Northern Cement Corporation

Labayug, Sison, Pangasinan

Date Visited: January 20, 2015

I.INTRODUCTION

MISSION-VISION
Promote the cement industry as a key partner in contributing to infrastructure
development and economic growth; an effective advocate for all members of the
Philippine cement industry; a responsive organization in addressing industry-wide
issues; a foundation for stronger, more stable relationships among all stakeholders of
the Philippine cement industry.
An organization that is committed to make the cement industry a growing and
sustainable partner in nation building, by ensuring that high quality cement is produced.

CORPORATE PROFILE

Northern Cement Corporation is a cement industry that offers the market a variety of
Portland cement products that are widely used as general infrastructure material.

TECHNICAL DESCRIPTION

Northern Cement Corporation is situated at the extreme south-western flanks of

Cordillera mountain range. The area is characterized by low flat lying alluvial plains and
eventually rises towards the north and east exhibiting a gently rolling to moderately
rugged terrain. Rolling hills occupy mostly the western and southern portion of the
company which is at the foothills of the Cordillera and sliced in between by the Aloragat
River. High relief starts from the cement plant abruptly rising to the north and east
reaching an elevation of about six hundred (600) meters above sea level. On top of the
limestone deposits forms a plateau-like terrain with an average altitude of three hundred
(300) meters. The companys cement plant complex is twenty five (25) kilometres away
from Urdaneta City and could be reached by any motor vehicle following the Manila-
Laoag national road up to Barangay Paldit junction in Sison, Pangasinan. A six (6)
kilometres stretch due east reaches the cement plant complex.
 Northern Cement Corporation was incorporated on February 10, 1967, on the same
year, Mr. Eduardo Danding Cojuangco, Jr., showed the first ray of hope and blessings
to the people of barrio Labayug, Sison, Pangasinan by transforming this idle forested
land into an industrialized community. Under his leadership and guidance, the Atlantic
Gulf & Pacific Company of Manila (AG&P) was commissioned to construct what was to
become the largest and the most modern cement plant in the country during that time. A
team of engineers arrived in Sison, Pangasinan and taught the barrio folks whose only
skills is to till the soil; the precious knowledge of cement manufacturing that eventually
gave them livelihood without leaving their home town. The year 1969 saw the rise of
Northern Cement Corporation as the Countrys producer of quality cement. On the 6th
of December 1969, the first smoke was emitted from its chimney stack signifying the
firing of the Rotary Kiln. Twenty-one days later, the plant was blessed and inaugurated.
The first bag of cement was produced on January 28, 1970 and from then on, the
domestic markets have known Northern Cement as a household name in concrete
construction. The company also engaged in exporting its products from 1970 to the 80s
satisfying customers in India, Bangladesh, Kuwait, Bahrain, Saudi Arabia, China and
other countries in the region. An undeniable proof that quality product defies distance.
The company added to its mantle the certification on ISO 9002:1994 on September 2,
1999 and on October 25, 2002, the ISO 9001:2000, in its commitment towards
consistent product quality. On January 19, 2006, Northern Cement Corporation focused
on strengthening further its existing Quality Management System by including ISO
14001:2004 and OHSAS 18001:1999 for environmental protection and
occupationalsafety & health, respectively.

PLANT FACILITIES
1. Impact Crusher- machine designed to reduce large rocks into smaller rocks,
gravel, or rock dust.
2. Rotary Dryer- a type of industrial dryer employed to reduce or minimize the
liquid moisture content of the material it is handling by bringing it into direct
contact with a heated gas.
3. Hammer Mill Control- suited for size reduction
4. Raw mill- equipment used to grind raw materials into "raw mix" during the
manufacture of cement.
5. Homogenizing Silos- continuous and work with air-agitation and with various
extraction systems. The bottom consists of a total of 12 segments (outer ring),
4 quadrants (mixing chamber) and final discharge chamber (tunnel), all
equipped with porous aeration boxes which can be aerated independently by
air from blower(s).
6. Rotary Packing Machines- ideal for a wide variety of bag styles and ranges as
well as offers quick changeovers.
7. Rotary Kiln- a pyro processing device used to raise materials to a high
temperature (calcination) in a continuous process.
8. Clinker Cooler- clinker has a temperature of over +1300 C (+2372 F) after
leaving the rotary furnace and must be cooled down to a temperature of about
+200 C (+392 F) for intermediate storage.
 9. Gas Conditioning Towers- used to reduce the temperature and to increase the
moisture level of the dusty exhaust gas from the kiln, before it is passed
through the bag house and ESPs.
10. Static V-Separator- cyclone a simple mechanical device commonly used in
the grinding circuits to remove relatively large particles from gas streams.
11. Cement Ball Mill- equipment used to grind the hard, nodular clinker from the
cement kiln into the fine grey powder that is cement

