In 1935 Ben C. Williams founded B.C. Williams Bakery Service out of passion, and out of necessity. The baking industry needed a reliable source that could supply quality products with a distinctive brand of service. B.C. Williams Bakery Service sales and distribution company has become one of the most diversified ingredient suppliers to the baking industry. They maintain an extensive warehouse and trucking system with weekly deliveries to over 350 food operations over 42 states. Their national reach allows them to meet their customers’ needs on time, every time.
The Situation
As part of a pollution prevention and CARES Act grant providing onsite assistance to Food & Beverage manufacturers, TMAC reached out to B.C. Williams to see if they were interested in participating in receiving assistance from the grants. Shane Collins, Director of Operations welcomed the opportunity and asked TMAC to review their sesame seed loading bag operations at their Dallas location. After observing the operation, TMAC identified several opportunities which included a recommendation to identify another method to help keep the stacked bags from sliding during transportation. The current method required spraying an extremely flammable aerosol glue onto the surface of each bag before the next layer was placed. In addition to added labor time to spray the aerosol glue, operators were inside the trailer with limited ventilation.
The Solution
TMAC researched options to identify a hot melt glue that could be applied with a mobile spraying system specially designed to apply a thin layer of adhesive with FDA clearance for food contact across each stacked bag layer. TMAC then participated in onsite testing of the new system to validate the required specifications needed for the process. The hot melt system performed well and would enable B.C. Williams to fully eliminate the aerosol glue and improve the working conditions for the operators spraying the adhesive. In addition, the extended hot melt glue curing time allowed operators to adjust bag placement if necessary, eliminating 1,100 damaged bags per year from tearing reducing product losses by $38,000 annually. Bag tearing was also eliminated at the customer’s facility when the bags are removed from the pallet. The operators were also excited to get rid of the old aerosol glue which would now eliminate 1,850 empty cans from being thrown into the dumpster and ultimately into the landfill. Eliminating the aerosol glue would reduce 1,446 pounds of hazardous aerosol spray each year from negatively impacting air quality. The operators are now no longer exposed to a health risk and the the hot melt is easier to clean off their skin and clothing.
The Results
Next Steps
B.C. Williams then investigated an optional spraying system to deliver the FDA approved-for-food contact glue and purchased a system. Other recommendations taken by B.C. Williams included adding water coolers next to the loading area to help staff stay hydrated and adding fans to help increase the circulation inside the truck trailers. TMAC also provided B.C. Williams with a technical layout to improve the loading and unloading process using flexible conveying equipment.
1,446 lbs hazardous waste reductions
Reduced product loss by $38,000 annually
Eliminates landfill disposal of 1,850 cans per year
Improves operator working conditions
I was very excited about this project to improve our bag loading operations. I really enjoyed working with the TMAC team to help us identify an innovative system to secure our bags. We are looking forward to staying connected with TMAC as we continue our efforts to seek innovative solutions for our customers. This added great value to the operation, thank you for everything!
-Shane Collins
Director of Operations
