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Trappist Caskets

Trappist Caskets is a small-volume producer of traditional, high quality wooden caskets and urns. As an authentic Trappist product, the company is owned and operated by the monks of New Melleray Abbey(1), members of the Order of Cistercians of the Strict Observance(2), commonly called Trappists. Trappist Caskets and New Melleray Abbey are located 12 miles southwest of Dubuque, IA. This work provides for the modest living expenses of these contemplative monks. It’s also a means to fulfill a foundation of Cistercian spirituality which is manual labor, while imparting the sanctity of a life of prayer into their work. History

New Melleray Abbey was founded in 1849 by Mount Melleray Abbey, County Waterford, Ireland (3). For over 150 years, farming the 2000 acres of the Abbey supported the monks. In the 1990's, certified organic farming methods were introduced but over time, gradually increasing expenses made the farm profitable. In 1999 a proposal was made by local businessman and casket maker, Sam Mulgrew, who persuaded the monks to enter the third party casket market (i.e. providing caskets directly to the end user). Wood was provided in part by the Abbey's award winning 1300 acre forest, and labor would be provided by the monks, along with outside help. Although much equipment needed to be purchased, two existing buildings, a carpentry shop and a decommissioned alfalfa dehydration plant were retrofitted for the work. Making Caskets

In keeping the design and function consistent with the monks’ values, simple rectangular pine caskets were the entry point into market. After the wood was planed, sanded, cut, assembled and sanded, a lacquer coating was sprayed as a finish to bring out the beauty of the natural wood. The company began and continues to use custom made metal handles, rather than the wooden bars seen on most commercially manufactured caskets. The interior of the caskets was then upholstered with natural unbleached muslin. For the first years, the pillow and mattress were stuffed with the organic stray from the farm fields. Both the caskets mattress and pillow are now filled with foam products. After installing an elevating bed, a checklist was performed before placing the caskets into inventory for sale and shipment.

After a few months, a European style shaped pine casket was introduced into production. Sales continued to increase as the monks were learning a craft and a new industry. The next innovation was producing premium rectangular and shaped caskets using the various woods available in the property. Red oak and walnut added value and an attractive alternative to those made of pine. The next stage was the introduction of appropriate wood shaping tools that would make tongue and groove joints and a raised panel, adding additional aesthetic style to the caskets. Laser engravers were eventually added to the production process to personalize a casket with personal names and dates. After the initial startup period, Trappist Caskets was generating positive income for the Abbey, consequently more monks and hired laypersons were added to the operation to meet production requirements for new sales. The Abbey gave the green light to continue expanding production and sales throughout the US. Getting the Word Out

Because of their uniqueness, seeing a Trappist Casket at a funeral service has always been the best way to promote and increase sales. Media outlets such as local newspapers and America Magazine were used to advertise the monk’s caskets. Working with regional design artists, a web page and advertising flyers were produced. Both have gone through many revisions through the years and improved in quality. A feature in Smithsonian Magazine(4), and a radio feature on NPR boosted the awareness of the product, as did feature stories in the New York Times and Wall Street Journal. A New Plant

After a few years, Trappist Caskets was selling and shipping caskets throughout the entire United States, and sales increased every year. The original manufacturing facilities were outdated and too small so a new plant was designed and built in 2007. In addition to the 35,000 sq. ft. of manufacturing space, the new building includes a Welcome Center. All the models of caskets are exhibited, as well as an area with pictures and descriptions of the history of New Melleray Abbey. Photos on the life of the monks and the manufacture of the caskets are included in the display. The new building also includes a chapel which is used for masses celebrated several times a year to remember those who have been buried in Trappist Caskets, as well as employee’s family and friends who have died in the recent past. The chapel can also be used as a place of relaxation and reflection.