one of its saddlestitching lines. The flood’s only unequivocal survivor was an envelope tabbing machine that had been placed on an elevated surface at some earlier point.

The hard work of reclaiming the plant—including drying, repainting, tearing out and rebuilding walls, and treating the entire 32,000-sq.-ft. building to prevent mold—went on for months, often in miserably cold and dark conditions. Basile and McGee reckon that the damage to plant and equipment came to about $2 million. They estimate that payments from FEMA flood insurance will cover a little less than one-third of the losses they sustained.

The partners’ quick reaction, both in attending to the cleanup and in making sure that production of customer work wouldn’t be interrupted, undoubtedly is what saved the business from extinction. The storm hit on a Monday, and by Thursday, McGee and Basile were brokering work and assuring clients that all would be well. As McGee says, “if you claim to be a service provider, you’ve got to provide service.”

Brokering went on for about three months until production could resume. The partners are under no illusions about the difficulties they will continue to face as they try to put Sandy and the losses it inflicted permanently behind them. But, the mere fact that the plant is back open and producing represents one of the most remarkable stories that the metro area printing industry has been able to tell in Sandy’s aftermath.

McGee relates it in his own words at his personal blog, where this remark sums up the extraordinary grace under pressure that he and Basile have shown ever since the day the skies darkened so ominously over Upper New York Bay:

“What to do? We never really asked the question. We’re going to rebuild and restore and make it better than it was.”

 

 

Sandy Alexander Brings Second HP Indigo 10000 On Line, Expanding Its Capabilities in 1:1 Marketing

June 18Sandy Alexander (Clifton, NJ), a leading direct mail and commercial print provider, announced today that it has concurrently brought on line its second HP Indigo 10000 Digital Press while also expanding its capabilities in 1:1 marketing.

Sandy Alexander was one of the original beta sites for the HP Indigo 10000 and the first in the U.S. to be operational with the new press.  Since the system is primarily used for 1:1 marketing / variable data printing campaigns, the company also has expanded its team of experts and its capabilities in variable data composition, data management, and custom workflows.

“The demand for the new, larger sheet size provided by the HP Indigo 10000 in combination with our variable data printing capabilities has been phenomenal,” said Mike Graff, CEO and president of Sandy Alexander. “The HP Indigo 10000 allows us to transform our offerings, created by the unique combination of format size and image quality. That capability in combination with our industry-leading 1:1 and cross marketing capabilities lets us support new programs for our Fortune 500 clients in the automotive, retail, financial and travel industries.”

The HP Indigo 10000 Digital Press is the first B2-format (29.5″ x 20.9″) sheetfed solution from HP Indigo.  According to Graff, combining the new sheet size with expanded content management offerings enables clients to more easily implement and manage personalized communications with highly targeted messaging.

“This has provided our clients with increased creativity and efficiency and has resulted in more impactful marketing campaigns,” he said.  “This has generated a competitive advantage in the marketplace for our clients while also dramatically increasing their marketing ROI.”

The two HP Indigo 10000 Digital Presses are complemented by an HP Indigo W7200 digital web press and an HP Indigo 7000 sheetfed press. The company has also applied its proprietary cross-platform color management solutions to these systems.

Sandy Alexander Inc. is the largest independently owned, high-end commercial graphics communications company in the nation, serving the needs of Fortune 500 companies and many other enterprises from coast to coast.  Sandy Alexander’s broad array of services ranges from digital solutions, sheetfed and web capabilities, webs with in-line finishing and personalization, and wide- and grand-format printing for retail visual merchandising.

Sandy Alexander is also a leader in protecting the environment with 100% wind energy; Sustainable Green Partnership (SGP) certification; carbon-neutral facilities for digital, wide- and grand-format production; and tri-certification for chain-of-custody paper.

For more information, call Doug Hazlett at (973) 470-8100 or visit www.sandyinc.com.

The Wall Street Group Rebuilds, Endures, and Thrives in the Wake of Hurricane Sandy

Editor’s note: the following was provided by The Wall Street Group, a full-service offset and digital printing company in operation since 1966.

