Rusty Vallee is president of Maine Thread Co. and the third generation to run the business that ships all over the world from its headquarters in Lewiston’s Pepperell Mill.
1. Describe a day in the life at Maine Thread.
During the very early hours of the morning, automatic timers turn on power to our wax tanks so that our waxes will be melted to the proper temperature when we arrive. We switch on the compressor, which runs air power to all parts of the factory where it is needed. The chugging of that compressor is the very familiar sound that signals the 7 a.m. start of each workday. Our factory consists of two floors, so we have a crew that works downstairs and a crew that works upstairs. The bottom floor consists of our textile factory where we twist, wind, wax, cut, taper and pack our thread products for footwear companies.
Upstairs, we have offices, warehouse space and manufacturing space, where we also do some waxing, winding and have specialty projects as well. I use to spend the bulk of my time on the manufacturing floor, but I have great employees, which gives me the freedom to explore new markets, products and manufacturing techniques. I don’t do much traveling, but I stay in touch by email with our international customers daily.
I continue to grow and move this company forward, but cautiously. Maine Thread Co. is almost 60 years old and I know all the work and sacrifice that has come before me, so in this fast and furious world, I prefer, “Steady as she goes.”
2. Your product is in Hobby Lobby, Michaels and high-end shoes at Lamey Wellehan, to name a few. How did you make those connections to become such a big player on the world thread stage?
We manufacture a niche product for footwear, which is a waxed polyester thread with tapered ends that are used for hand-sewn footwear, moccasins and boat shoes. Many years ago, most of these shoe factories were located here in Lewiston/Auburn and surrounding areas. In the 1980s, production of almost all these labor-intensive shoes began to move offshore. In other words, American footwear companies closed factories in the USA and began sourcing their shoes from factories overseas. We stayed diligent and chased this business around the globe. We were fortunate to make new connections and today, we are shipping in bulk to factories in China, India, El Salvador, Dominican Republic, Indonesia, Italy and others. The shoes are sewn by hand and then shipped back to retailers here in the states and other parts of the world. Although most of the domestic shoe production left this area long ago, there are a few companies in Lewiston that still sew shoes on the last (a holding device shaped like a foot) in the traditional way. It is an amazing process.
We have always tried to accommodate the needs of small crafters and cottage industry and the rise of the Internet has made it economical and opened up so many new avenues for us. We developed a line of waxed cord in different sizes and colors that we keep in stock, along with other threads and findings. This gives us the freedom to offer smaller put-ups from stock instead of stopping production for small quantities. So now we run these in bulk and try to stay ahead of demand. Instead of a dozen local crafters, beaders, artists, etc., now we have thousands from all over the world. It continues to grow, and our Maine Thread brand is being recognized as a high-quality cord used in so many ways and in so many places.
Large distributors of craft supplies also use our waxed cord in their kits. They immediately realized that this cord is superior quality and is made here in the states. We sell our goods to them private label, which means we manufacture our waxed cord with their name on it. This setup has worked out great for both of us.
3. Policy or issue you’re following this summer at either the state or national level, and what impact could it have on your business?
No doubt there are always issues to watch. Currently, the strong U.S. dollar makes us less competitive in some international markets, but to be honest, I am focusing most of my energy inward. In my opinion, business is about problem-solving. No matter what problems arise, you must be able to make the adjustments and move on.
4. What advice did the first generation pass on for running the business? The second generation?
Wow, good question. I am sure that all family businesses have different dynamics. Our family business was founded on the strong principles of my grandfather, Alfred “Honey” Baril. He rose from poverty by working hard, finding a niche and by filling a need. We follow his example of work ethic, character and will to succeed. There has never been any infighting because we understand the importance of a chain of command.
My dad, Ronald Vallee, has taught me many lessons firsthand. When you are in a situation where you disappoint a customer for any reason, you can’t pass the buck. Even if the circumstances are beyond your control, you must take responsibility — so take your lumps and own your mistakes.
Business is cyclical. There are good times and slow times, so you must prepare for the slow times. When business is booming, be smart and don’t overextend. I have seen too many companies over the years that have upswings so they spend more and pay themselves more. When they hit a downturn, they have nothing to fall back on.
5. If you received a $1 million grant tomorrow, no strings attached, what would you invest it in?
A modern facility with loading docks. We have been in the Pepperell Mill (a.k.a. Lewiston Bleachery and Dye Works) for decades. The historic mill was built in the late 1800s; there were railroad tracks running through this mill back in the day. Today, we are faced with trying to move freight in and out of tight spaces with trucks hauling 53-foot trailers.
6. You’re at a black-tie event. You lose a button on your tux. What are the odds you have any thread on your person or in your car to fix it?
What is this, a trick question? Buttons don’t fall off when they are sewn with Maine Thread!
Six Questions For The CEO is a monthly feature on the faces and names that keep business interesting. Contact staff writer Kathryn Skelton at kskelton@sunjournal.com
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