II. MANUFACTURING PROCESS

RAW MATERIALS

Portland cement is manufactured from lime-bearing materials, usually limestone,

together with clays, shale, or blast-furnace slag containing alumina and silica, in the
approximate proportions of 60% lime, 19% silica, and 8% alumina, 5% iron, 5%
magnesia, and 3% SO. Some rocks, called cement rocks, are naturally composed of
these elements in approximately suitable proportions and can be made into cement
without the use of large quantities of other raw materials. In general, however, cement
plants rely on mixed materials.
In the manufacture of cement the raw materials are ground together, the mixture
is heated until it fuses into a clinker, and the clinker is ground into a fine powder. The
heating is usually accomplished in rotary kilns more than 150 m (500 ft.) long and 3.7 m
(12 ft.) or more in diameter. The kilns are slightly tilted from the horizontal, and the raw
material is introduced at the upper end, either in the form of a dry rock powder or as a
wet paste composed of ground-up rock and water. As the charge progresses down
through the kiln, it is dried and heated by the hot gases from a flame at the lower end.
As it comes nearer the flame, carbon dioxide is driven off, and in the area of the flame
itself the charge is fused at temperatures between 1540 and 1600 C (2800 and 2900
F). The material takes approximately 6 hours to pass from one end of the kiln to the
other. After it leaves the kiln, the clinker is cooled quickly and ground, and then
conveyed by a blower to packing machinery or storage silos. The amount thus produced
is so fine in texture that 90 % or more of its particles will pass through a sieve with 6200
openings per sq. cm (40,000 per sq. in).
In a modern kiln, 45 kg (about 100 lb.) of raw material will make 27 to 30 kg
(about 59 to 66 lb.) of cement. The weight lost is largely carbon dioxide and water. Kilns
usually burn coal in the form of powder and consume about 450 g (about 1 lb.) of coal
for about every 900 g (about 2 lb.) of cement produced. Oil and gas are also used.

PROCESS FLOWCHART/EQUIPMENT
 FINISHED PRODUCT
The finished products are then subjected to special packaging according to what
type of Portland cement the company has to offer. Northern Cement Corporation is
producing 3 types of Portland cement which is Type I (regular Portland cement), Type I-
P with Philippine tuff cement, and Type N (Master palitada masonry cement). The
packaging material they mainly use is paper which also has special specification due to
where they are being sold, this also is one of their marketing strategies.

III. QUALITY CONTROL PROCEDURES

IN-PROCESS TESTING
The limestone gathered in their quarry area is being tested according to its purity at
their Quality Assurance lab, which are done by their chemical engineers. The more
impure the limestone is the best raw material to use.

FINISHED PRODUCT
The finished product is then subjected to physical test and tests on cement.
Physical test includes fineness of the powdered form of cement, setting time,
soundness of the hardened cement, and compressive strength. On the other hand, test
on cement includes loss in ignition, silicon dioxide content, ammonium hydroxide
content, calcium oxide content, magnesium oxide content, sulfur trioxide content, ferric
oxide content, aluminum oxide content, and insolubility of residue. These tests are done
in their laboratory for safety measure and to keep track of the quality of the products
they are producing.

IV. WATER AND WATER TREATMENT

Northern Cement Corporation doesnt have a waste water treatment because the
company uses dry process and according to our tour they use minimal water.