This video shows the extent of the damage done to plant and equipment of The Wall Street Group by superstorm Sandy last October.

Jersey City, NJ – On the morning of October 29th, 2012, the paper was loaded onto double skids, sand bags were placed by the large overhead doors of the plant’s loading bay, the lights turned off, and employees sent home where they waited, for Sandy. That night, she hit.

The next morning, Al Basile, Sr. and Philip J. McGee of The Wall Street Group arrived at their plant of 43 years to find an overhead bay door to their building bent and lying in the parking lot. Skids of wet paper were broken and strewn all over the area: in the road, in the grass, on the fences. Inside, the building was dark and wet, pallet skids were knocked over, coating the floor with wet paper. The devastation that Sandy brought upon the building was astounding, including the visible four-foot water marks left behind by the flooding. There was no power, no heat, and no phones.

What was truly remarkable was that their first order of business in rebuilding was to off-load the customer work they had in-house so that deadlines would be met and schedules maintained.  The projects that had been printed and waiting to be delivered prior to the storm were destroyed and had to be reprinted.  All of this work was sent to four or five printer partners in the area that were not as adversely affected by Sandy, and after two weeks the network was up, allowing jobs to be sent electronically. A good start, but such a long road to go.

While these pressing jobs were taken care of they acquired pumps and generators and dumpsters so that they could start to clean, repair, and rebuild.  Long-term relationships with service companies and mechanics paid off as these folks pitched in with employees to get the plant back on line. Never once did they think about closing the doors and retiring. These seasoned men, the true salt of the earth, thought about getting their plant and their business back to the place it had been—where both their customers and employees depended on them.

January was the start of everything coming together, but it still remained a bumpy ride. All stored materials needed to be replaced. The mechanics, working with the pressmen, pulled out and replaced about 50 motors of varying sizes from the salvageable presses that were damaged by the flood waters. Their digital presses were completely ruined and so new state-of-the-art machines were purchased that today make up half of the business at Wall Street Group.

Little by little all of the equipment was either replaced or fixed.  All of the printed material that was stored at the plant was reprinted and today is safe and ready for customers. Despite having no electricity for two and a half weeks and no heat for five months, they got the job done. If not for the fortitude of their staff, their very loyal vendors who helped rebuild the motors and the printing presses, and their empathetic and understanding customers, the presses would remain silent.

As with every piece of equipment that needed to be rebuilt, so too the company and its owners and employees were rebuilt and today The Wall Street Group endures.  After a long delay in receiving assistance from FEMA and still battling with insurance providers, the nature of the owners of The Wall Street Group remains and endures as well: that toughness, that grit that got them through the worst storm to hit the Northeast in recorded history. They not only survived, but now they thrive. Everything is new again, and growing. As Phil McGee says, “We’re better than ever.”

Staten Island Printer, Battered by Sandy, Is Back Up and Running

Congratulations to 3 Sons Printing for reopening on Staten Island after a six-month shutdown in the wake of Hurricane Sandy.

The Staten Island Advance reports that the third-generation family business is back in production at a new location on Canal Street. The storm ruined the firm’s previous building on Bay Street, but the Esposito family hopes to demolish and rebuild it, according to The Advance.

For now, the full-service commercial printing company has found a safe haven where it can resume its role as a one-stop source of general printed products, advertising and marketing pieces, stationery, calendars, apparel, and accessories. 3 Sons Printing also operates Sign Men, a sign shop that soon will relocate to expanded space on Arthur Kill Road.

We’re glad to see 3 Sons Printing back on its feet and returning to growth mode after the pounding that Sandy gave it. We hope that all graphics firms in the region that took similar beatings from the killer storm will eventually have the same happy tale of recovery to tell.

Printing Industries Alliance Hosts A Solid and Satisfying “Innovation Forum” on Long Island

Regional printing trade shows mostly are things of the past—just try to find anyone these days who remembers the Graph Tech expos for the Northeast or the Gutenberg Festivals that once tried to take root on the West Coast. Vendors can’t justify the expense of exhibiting at these local affairs, and printers can’t find the time to attend them. Besides, isn’t pretty much everything we need to know about equipment, technology, business trends, and our counterparts in the printing industry available right here on the Internet?

