Baking & Snack - July 2016 - 35
ning was handled within Ellison Bakery's staff, but contractors
were hired when necessary. The plant remained in operation
during installation, which required preparation beforehand and
plenty of site preparation before the oven arrived. "Planning is
key to this process," Mr. Wallin stressed. "Our team reviewed
with contractors and equipment vendors the needs that we had
in terms of what could and could not be done at certain times or
in certain locations within the plant. This was something that we
had to monitor constantly, and as customer needs changed, we
had to adapt and alter our plan. Constant vigilance is required."
"Our R&D department is
small, very skilled and
able to create excellent
opportunities for our
customers to launch new
innovative products on an
extremely tight timeline."
Todd Wallin, Ellison Bakery
With the addition of Line 3, Ellison Bakery went from approximately 85 employees to 120. With so many new people -
most without food manufacturing experience - the company
had its work cut out for itself. New employees were scheduled
for training in flights to keep things manageable. "Our existing
staff was taxed, so bringing those guys in was a big relief to our
personnel," he said.
When all was said and done, the new oven was installed before the Christmas holiday, a goal the company had set to provide inspiration to have the project finished on time.
Operating with flexibility
Line 3 currently runs cookies that will become components for
other food manufacturers' products. With the new oven taking
some strain off of the other two lines, the bakery is in the process of moving most of its retail and private-label business onto
Line 2, leaving Line 1 mainly for foodservice products.
Line 1 has a Baker Perkins 48-in.-wide oven that's 120 ft
with two zones; Line 2 relies on a Baker Perkins three-zone,
39-in.-wide oven running 150 ft. Ovens 1 and 2 can produce
both wire-cut and rotary cookies, and there is talk of retrofitting an older wire-cut machine to give Line 3 wire-cut capabilities to keep production as flexible as possible. Ellison
Bakery has about two dozen rotary dies to create a wide variety of cookies.
Ellison's ability to remain flexible has contributed to its
www.bakingandsnack.com / July 2016 Baking & Snack 35
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Baking & Snack - July 2016
Table of Contents for the Digital Edition of Baking & Snack - July 2016
Baking & Snack - July 2016 - 1
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