V.ROLES/JOB OF CHEMICAL ENGINEERS

QUALITY CONTROL
Monitors the manufacture of their product to ensure that it meets specifications.
Also, tests materials to determine how they change over time.

PROCESS ENGINEER
They provide technical support staff and troubleshoot processes in the facility and
works closely with operators to get feedback to determine how to avoid shut down.

DESIGN
Designs and maintains plants and processes that are safe for workers and
communities

RESEARCH AND DEVELOPMENT

Seeks out new and more efficient ways of using and producing existing products.

WASTE WATER TREATMENT

N/A

VI. RECCOMENDATION

VII. APPENDIX
www.ncc.com.
 NATURES SPRING

Cagayan Valley Road,Guiguinto Bulacan

Date Visited: January 21, 2015

HISTORY
PHILIPPINE SPRING WATER RESOURCES, INC. (PSWRI), a 100% Filipino owned
and managed company. It is a manufacturer and distributor of NATURE'S SPRING
bottled drinking water products for both local and international markets.
The production and distribution of purified, safe and affordable drinking water was
conceived by its President and Chief Executive Officer in 1991 when the need was so
magnified after super typhoon Ruping (the Philippine name for internationally christened
typhoon Mike) hit Cebu, Philippines sometime in November, 1990. The destruction it
had caused brought unimaginable havoc and paralyzed the whole island. There was no
electrical power which also caused the disruption of the water distribution. The
populaces were only relying on unsafe deep well water sources. This resulted on an
outbreak of water bound diseases like El Tor, Cholera, Diarrhea and Hepatitis A.
The need for a safe drinking water was an immediate concern. The demand for safe
bottled drinking water products was emphasized. Unfortunately, these where not readily
available in the market. There were only a handful local brands and few expensive
foreign bottled water. Stocks were very few and in some cases no supply at all.

I. INTRODUCTION

VISION-MISSION
To build a strong Brand Equity, with emphasis on consistently providing the Best Quality
products with the Highest Standards of Safety and Purity at very Competitive Pricing .
To be able to understand the consumers needs and extend Service that is Efficient and
Flexible, thereby acquiring a dominant status in the market. To be on the forefront of
Technology Acquisition and Manpower Development to keep up with market change.
The challenge is not be stuck with words, but proceed unto decisive responsible action,
and go beyond our boundaries to accomplish our Vision.
CORPORATE PROFILE

Corporate Social responsibility in education and tourism comes in a form of opening

plant gates to educational tours & corporate bench marker equating likewise to
transparency and confidence in quality.

TECHNICAL DESCRIPTION
Our brand name NATURE'S SPRING PURIFIED and DISTILLED BOTTLED DRINKING
WATER comes in two types of packaging, the NATURE'S SPRING Non-Returnable
Bottles (NRB) which comes in several sizes, and the NATURE'S
SPRING PURIFIED and DISTILLED Five Gallon Bottles (NS5G) bottles, which are
available with different types of water dispenser units. NATURE'S SPRING FLAVORED
WATER available in four flavors, Apple, Grape, Lemon and Honeydew is also available
in the market. Raw water is processed and purified using state-of-the-art processing
equipments and technology. Internal PSWRI laboratory tests, and external regular
monitoring and inspection by the Bureau of Food and Drugs (BFAD) & the Philippine
Bottled Water Standard proves the company's strict and meticulous eye for quality
control & utmost norms PSWRI passed the very strict standards. PHILIPPINE
SPRINGWATER RESOURCES, INC. (PSWRI) also holds the distinction of being the
only HALAL certified bottled drinking water product in Mindanao. Having received the
certificate of accreditation from Office of the Muslim Affairs (OMA).

PLANT FACILITIES
A fully automated machine that is complete with FILTERS, RINSER, FILLERS,
and CAPPING ENGINES created by Krones (Germany).