All of the above may be true, but in spite of that, members of the industry still find value in the knowledge-sharing camaraderie that only face-to-face encounters can provide. At its “Innovation Forum” on the evening of March 20, the Long Island branch of Printing Industries Alliance (PIA) offered about 150 registered attendees the opportunity to come together for just such a program: a business networking exchange for graphic communications professionals, complete with educational sessions and displays by more than two dozen sponsoring exhibitors.

The event, held at the Holiday Inn in Plainview, NY, lasted for only three hours, and the displays consisted mainly of literature on table tops. It may not have been a “trade show” in the strictest or even a loose sense of that term, but it was a welcome demonstration of industry solidarity that PIA president Tim Freeman was correct to call a “win-win” for everyone who participated.

It also was a successful second try at hosting a get-together that Hurricane Sandy forced PIA to cancel when that killer storm blew through the area last October. Since then, Freeman and fellow PIA stalwart Bill Dirzulaitis have been working the phones in an effort to rekindle interest. Freeman gives Dirzulaitis—the former president of what used to be the New York City metro area’s largest printing trade association—much of the credit for driving the turnout.

Freeman also saluted his Long Islanders for being “probably the best group we have” in terms of member activism within PIA, a trade group serving New York State, northern New Jersey, and northwestern Pennsylvania.

And while the exhibits may have been small, the names behind them weren’t, with HP, Xerox, Heidelberg, KBA, and other national and local providers lending their prestige to the gathering as they interacted with their Long Island  customers. HP earned extra attention by hosting the open bar and buffet that refreshed attendees throughout the evening.

Tim Freeman, president, Printing Industries Alliance

 A pair of educational sessions addressed topics that are. or should be, of high interest to printers on Long Island and everywhere else: opportunities in high-volume inkjet production; and strategies for mergers and acquisitions (M&As) in an environment that, sooner or later, may require most print business owners to choose between selling their firms or absorbing other companies.

Fred Simonson, a consultant with Gimbel & Associates, surveyed available high-volume inkjet printing technologies and offered guidelines for investing in them. To achieve ROI with one of these presses, he said, a printing company should be capable of placing at least 10 million pages per month on it in one of the “sweet spot” product categories for inkjet: transactional printing, direct mail, and books.

According to Simonson, the investment in an “entry level” inkjet press can run from $2 million to $2.5 million when the costs of the controller, software, pre- and post-feeders, training, and other necessities are factored in. Given a sustained workload in the right applications, he said, the economics of print manufacturing with equipment of this kind can be “very favorable—but you need to drive that printer all the time.”

Printers also must remember that the interaction of water-based ink, paper, and heat in an inkjet production run sometimes “does some strange things” to the quality of what’s being printed. “You’re literally changing the physics of that sheet of paper” when putting it through an inkjet press, said Simonson, who recommended running on pre-treated or coated paper for the best results.

New Direction Partners (NDP) is a consultancy that brokers and manages M&As within the graphic communications industry. Peter Schaefer, its representative at the Innovation Forum, said that these transactions “have become a mode of survival in the printing industry” because of the shrinkage of the demand for print and the resulting contraction of the industry’s business base.

Another piece of handwriting on the wall, said Schaefer, is the fact that “printing is one of the most fragmented industries in the United States, and fragmented industries inevitably consolidate.”

As Schaefer described them, well executed M&As are proactive and profitable responses to this looming trend for buyers and sellers alike. Print company owners who are finding organic growth hard to achieve can obtain the broader customer base and capabilities they need by purchasing these assets from other companies. By agreeing to be acquired, owners ready to exit the business can do so gracefully without having to resort to liquidation or other equally unattractive alternatives.

Schaefer reviewed various types of M&A transactions and discussed characteristics that make printing companies desirable or undesirable as acquisition targets. He also noted that multiple of EBITDA, the primary yardstick for determining selling price, now averages between 4 and 5 for printing companies that are healthy and growing or have a specialty that other firms will want to acquire.

