Blue Bell Ice Cream news

NOTE: Blue Bell Creameries will issue periodic updates to keep the public informed about developments and progress in the Blue Bell Ice Cream recall and the company’s process for returning to the marketplace.

May 7, 2015

Product Retrieval:  Blue Bell has collected approximately 8 million gallons of ice cream and ice cream products from retailers, institutions and other outlets in the U.S and internationally, and this phase of the product recall is now complete.  Consumers who may still have Blue Bell products are encouraged to dispose of them or return them to a local retailer for a refund.  Consumers should call 979-836-7977, Monday through Friday between 8 a.m. and 5 p.m. CST, with any questions.

Production Facilities: The Blue Bell production plants in Brenham, Texas, Broken Arrow, Oklahoma, and Sylacauga, Alabama, are closed and no ice cream is being produced at this time.  We are continuing the process of thoroughly cleaning and sanitizing each facility, including disassembling equipment, conducting extensive maintenance and repairs, and conducting employee training in microbiology and sanitization.  We are also reviewing all of our operating procedures and every step of the production process to eliminate possible contamination pathways. 

All plants are, or will be doing, the following:

• Evaluating and making facility repairs, including replacing floors, floor tiles and ceiling tiles, as needed.

• Conducting thorough cleaning and sanitizing, including disassembling and steam cleaning all equipment, and inspecting and sanitizing all HVAC systems.

• Working with a team of independent microbiologists to review and revise all cleaning and sanitization procedures, and installing new control systems to provide higher hot water temperatures for cleaning and sanitizing.

• Eliminating possible contamination pathways, including redesigning work spaces to re-route traffic in production areas, placing barriers between work areas, installing additional foot washers at doors into production areas, and discontinuing use of outside materials such as wood pallets in sanitary areas.

• Establishing revised protocols and quality assurance requirements for environmental and product sample testing, including a more rigorous monitoring program for Listeria.

• Destroying existing cardboard containers, boxes and product wrappers that could potentially provide a pathway for contamination.  Plants will discontinue the reuse of cardboard shipping sleeves.

• Continuing employee training in microbiology and detailed cleaning and sanitization methods and systems.

Sylacauga, Alabama

The Sylacauga facility has been closed for cleaning and sanitizing since April 24, 2015.  The facility is undergoing extensive maintenance and improvements, as well as a thorough cleaning and sanitization program.  The U.S. Food and Drug Administration (FDA) has completed its inspection of the Sylacauga plant, and the company is in the process of preparing a detailed response to the agency’s inspection observations.  

Broken Arrow, Oklahoma

The Broken Arrow plant has been closed for cleaning and sanitizing since April 3, 2015. Numerous cleaning, upgrade and facility construction projects are well underway or have been completed, including floor repairs, extensive equipment disassembly and sanitizing, and a re-design of the processing and production areas to increase production and cleaning efficiency and eliminate potential contamination pathways. The FDA has completed its inspection process for the Broken Arrow plant, and the company is in the process of preparing a detailed response to the agency’s inspection observations.

Brenham, Texas

The main Brenham plant has been closed for repairs, cleaning and sanitizing since April 24, 2015. A full assessment of facility repairs and upgrades is underway, including floor modifications.   In the interim, workers have begun a variety of equipment disassembly, maintenance and cleaning processes, and continue to receive training.  Additionally, the design and traffic flow patterns of the processing and production areas are being evaluated to identify potential improvements to enhance production and cleaning efficiency, and eliminate potential contamination pathways.  The FDA has completed its inspection of the Brenham plant, and the company is in the process of preparing a detailed response to the agency’s inspection observations.

The Brenham Snack Plant is also closed and a full assessment of facility repairs and upgrades is underway.  

Estimated Timeline

The extensive and detailed process of updating, cleaning and sanitizing our four production facilities, as well as training employees and implementing new programs and procedures, will take longer than we initially anticipated.  Each facility will have its own timetable and production may resume in some locations before others.  Blue Bell is committed to a thorough process that will ensure the highest quality and safety of our products for our customers going forward.  We know we have to get this right, and we intend to do so.  That is our top priority. 

“Unfortunately, we do not yet have a firm timeline for when Blue Bell Ice Cream will be back in stores, but we believe at this time that it will be several months at a minimum,” said Blue Bell CEO and President Paul Kruse.  “We are evaluating all of our operations in light of this extended timeline, we are working closely with the appropriate federal and state regulatory agencies and our microbiology experts, and we are mapping out the many details of returning to production and distribution as soon as we can do so with confidence.  We thank all our customers for their support and patience as we work to create the cleanest, safest environment possible to produce the high-quality, great-tasting ice cream people expect from Blue Bell.” 

May 15, 2015
 

Due to the extended timeline required to ensure the highest quality and safety of Blue Bell’s products when the company resumes production, and because supply and distribution will be limited for some time to come, Blue Bell Creameries CEO and President Paul Kruse today announced “the agonizing decision” that the company will have to reduce the size of its work force and take other cost-cutting measures, including furloughs and salary reductions.

“The agonizing decision to lay off hundreds of our great workers and reduce hours and pay for others was the most difficult one I have had to make in my time as Blue Bell’s CEO and President,” Kruse said.  “At Blue Bell, our employees are part of our family, and we did everything we could to keep people on our payroll for as long as possible.  At the same time, we have an obligation to do what is necessary to bring Blue Bell back and ensure its viability in the future. This is a sad day for all of us at Blue Bell, and for me personally."

The process of cleaning and improving Blue Bell’s four production plants is going to take longer than the company initially anticipated, especially at the main plant in Brenham where major repairs and equipment replacements are expected.  There is no firm timeline for when Blue Bell will begin producing ice cream again. When production resumes, it will be limited and phased in over time.

Kruse said the employee actions affect three groups: 

• Employees who are essential to ongoing operations and cleaning and repair efforts will continue to work but have their pay reduced. 
• A second group of employees will be placed on partially paid furlough.  They will be paid a substantial portion of their current pay, with the expectation that they will return to work as production resumes. 
• Because there is not a clear timeline for when production will resume, and because supply and distribution will be limited when it does, a third group of employees will be laid off. 

Approximately 1,400 employees will be furloughed, and approximately 750 full-time and 700 part-time employees – or 37 percent of the total Blue Bell workforce of 3,900 – will be laid off, Kruse said.

Blue Bell also made the difficult decision to suspend operations and lay off employees at the following distribution centers: Phoenix (2 branches) and Tucson, Arizona; Denver, Colorado; Indianapolis, Indiana;  Kansas City and Wichita, Kansas; Louisville, Kentucky; Albuquerque, New Mexico; Las Vegas, Nevada;  Raleigh and  Charlotte, North Carolina; Columbia, South Carolina; and, Richmond, Virginia.

These decisions were based on the ability to service those locations given the limited production capacity Blue Bell expects when it resumes operations.  Distribution centers typically service a 75 mile radius.

Blue Bell executives will be contacting area chambers of commerce to ask for their help for employees who have been laid off, and business owners who may have jobs available are encouraged to contact Blue Bell at 979-830-9831 or at jobs@bluebell.com.