II. MANUFACTURING PROCESS

RAW MATERIALS
1. Raw Water from mountain spring water located at Brgy. Corte, Carmen,
Cebu
2. For their bottle containers, they are using resins that are then blown to attain
the desired shape of specific containers for each kind of water they are
producing.
The processed water is then PACKED in PSWRI newly manufactured PET bottles
using state-of-the-art highly automated lines.
 PROCESS FLOWCHART/ EQUIPMENT

FILTRATION WATER FILTRATION

(5micrometer) SOFTENING (1 micrometer)

REVERSE MICROFILTRATI CARBON

OSMOSIS ON (multi-layer 1 FILTRATION
micrometer)

MICROFILTRATIO OZONATION RE-OZONATION

N (0.03 micrometer) (30 seconds)

FILLING AND BLOWING OF MICROFILTRATIO

CAPPING RESINS N (0.01 micrometer)

LABELING,
PACKING AND
DISTRIBUTING

FINISHED PRODUCT
1. PURIFIED WATER- Nature's Spring Drinking Water is purified and processed
through the latest state-of-the-art technique that includes carbon filtration,
water softening, reverse osmosis, microfiltration, and ozonation to guarantee
its quality and potability.

It comes in 7 different Non Returnable Bottles:

350 ml 1L 4L 10 L
500 ml 1.5 L 6L

2. DISTILLED DRINKING WATER- Nature's Spring Distilled Drinking Water is a

purified water processed through the use of the latest state-of-the-art
technique in water purification that includes carbon filtration, purification,
water softening, reverse osmosis, distillation, hyper filtration, and ozonation to
ensure its purity.
It comes in 7 different Non Returnable Bottles:
350 ml 1L 4L 10 L
500 ml 1.5 L 6L
 3. ALKALINE DRINKING WATER - Nature's Spring PH 9 Drinking water is a
bottled water process through state-of-the art water treatment technology
such as the modern filtration, purification, ozonation to guarantee its quality
and water ionizer machine to produce water higher in ph via the scientific
process of electrolysis.
It comes in 7 different Non Returnable Bottles:
350 ml 1L 4L 10 L
500 ml 1.5 L 6L

4. BUBBLE BOTTLE - is a purified water and processed through the latest

state-of-the-art technique, that includes carbon filtration, water softening,
reverse osmosis, microfiltration, and ozonation to guarantee its quality and
potability. It is packed in the new 300 PET disposable bottle.

5. CRYSTAL TUBE ICE - is a hallow and crystal ice made of purified drinking
water. It is sold by 3 kilos per pack.

6. NS5G - is a purified water and processed through the latest state-of-the-art

technique, that includes carbon filtration, water softening, reverse osmosis,
microfiltration, and ozonation to guarantee its quality and potability. It is
packed in a 5 gal PET refillable bottle.

7. Customized Packing - special packaging using Nature's Spring Bottle and

label with customer's logo/brand name.
Toll Packing special packaging using generic bottle with customer's own
name or brand.

8. Bai Products- is a premium distilled drinking water bottled for high end
consumers and is packed in a 500 ml PET bottle.