Printing Industries Alliance has headquarters in Amherst, NY, and an office for the New York-New Jersey metro area in Roselle Park, NJ. Upcoming events include a 10-hour OSHA outreach for printers and a two-day human resources conference.

To B2 or Not To B2? Sandy Alexander Says ‘Yes’ in Its Beta Test of an HP Indigo 10000 Digital Press

At the HP Indigo 10000 in beta test at Sandy Alexander are Rob Mayerson (left), vice president and general manager, and Mike Graff, president and CEO.

B2-format digital presses were the talk of drupa, and many in the industry are still speculating about where these platforms fit into the scope of commercial print production. But, Sandy Alexander (Clifton, NJ) isn’t paying heed to the rumor mill—it’s weighing the merits of B2 digital printing for itself by beta-testing one of the most advanced examples of the technology.

The test case is an HP Indigo 10000, a 29.5″ x 20.9″ sheetfed press that HP introduced at drupa and plans to make commercially available this year. Sandy Alexander has been working with the machine since October, becoming one of four sites in the U.S. where beta testing is taking place.

The company expects to acquire the machine when testing concludes in March. If all continues to go well, a second HP Indigo 10000 may be on its way to Sandy Alexander’s digital press department as the company gears up to meet what it says is a rising demand from its customers for variable-data printing in color.

For Sandy Alexander—a full-spectrum provider of graphic communications services with a history of being first to test emerging production techniques—early adoption of digital printing in B2 format was a predictable step forward.

The company, which also offers sheetfed and web offset litho and grand-format printing, has been running digital presses for five years, settling on the HP Indigo platform as the solution that best meets its high-end quality requirements. But over time, those requirements began to outgrow the 13″ x 19″ sheet size that, until recently, represented the largest format that most sheetfed digital presses were capable of printing.

A B2 press, on the other hand, can print eight 8.5″ x 11″ pages in duplex, four to a side—a format that gives commercial printers the flexibility they need. That makes B2 the “logical layout” in variable-data digital output for the commercial market, according to Mike Graff, president and CEO of Sandy Alexander.

“It would be naïve to think that 1:1 marketing could be constrained to a four-page product,” he says. To expand into B2, Graff decided to replace a pair of existing HP Indigo 7000s with the HP Indigo 10000 he currently is testing and, depending on discussions now in progress with HP, a second installation of the machine.

One of the HP Indigo 7000s has been retired, and one remains. To help Sandy Alexander maintain digital capacity while the new B2 press comes fully online, the manufacturer has temporarily provided an HP Indigo W7200 web press that will fill any gaps in production until the second HP Indigo 10000 comes in. HP also is supporting the transition by providing an Indigo technician from the factory in Israel to monitor the testing.

Being in the vanguard of B2-format digital printing is “not for the faint of heart,” acknowledges Rob Mayerson, vice president and general manager in charge of digital operations at Sandy Alexander. Nevertheless, testing has progressed to a point where the press now is printing its first live job, a variable-data project running in batches of about 10,000 sheets per day.

Those who have seen the results are enthusiastic, and the kudos are coming not only from personnel at Sandy Alexander. “Customers would like us to be beyond beta” with the HP Indigo 10000, says Douglas Hazlett, vice president of sales and marketing. “They are lining up.”

Industrywide, most of what goes into digital production consists of static output. The HP Indigo 10000 at Sandy Alexander, however, is intended largely if not exclusively for variable-data printing. The company is so committed to reserving the device for VDP, says Mayerson, that it has installed an additional offset press—a six-color Heidelberg Speedmaster SM 52 perfector— “to take the static out of here.”

With VDP, Sandy Alexander can offer its customers printing that lets them leverage what they know about the consumers who are buying products and services from them. Print customized with 1:1 content generates response rates that static promotions can only dream about—as high as 30% in some cases, Hazlett says.

