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View Full Version : Anybody ever visited a bee packaging operation? I did...



fatscher
05-06-2009, 12:51 PM
I made a recent trip to Georgia, Reggie Wilbanks' operation in Claxton, Georgia, to pick up 375 packages of bees for several clubs in our Northern Virginia region. It was truly an education and a half.

Starting at the bee headquarters (Wilbanks Apiaries, Hagan, Ga) A crew of about 15 Mexicans, Hondurans, Bolivians and others south of the border (I didn't ask their nationality), load up in several trucks at 7 am and off we go down the dusty red roads of south Georgia, lined with Spanish moss-draped oaks, and tall slender Georgia pines. Amazingly there's little humidity at 7 am at 77 degrees. After what felt like an hour's drive (more like 10-15 mins) we arrived at a bee yard totally in the shade

The workers jumped out, led by two from Mexico, Gomez and Enrique, donned their folding hat veils, and lit their smokers. They all tightly grab a huge clump of pine needles off the ground in their fists, and light from the bottom with a lighter. Once the needles get ablaze, and without setting their clothes on fire, they stuff them down into the smoker. I never once saw them relight their smoker, for the next 2 hours we worked...it defied physics, but they did have the 11 incher smokers, so maybe that made the difference in keeping the fires going.

The 1st beeyard we visited was in pure shade, not dark shade but more shade than dappled, Spanish moss draping from oaks. It was surreal. I felt like I was in Brazil with so much Spanish spoken (yeah, I know for all you smart alecks out there they speak Portugese in Brazil -- there's a smarty pants in every bee blog, isn't there?) in an almost tropical setting. This bee yard had about 60 hives, each was a single deep painted white, with 9 drawn frames and a division board feeder in the 10 frame position---these feeders are made of wood & masonite, lined with tar in the inside. The hives have migratory covers and each sits on two cinder blocks.

Reggie has 80 bee yards like this with some hives numbering up to 75-80 in some yards. Our average shake was about 2 hives to make a 3.5 lb package of bees. Little Mac, the only non-latino employed by Reggie and who's been working for Reggie since Reggie took over the business from his dad years ago, can tell if a package as 3.2, 3.4, or 3.6 lbs of bees just be looking at it. They shake the bees to the bottom and if the top line of bees comes up just under the syrup can cross bar, then that's officially 3 lbs. The bees were shaken into the top hole of the boxes using a 3 ft tall fiberglass funnel fitted especially for the round hole in the tops of our packages. The workmen were able to balance a package onto the top of one foot, and "walk" from hive to hive with the funnel stuck into the hole. You can't drag the funnel with the box or else the funnel will come out. Very efficient.

The 15 or so latino workers were divided up into "pullers" and "locators." There were maybe 3-4 pullers, and 10 locators, to locate the queen, so she wasn't shaken into a hive. I guess 10 sets of eyes are better than fewer.

The pullers would pull the frames (around 5 or 6 or so) that looked most prime for shaking. The locators standing over the pullers' shoulders searching intently for mama and her huge golden abdomen. When located, a puller would grab mama in his hand while also handing frames, and hold on to her until he was done shaking, then he'd toss her back into the hive, restore the frames and top cover.

These pullers used their hive tools furiously, furiously scraping honey-saturated burr comb off the inside of the top cover and the top bars, and throwing it onto the ground into the Georgia sandy, pine-needle covered ground. The bees eat the honey out of the wax, returning into the hive. Then someone else comes along a day or two later and collected the sugar cookie sandy wax, yuck which is then melted down into these 5 gallon bucket size of beeswax cylinders that Reggie keeps in a 40ft ceiling high warehouse.

Ok, this next part is not for the faint of heart. Kids need to be sent to bed for this next part. I saw hundreds maybe close to a thousand nurse bees crawling on the sandy ground, who had been shaken into the boxes, and who missed the mouth of the funnel, confused where home was, never to return, who would eventually die from exposure. Remember nurse bees are youngsters, they've never flown outside the hive before, they don't know what the sunlit world is like. The flap their wings but can't get off the ground. In the ensuing massacre and fury of scraping burr comb off top bars, hundreds and hundreds of poor young nurse bees are sacrificed. It was really a pitiful site, if you have a soft heart. And there's nothing you can do, but watrch or turn away, that was the gory part of this operation.

I asked Reggie about CCD, (like so many average joes who know nothing about it ask me about it). Reggie said he experienced nothing like he had heard on the news. Reggie is a large man, soft spoken, Georgia drawl. He is very friendly but reserved in talk, he thinks before he speaks. He likes people, genuinely does. We wrote a check for over $20,000 dollars straight out to Reggie for the packages. Reggie has likely spent ~$120,000 in sugar syrup since Jan. A freighter truck full of HFCS costs somewhere around $25-$40,000 each delivery. Unsure how many gallons that is.