III. QUALITY CONTROL PROCEDURES

IN PROCESS TESTING
The initial step involves water passing through a FILTRATION which has about 5
um in diameter to remove large particles and sediments that come from natural
groundwater.
WATER SOFTENING is the next stage. The process starts with the removal of
hardness in water usually Ca (Calcium) and Mg (Magnesium) compounds. Basically, the
softener works by an ion-exchange process whereby hard ions in the water are
exchange for soft ions (usually sodium) in the salt bed of the softener. It is advisable to
remove hard minerals prior to distillation to prevent scaling of the still unit. The benefits
of the softening include reduced maintenance and greater efficiency of the still and
distillation unit.
 Water will pass through FILTRATION process using 1 micron (absolute) filter bag to
remove suspended solids from the water. Sediments and bacteria more than 1 micron
meter in diameter will be removed.
CARBON FILTRATION is followed a method of removing organic compounds,
chlorine, and their associated odors and taste. This process is used to removes
particles and at the same time improves water taste, color, and smell.
The next step is Multi-layer Filtration bag with 1 micron porosity to filter out fine
suspended solids, dirt, some bacteria present in the water.
Then the PURIFICATION process is followed using the REVERSE OSMOSIS UNIT.
Using this process, water is forced under pressure through membranes which removes
virtually all dissolved minerals. It generally rejects 98% of dissolved salts (ionic
contaminants), and 100% dissolved organic in water. Reverse osmosis water is second
to distilled water. So what comes out in the reverse osmosis unit shall be WATER In its
PUREST FORM.
Next stage is the MICROFILTRATION using about 0.03 micron meter diameter in its
pore size. This is used to remove contaminated bacteria and finer particles more than
0.03 microns in size.
The final stage in the purification of water is disinfection using OZONATION. Water
is sterilized using Ozone Gas. A form of oxygen to disinfect the water. Ozone is a
powerful oxidizer which is capable of getting rid of all microorganisms found in water. It
can remove odor, color, and turbidity in water. It is 3,500 times faster than chlorine in
killing bacteria. The advantage of using ozone is that, it reverts back to oxygen in a very
short period of time without adding any off-flavors to the water.

PARAMETERS AND PROCEDURES

The 3 stages of the classic NS RO water filter system are:

Stage 1: The water first enters a 5 micron pre-filter which filters out the sediment and
particles to protect the RO membrane.

Stage 2: The large semi-permeable reverse osmosis membrane that efficiently remove
dissolved solids such as iron ,lead, cadmium, and volatile chemicals such as chlorine
and fluorine and their by-products.

Stage 3: The last filter is a solid-block activated carbon filter that removes traces of
pollutants.

IV. WATER AND WASTE WATER TREATMENT

 The companys product is water so they just treat the water directly to
become potable. For the bottles that are rejected from the filling line it
is just disposed according to our tour guide.

V. ROLES/JOB OF CHEMICAL ENGINEERS

Quality Control
In the quality control section, chemical engineers monitor the manufacture of
Natures Springs products to ensure that it meets specification. Also, chemical
engineers test materials to determine how they perform overtime.
Process Engineer
Process engineers in Natures Spring monitor every processes and procedures
involve in the manufacturing of their products. They are responsible for keeping the
plant running efficiently, especially in the treatment of drinking water.

Design
The chemical engineers in this section are responsible for the design of their
equipment most especially in the making of their bottles. They also institute scale-up
and scale-down processes including appropriate changes to equipment design and
configuration.
Research and development
They optimize day-to-day processes while considering environmental and supply
variables.
Also, chemical engineers maintain engineering documentation, with emphasis on
compliance with engineering codes and standards and oversee production environment,
and track metrics like temperature, flow rate and electricity usage. They also propose,
design, and oversee solutions for chemical process issues.
Waste water treatment
Chemical engineers here design lift stations, water wells and pump stations. They
oversee the pre-design and construction of new equipment and analyze the amount of
power consumed during the storage and treatment of wastewater. Chemical engineers
also work with modeling software to document the wastewater treatment process.
VI. Recommendations

VII. Appendix
.
http://ozarkwaterandair.org/products/natures-spring-counter-top-reverse-
osmosis-unit
http://naturespring.com.ph/
GARDENIA

Gardenia Center, Star Avenue Laguna International Industrial Park

Mamplasan, Binan, Laguna
Date Visited: January 22, 2015

I. INTRODUCTION

Our Vision
 To become the premier company in the baking industry and the related food and
beverage industry, known and emulated for our best quality products that delight the
consumer. It is the pride of every employee, investor, trade partner and stakeholder.

Our Mission

To serve consumers with the best quality assortment of great-tasting bakery and
related food and beverage products, with world-class manufacturing facilities and an
efficient nationwide distribution network, thereby providing a fair return on shareholder
investments.

Corporate Profile

Gardenia Bakeries Philippines is committed to providing the Filipinos with quality

bread products to ensure consumer delight. Furthermore, Gardenia aims to achieve
positive impact to the community through corporate social responsibility initiatives.