Sandy Alexander produces VDP-enhanced materials for automotive, fashion, cosmetic, and retail accounts. Clients furnish the data through a custom content management system that lets them create templated documents, update text and images, and manage their projects in real time. This channel for client input “is as important to the selling proposition as the iron,” Mayerson says.

The result is printing that drives behaviors and triggers outcomes by responding to specific consumer preferences and requests. “Hand-raisers”—expressions of interest culled from web sites and other sources—can be translated into brochures and other pieces that deliver precisely what the end-user wants to see.

Tens, hundreds, or thousands of pieces customized in this way can be printed in the same run on Sandy Alexander’s HP Indigo 10000. Thanks to the 1:1 power of VDP, says Mayerson, “we don’t send you anything that you don’t ask for”—a  benefit that adds value to variable output and enables VDP producers to charge a premium for it.

The VDP-capable HP Indigo 10000 can print in B2 format (29.5” x 20.9”) in up to seven colors at about 1,700 sph (4/4).

Mayerson says that the B2 platform on which this proposition rests is now running on two shifts at speeds of about 1,700 sheets per hour, 4/4, on both coated and uncoated stocks. He points out that because the B2 sheet offers more than twice the printing area of a 13” x 19” sheet, printing the larger format at the same speed increases productivity in proportion.

Like all Indigo presses, the HP Indigo 10000 is an electrophotographic device that uses a printing fluid dubbed “ElectroInk” by HP. Sandy Alexander’s press can run up seven colors of ElectroInk, including Hexachrome, spot colors, and white. For the moment, production is limited to CMYK, fully color-managed with the company’s offset and grand-format processes. The press is soon to receive a field upgrade that will enable it to handle stocks as thick as 18 pt.

A press as formidable as the HP Indigo 10000 “is not meant for someone who dabbles,” says Mayerson, who had to raise the ceiling in the digital pressroom before bringing it in. The machine is heavy enough to need a reinforced floor, and it has temperature-control requirements as well.

Although, as a half-size color press, the HP Indigo 10000 conceivably could take work away from the equipment in the company’s offset pressroom, that kind of job migration isn’t likely to occur. That objective was “very, very secondary” in the decision to install the press, says Mayerson, noting that the machine “was not purchased as a cost-saving device to replace offset.”  There would have been scant ROI, he adds, in paying what the company had to pay for its HP Indigo 10000 just to gain a little production efficiency.

Besides, the two processes can be teamed profitably in projects like the car owner’s information kit that Sandy Alexander produces for one of its automotive customers. Here, the mailing envelope and the portfolio enclosure are printed on litho equipment. Digital printing customizes the diecut, tabbed, and wire-bound booklet inside the portfolio.

The company’s advance into B2 digital production is in keeping with its policy of making continuous technical progress on multiple fronts. Among its other innovations, Sandy Alexander was one of the first printers to use gray balance as a technique for controlling color on press. It also served as a beta test site for GRACoL G7 certification, and it was the first printer in the East to install an eight-unit litho press.

“If you stand still, you are guaranteed not to succeed,” says Graff. Pioneering new methods of solving problems for Sandy Alexander’s customers is “just the fabric of the company,” he says.

Some Metro Firms Report Recovery in Sandy’s Devastating Wake

Saturday, November 3, 2012 — No small part of the $50 billion economic loss being attributed to storm Sandy will come from business interruptions suffered by printing firms throughout the tristate metro region. Wherever the damage was worst, the toll taken on these highly vulnerable manufacturing operations was highest. Many remain out of commission, their electrical power gone, their communications severed, their work piling up, and their employees stranded at home with gas gauges pointing at empty. But, as early as yesterday, in some of the less hard hit boroughs and towns, the first signs of recovery were beginning to appear.

Printing Industries Alliance (PIA), the trade association for graphics firms in the region, has been trying to maintain contact with its downstate New York and northern New Jersey members since Sandy made landfall last Monday (Oct. 29). Reaching them has been difficult, said PIA president Tim Freeman, who had been forced to cancel a PIA-sponsored “Innovation Forum” scheduled that day on Long Island as the storm roared in.