We went to the 2nd yard, and eventually ended shaking a total of 60 packages on Saturday, 315 other packages had been shaken on Thurs & Friday, and stored in a cooled room back at the warehouse kept 65 degrees to keep the bees from burning themselves up...any idea how much heat one package of bees can put out???

With speed and precision, those workers put the packages into our truck and trailer (an open trailer from Uhaul specially modified with plywood front, side and top panels to keep the bees from blowing in the 635 mile highway wind while also keeping them from overheating. We pulled out of Hagan, Ga at 10:57am eastern time, after leaving for the beeyard at 7:10 that morning. So it took almost 4 hours to go shake 60 packages of bees and get them loaded on to the truck and for us to leave town. Not bad.

ttruluck
05-06-2009, 01:36 PM
I keep a few hives in SC & I thought the article was very interesting,Thanks ttruluck

NorthALABeeKeep
05-06-2009, 02:19 PM
Interesting read. Well done. How long did it take to make the drive home?

fatscher
05-06-2009, 02:33 PM
Interesting read. Well done. How long did it take to make the drive home?

The drive should only take 10 hours but we had some, um, technical difficulties. We left Georgia at 10:57am Saturday May 2nd, and rolled into Arlington, VA (suburb of Washington, DC) at 10:11PM, so a little over 11 hours. That's a long trip when you're hauling over 1,500 lbs of bees on your back side. And that's just the weight in bees alone, I'd guess 375 cans of syrup in the packages would add maybe 400 more lbs.

The tech difficulties were as follows. Chain in the hitch came loose, but no disconnects, and the connections to power (tail lights) Since I was the driver this was my responsibility to hook those up and I forgot -- senior moment. After 500 miles of highway pavement those male electrical connectors were pretty worn, but we were able to get 'em working.

bnatural
05-06-2009, 03:25 PM
Now THAT was an interesting read.

Thank you.

Bill

p.s. I could probably do the math, based on the info you provided, but did Reggie tell you how many packages he does a year? Sounds like it would be close to 3,000 (okay, I did do the math).

fatscher
05-06-2009, 03:39 PM
I could probably do the math, based on the info you provided, but did Reggie tell you how many packages he does a year? Sounds like it would be close to 3,000 (okay, I did do the math).

I'm not sure what information I provided that led you to that answer. 60 packages in 4 hours x 2 times per day x 5 days x ~30 weeks a year...???

That number may vary. I cannot say what Reggie's volume is.

But I will say this...there's not a nicer man that I've met in the beekeeping world. I mean there are a LOT of nice people in beekeeping, but Reggie is just super nice, and there's nothing he HATES more than having to tell customers their bees are going to be late because of Mother Nature.

thelorax
05-06-2009, 04:23 PM
very interesting post, thanks

indypartridge
05-06-2009, 06:39 PM
Does your bee club have a newletter? Sounds like you have the next issue half-written!
Nice write-up. Thanks for posting.

bnatural
05-06-2009, 06:57 PM
I'm not sure what information I provided that led you to that answer. 60 packages in 4 hours x 2 times per day x 5 days x ~30 weeks a year...???

80 yards x 70 hives / 2 shakes per box = 2800, if he only does it once using all his hives.

Bill

SlickMick
05-06-2009, 08:34 PM
That must have been a great experience for you Fatscher to see how commercial operations deal with the process of supplying packages. I imagine that there are some operations over on this side of the pacific that do something similar but from my limited experience in south east Queensland nucs seem to be the go

Mick

fatscher
05-07-2009, 09:37 AM
80 yards x 70 hives / 2 shakes per box = 2800, if he only does it once using all his hives.

Yeah theoretically, you could be right.

Problem is one big VARIABLE -- Mother Nature!

I lived near Macon Georgia from 1992-1995. In those 3.5 years I grew to learn that Georgia weather is just as crazy and unpredictable as any other part of the USA, or world, for that matter.

Reggie Wilbanks, as a businessman, must give his best assessment of when packages will be ready for pick-up. Customers demand this of him. After all, we all have our own individual schedules, right? Some customers are very understanding, and others are just down right ornery and refuse to understand. Then there's customers between those extremes. Reggie does the best he can to manage expectations. But often, Mother Nature throws poor Reggie "under the bus." So now he's having to explain to people who aren't flexible that bees aren't ready. Reggie cannot afford to trash his own business meeting ALL customers exact demands 100% of the time. He'd be out of business in 24 hours because he would have shaken all of his "capital" into packages and shipped it off for hobbyist Jane Doe to enjoy in her back yard.