Key CSR efforts focused on health, education, social aid and environmental
concerns. Specific examples are programs and initiatives in promoting healthy eating
paired with an active lifestyle; providing learning assistance and educational activities;
responding to the needs of the community; ensuring sustainable environmental
practices; and providing employee welfare initiatives.

NUTRITION AND WELLNESS CAMPAIGN

To help address the problems of elementary school children coming to school

hungry, which result to low performance in class, Gardenia launched the Nutrition
Assistance Program (NAP) with various public schools. The program aims to educate
the less privileged school children about the importance of eating a well-balanced
breakfast meal, thereby lessening malnutrition amongst public elementary schools in
Luzon, and hopefully, in the entire country. In 2013, almost 6,000 students benefited
from this health advocacy initiative which included a feeding program.

GIVING BACK TO THE COMMUNITY

Gardenia Bakeries has been the top choice of Filipinos when it comes to bread and
bakery products for fifteen years. As a way of sharing the success of the company and
expressing its gratitude, Gardenia conducts and facilitates various philanthropic
activities and encourages corporate social responsibility programs which include
calamity donations, entrepreneurship, and sponsorships.

CARING FOR THE ENVIRONMENT

One of the commitments of Gardenia is to help mitigate negative environmental

impact through sustainable practices that promote environment protection and
conservation.
 Technical description

Gardenia Philippines is a bread manufacturing company that offers wide array of

superior bakery products including white, wheat and health breads, flavored loaves,
pandesal and snack items like snack cakes, muffins and toasts. Gardenia breads are
known for their good taste, freshness, softness, oven-baked aroma and nutritive value.
The popular Classic White Bread is cholesterol free and bromate free, has zero trans-
fat, and is vitamin and mineral fortified, exceeding DOH recommendations. Its product
slogan "So good...you can even eat it on its own" best describes the product benefits.

Gardenia, being a consumer-focused and branded food company, is singularly

driven in delivering superior consumer value through providing consumers with superior
products. The Gardenia trademark means value and is respected all over Asia.

Gardenia has been awarded with International Organization for Standardization

ISO 9001: 2000 certifications from 2003 to 2009 and has now upgraded to ISO
9001:2008 in compliance with Quality Management System and certification for product
quality excellence. This assures that consumers only get the highest quality products in
the market. Moreover, Gardenia is HACCP (Hazard Analysis and Critical Control
Point) certified since 2003 to presentproof of the companys adherence to the
systematic approach in the identification, evaluation, and control of food safety
standards. From 2004-2010, Gardenia was accorded super brands status by Super
brands Ltd., an independent authority and arbiter on branding. This, on the other hand,
re-affirms that Gardenia has met the stringent criteria of market dominance, longevity,
goodwill, customer loyalty and overall market acceptance. Another notable award is the
Annual National Consumers Award (ANCA) as the Outstanding Bread
Manufacturer for five straight years.
Plant Facilities
1. Giant Silo
2. High-Tech Automation Machine
3. Oven
4. Twin Spiral Cooling Towers
5. High-Speed Bagging Machine

II. MANUFACTURING PROCESS

Raw Materials
1. Wheat flour,
2. Sugar
3. Salt
4. Fermentation agents

Process Flowchart/Equipment
INGREDIENT PREPARATION SPONGE DOUGH MIXING
(70 TON CAPACITY) MIXING
MOULDING INTERMEDIATE MOULDING INTERMEDIATE
ROUNDING PROOFING PROOFING

FINAL DEPANNING, PACKING METAL

PROOFING COOLING, DETECTORS

PACKING
DELIVERY
DISTRIBUTION
CENTER G-
LOCKING

Finished product
1. White Bread
o Classic White Bread Regular Slice
o Classic White Bread Thick Slice
2. Health Bread
o High Fiber Whole Wheat Bread
o High Fiber Wheat Raisin Loaf
o Slim n Fit Wheaten Bread
3. Flavored Bread
o Chocolate Chip Loaf
o California Raisin Loaf
4. Pandesal and Buns
o Premium Pandesal
o Soft Delight Pandesal
o Whole Wheat Bun
5. Snacks
o Twiggies
o Cream Roll
o Fun Bun
o Muffin
6. Toast
o Butter Toast
o Toast - Garlic