Freeman says that his group stands ready to help any printing firm in the region, PIA member or not, that may need to outsource work until its own plant is back up and running. Upstate firms as well as printers from other parts of the country have offered to pitch in, according to Freeman, who can be contacted at 716-983-3826 or by e-mail at tfreeman@pialliance.org.

On Thursday (Nov. 1) and (Nov. 2), with power outages still crippling lower Manhattan and many parts of Long Island, New Jersey, and Connecticut, we failed in most of our own attempts to speak with printers caught in the disaster and its aftermath. But, a few calls did go through, and what we heard from these sources was encouraging.

“We are turning cylinders, and we are printing,” said Tom Saggiomo, CEO of DG3 (Jersey City, NJ). The plant closed at noon on Monday, a few hours prior to a power loss that persisted until Thursday evening. No flooding or other storm damage was sustained, according to Saggiomo, who said that now, “our main priority is to get dated material out the door.” Saggiomo called in his second shift on Friday in anticipation of being back in full production by the end of the day.

On Long Island, Disc Graphics (Hauppauge, NY) shut down Monday morning in what John Rebecchi said was an “organized fashion” to ride out the worst of the storm. Rebecchi, senior vice president of the packaging firm, said that the company had previously organized a “response group” of sales personnel and CSRs to stay in touch with customers and reassure them about their work in progress.

Disc Graphics has an affiliated plant in the Midwest, and thanks to this facility, said Rebecchi, some customers have experienced “zero interruptions” in the production of their work. Those for whom production has been delayed have been “highly understanding,” Rebecchi said.

The lights came back on in Hauppauge on Thursday afternoon, revealing no storm damage and enabling Disc Graphics to resume deliveries from the home plant. As of Friday, Disc Graphics was open for business and fully operational, but Rebecchi said the situation still has a way to go before routines will be entirely back to normal.

For one thing, phone and e-mail malfunctions outside the plant are making some customers difficult to reach. Many of the Long Island-based trade shops that Disc Graphics relies upon for finishing and other services were knocked out by Sandy and remain down, Rebecchi said.

The biggest immediate challenge, however, is employee logistics. About 250 people work for Disc Graphics, many of them still without power at home and all of them facing a gasoline shortage that has brought commuting on car-dependent Long Island to the edge of a standstill. The company is helping its staff to cope by organizing carpools and by providing catered meals at the plant. It also is reaching out to community groups in its employees’ residential areas, offering what assistance it can.

“Right now, it’s all about a community effort,” Rebecchi said.

Mike Graff credits a contingency communications plan, a backup generator, and the “unbelievable” response of his employees with getting Sandy Alexander back to nearly full production soon after the departure of a storm that literally had the name on the Clifton, NJ, commercial printing firm on its back.

The electricity went out on Monday afternoon, but Sandy inflicted no significant damage on buildings or equipment as it roared through, Graff said. On Friday, the company still was waiting for the return of utility power, but a rented generator was supplying about 70% of what the plant normally draws—enough, said Graff, to get his four sheetfed presses and one of two “power hungry” webs back on line. Sandy Alexander has a web plant in Florida that can fill in the gap in the meantime. The company’s digital and outdoor divisions also were back in operation, Graff reported.

He had nothing but praise for his staff of 125, many of whom made their way to the plant, ready for work, while it was still plunged in darkness. But Graff noted that these steadfast employees, like their counterparts at other firms throughout the metro region, would face serious commuting challenges until normal supplies of gasoline became available.

In the industrial section of Queens known as Long Island City, David Spiel is hopeful that as power returns to Manhattan and elsewhere, his customers will come to Spiel Associates on Nov. 7 and 8 for an open house that will reprise the dealership’s showing of graphic finishing equipment at Graph Expo 2012. Spiel said that although he closed the plant on Monday, he never lost power and was able to reopen with limited communications (now fully restored) the following day.

More tales of recovery like these will emerge as metro area printers regroup in the wake of the worst natural disaster that most of them have ever experienced in their own backyards. We will continue to follow the recovery and can be contacted via e-mail by any firm in the region with a story to share.