Some days, it takes 10 hives to shake to make a package. Other days you can make 5 packages out of 1 hive!!! It all depends on how the bees have built up, which in and of itself depends on how the weather has treated the bees.

Also Reggie says he doesn't visit any one yard to shake bees out of those hives in that yard, any more frequently than once every two weeks. So that may be more math to allow better understanding of his volume. Reggie supplies bees to a wide wide range of customers---from the hobbyist with a hive in the backyard, to the major huge commercial keepers.

bnatural
05-07-2009, 07:45 PM
Gotcha. I was just trying to get a sense of scale. One assumption I made was that they could do multiple waves of packages. Whatever the number, it's a lot.

Thanks,

Bill

tecumseh
05-08-2009, 05:57 AM
bnatural writes:
80 yards x 70 hives / 2 shakes per box = 2800, if he only does it once using all his hives.

tecumseh:
as I think you have figured out during an acceptable to good year you can shake bees from a robust hive twice on about a two week + schedule.

nice description... process will somewhat vary depending on location.

if you are old enough to remember the days of the sears and roebuck farm catalogue you may recall that you could order packages from sears. during the mid 1980's I worked for the commercial concern that had the contract with sears. if you acquired bees in this manner during this period I quite likely helped shake and scale the package.

tecumseh
05-08-2009, 06:06 AM
a snip:
So it took almost 4 hours to go shake 60 packages of bees and get them loaded on to the truck and for us to leave town. Not bad.

tecumseh:
of course from a purely economic angle price of the end product has a great deal of bearing on it's economic viability.

the math would suggest that the productivity of the labor here is 1 package/hr/hand.

fatscher
05-08-2009, 11:42 AM
of course from a purely economic angle price of the end product has a great deal of bearing on it's economic viability.

the math would suggest that the productivity of the labor here is 1 package/hr/hand.

Actually I should clarify... ...because part of those 4 hours included loading 315 OTHER packages onto our trailer and truck, getting the shoring and the cubing and spacing right so the bees didn't burn up in their own cluster heat. To fill just the 60 packages probably took about an hour and a half, then another half hour to drive back to HQ and load our vehicle. I know Reggie was shouting out, "Apurate! Apurate!!" to the workmen.

bnatural
05-08-2009, 01:04 PM
if you are old enough to remember the days of the sears and roebuck farm catalogue you may recall that you could order packages from sears. during the mid 1980's I worked for the commercial concern that had the contract with sears. if you acquired bees in this manner during this period I quite likely helped shake and scale the package.

Growing up in suburban NJ (think 'The Wonder Years' TV show), I never saw a farm catalog. But, every year we got a Burpee catalog, and they used to have bees and a 'starter kit' for sale on the last few pages of the catalog. As a kid I used to fantasize about keeping bees, but had to settle for an ant farm and a few terrariums.

Guess I am just living out a childhood fantasy......

Bill

fatscher
05-11-2009, 08:05 AM
Thank you to "winevines" for uploading these to YouTube!

YouTube Videos of Keith's trip to Willbanks and Packing Bees

http://www.youtube.com/watch?v=DrAsVtfcQEU

A few other shorter videos from the same trip can be seen here

http://www.youtube.com/user/PWRBeekeepers

WJensen
05-11-2009, 08:47 AM
Tecumseh, I was one of those who ordered bees through the Sears catalog. Sears was great. You could also order chickens, or ducks too.

This was my first colony, in 1981. I ordered the starter kit. The kit came probably from Dadant's, as it featured their Durogilt foundation. Got the kit, assembled it from instructions. Assembled frames. Painted it (white naturally). When the package arrived, I was at work, so the wife had to go down to the post office and pick it up. As she describes it, she rode home in her Buick with 10,000 angry bees in the seat beside her.:D

Well, it's funny the way she tells it. But she has not had anything to do with bees since. Except to eat honey of course.

I would be interested in where the bees came from, though I think I know. PM me if you would like to reveal.

Wade

pbwhite
05-11-2009, 03:29 PM
Great trip report, and equally great videos to put some pictures with the words! Thanks for sharing.

Keith Jarrett
05-11-2009, 04:44 PM
Thank you to "winevines" for uploading these to YouTube!

YouTube Videos of Keith's trip to Willbanks and Packing Bees

http://www.youtube.com/watch?v=DrAsVtfcQEU
]

My god, That's got to be the most inefficient system I ever saw, are you sure that's in the USA?

KQ6AR
05-11-2009, 07:33 PM
Thanks for the nice story.



Another thing to consider is that some of the yards may be for queen breeding, & some of the hives may be drone mothers.

80 yards x 70 hives / 2 shakes per box = 2800, if he only does it once using all his hives.

Bill

mgmoore7
05-12-2009, 08:18 AM
Thanks for sharing the videos and your experience.