Each finished product is G-Lock sealed indicating the day the bread was baked.
1. Monday- Tan
 2. Tuesday- Orange
3. Wednesday- Yellow
4. Thursday-Blue
5. Friday-Green
6. Saturday-Red
7. Sunday-White

III. QUALITY CONTROL PROCEDURES

In-Process Testing
After the bread comes down from the cooling towers, QA will inspect the size,
quality, and taste of the product. This inspection is done by batch, if one from
each batch is rejected the whole batch is rejected.

Finished Product
To ensure product is safe the finished product passes through a metal detector that
checks if whether the product contains metal contaminants.

IV. WATER AND WASTEWATER TREATMENT (ECOLOGY AND

ENVIRONMENT)

Gardenia strictly implements recycling and waste segregation programs. The

company also uses liquefied petroleum gas in its baking process, and a Waste Water
Facility that treats water before it is discharged into the sewers. All delivery trucks
undergo regular maintenance to reduce air pollution. Gardenia participated in a tree
planting activity in Cebu in cooperation with the Pollution Control Association of the
Philippines Central Visayas, in support of the National Greening Program. An initial 100
trees were already planted out of the targeted 1000 trees within one year.

V. ROLES/JOB OF CHEMICAL ENGINEERS

Quality Control
The chemical engineers in quality control ensure that the products they produced
are of high quality. Also, they make sure that their products are into the standards. For
example, the loaf breads must have a particular taste and softness. This is being
confirmed and tested in the quality control section by chemical engineers.
Process Engineer
Chemical engineers as process engineers provide technical support, if possible, to
their staff. And because Gardenia has a continuous process in making their loaf breads,
it is necessary that someone troubleshoots processes in the facility.
Design
Chemical engineers here are involve in the design of the equipment and may also
be involve in the design of the package of their products. They are designing plant and
equipment configuration so that those can be readily adapted to suit the product range
and the process technologies involved, taking environmental and economic aspects into
account.
Research and development
There are many bread manufacturing companies and this means many competitors.
For Gardenia, the roles of chemical engineers in research and development section are
to ensure that the products remain competitive in the market. Also, chemical engineers
here develop new tastes and standards for their breads and other products to be able to
stand out against other companies.
Waste water treatment
Chemical engineers in this section of Gardenia provide tests for the treatment of the
companys wastewater. They are also responsible for monitoring the systems with
regards to the processes of the treatment.
VI. Recommendations

VII. Appendix
http://www.scribd.com/doc/138081850/Gardenia-Breads#scribd
http://www.gardenia.com.ph/index.php/about-us/52-about-us-the-
company.html
 PAG-ASA STEEL CORPORATION

408 Amang Rodriguez Ave., Bo. Manggahan, Pasig City

Date Visited: January 23, 2015

History
Pag-asa Steel was founded by Mr. Francisco Tong in 1948. It was established in 1964
to manufacture reinforcing steel bars for domestic construction market coincided with
the governments program to accelerate Philippine industrialization and economic
growth.

I. INTRODUCTION

MISSION-VISION
To excel as a competitive manufacturer and supplier of high quality rebars, and thus to
profit and grow, and contribute to national development.

Pag-asa Steel shall be the leading steel company, preferred for excellence, integrity and
reliability.

CORPORATE PROFILE

PAG-ASA STEEL is committed to provide products and services that offer superior
value to its customers by:

Interacting closely with our customers to ensure that we address and

satisfy their present and future product and service needs;
Maintaining a consistent superior level of product quality through
conscientious adherence to pertinent quality standards, and the use of
appropriate technologies; and
Enhancing employee involvement for a sustained commitment to
quality through strict adherence to the established quality management
system, as well as by keeping our workforce updated on technological
and market developments and customer feedback.

Pag-asa Steel Works, Inc. also known to the local market as Pag-asa Steel - is one
of the largest producers of concrete-reinforcement steel bars in the Philippines today.

