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A unique vest designed to carry everything from school books to photography gear has recently been added to the production line at Dirigo Stitching, a Skowhegan firm that has been battered by competition from Asian manufacturers in recent years.
But to Marsha Auster and Joan Tankey of Lewiston, the inventors of BukRap, Dirigo Stitching is tailor made for their product. "We originally started manufacturing the vests in the Dominican Republic because of the low costs," said Tankey. However, a combination of quality issues and the cost of traveling to the Caribbean nation several times a year prompted them to seek alternatives.
Maine home stitchers were used for awhile, but Tankey noted that keeping track of numerous subcontractors with varied skill levels was difficult. Finally, they contacted then-Gov. Angus S. King, whose office provided them with a list of Maine manufacturers who could potentially make a product like BukRap. "As it turned out, it was a perfect match," said Auster.
It couldn't have come at a better time for Dirigo Stitching, either, said Peter Schultz, owner and president. The Skowhegan firm had been a prime supplier of curtains, napkins, sheets, pillowcases and other household essentials for major department and chain stores for years. "But just about every account started buying from overseas because of the cheap labor costs. There was no way we could compete," said Schultz.
As a result, Dirigo Stitching's work force has decreased from 200 to 40 and its focus is now on specialty items in smaller quantities and niche accounts. They make American flags and custom-designed products for nursing homes and hospitals. And in Schultz's view, BukRap is an ideal fit for his company. "This is one company that really has its act together," said Schultz.
The BukRap concept started when Tankey, a retired health educator at Lewiston Middle School, noticed the number of children walking bent over by overloaded backpacks.
While the American Academy of Pediatrics and most chiropractors recommend that children shouldn't carry backpacks with more than 10 to 20 percent of their body weight, these standards are often ignored in the real world, said Tankey. "You can't carry that much weight on your back and shoulders day after day without having some adverse effect on your body."
So after hundreds of hours of research and thousands of dollars in prototype investment and legal fees, BukRap was born. Basically, it is a heavy-duty vest made of lightweight material with mesh pockets on the sides and back. There are shoulder pads and a reversible zipper so it can be be worn inside-out on a rainy day, thus protecting your books, CD player, manuscripts or whatever. But because of its lightweight construction, it can be draped on a chair and stored on a shelf or hung up easily in a cramped school locker.
Since the payload is distributed evenly in the front and back, BukRap users don't slouch or strain, even with a pocket full of books, sandwiches and snacks. Fortunately for Auster and Tankey, vests in general are becoming more popular among teens nowadays, although weaning youngsters from the backpack habit may take some time.
BukRap comes in four sizes and 11 colors, including orange, camouflage and hunter green. While originally designed to take the load off youngsters' backs, BukRap's newest marketing efforts are aimed at adults who like the flexibility of a rugged, multi-pocket vest. "These are ideal for hikers, fishermen and wildlife photographers. They can also be worn outside or inside a jacket," said Auster, a retired guidance director at Lewiston High School.
At present, BukRap is available primarily at trade shows or through the company's Web site—www.bukrap.com—as Auster and Tankey continue their marketing efforts. BukRap is also being promoted by doctors Jeff S. Slocum and Rok A. Morin of Bath, the founders of Learning Curves—www.learningcurves.us—an innovative program that teaches elementary students about spinal health, backpack safety and proper posture.
With the holiday season approaching, BukRap sales are expected to increase significantly, giving a much needed boost to the entrepreneurs and their Skowhegan manufacturer. "Dirigo Stitching has been wonderful in providing a quality product and great customer service. It's an ideal situation for both of us, and we're very upbeat about the future," said Auster.
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