Established in December of 1964 by Mr. Francisco S. Tong, an industry pioneer whose

work in the Philippine steel industry began in 1948, the company has built up a solid
reputation for superior quality, good service, and fair prices.

Pag-asa Steel supplies to a wide range of construction projects. Its bars are found in
low-cost housing, private residences, luxury condominiums, commercial and industrial
projects, high-rise buildings, schools, hospitals, bridges, highway over-passes and
viaducts, dams and power stations, tunnels, airports, seaports, aqueducts,
telecommunication sites, and other public infrastructure. Its plant site is located in Barrio
Manggahan, Pasig City.

TECHNICAL DESCRIPTION

Pag-asa Steel Works, Inc. also known to the local market as Pag-asa Steel -
is one of the largest producers of concrete-reinforcement steel bars in the
Philippines today.

Pag-asa Steel supplies to a wide range of construction projects. Its bars are
found in low-cost housing, private residences, luxury condominiums, commercial
and industrial projects, high-rise buildings, schools, hospitals, bridges, highway
 over-passes and viaducts, dams and power stations, tunnels, airports, seaports,
aqueducts, telecommunication sites, and other public infrastructure.

PLANT FACILITIES

1. FURNACE

2. COOLING TOWER

3. COOLING BED

4. BUNDLING MACHINE

5. UNIVERSAL TESTING MACHINE

II. MANUFACTURING PROCESS

RAW MATERIALS

MAGNETITE IRON ORES

PROCESS FLOWCHART/EQUIPMENT
 FINISHED PRODUCT

Pag-asa Steel produces plain as well as deformed steel bars, the latter
popularly called rebars, in standard sizes with lengths between 6 to 12 meters
and in Grades 230, 275, and 415 as specified in the Philippine National Standard
PNS-49:2002. Customized cut-and-bend services may also be offered.

III. QUALITY CONTROL PROCEDURES

IN-PROCESS TESTING

The Companys testing laboratory performs physical, mechanical, as well as

chemical tests - is geared primarily to service their internal requirements.
Nonetheless, the company also services external clients on a commercial basis.
 This however is done strictly subject to equipment availability, prior request, and
on a pre-arranged basis. As a third-party lab, they accept rebar and round bar
specimens - and, on occasion, plate specimens too - for physical and mechanical
testing, and/or chemical analyses.

The company has a machine that checks the strength, tolerance, and weight of
the bars. A bar is inserted to a machine and the machine compresses the bar
until it breaks. The reading result is directly directed to the computer that is
connected to the machine.

PARAMETERS AND PROCEDURE

The bars are checked through this GRADES AND

S P E C I F I C AT O N S

The three grades under this specification namely, Grades PNS 230, 275, and 415 trace
their roots to ASTM specifications. And the terms Structural, Intermediate, and High-
tensile originated from earlier versions of ASTM-A615 but remained unchanged in
deference to custom and familiarity among users. The table below provides a handy
reference as to the common understanding in the market regarding these grades.

ASTM vs
Popular Nomenclature Typical Application
PNS Codes
Grade 33 /
Structural Grade Low-rise Buildings and Low Loading Conditions
PNS 230
Grade 40 /
Intermediate Grade Medium-rise Structures / Infrastructure Work
PNS 275
Grade 60 /
High-Tensile Grade Medium & High-rise Structures / Infrastructu
PNS 415

The standard sizes that the Company manufactures and sells are as follows: 10mm,
12mm, 16mm, 20mm, 25mm, 28mm, 32mm, and 36mm. For special orders, it can also
make 40mm and 50mm bars.

Because variation in cross sectional area occurs during hot rolling, a corresponding
variation in linear weight is to be expected. For this reason, PNS-49 provides for an
allowable variation in mass (VIM) of 6%, measured using one meter of rebar.

IV. WATER AND WASTEWATER TREATMENT (ECOLOGY AND

ENVIRONMENT)

Pag-asa Steels water treatment is a cycle. After the water is treated it is again
pushed back to the water coolers. And after used in the coolers it again goes
back to the tank to be treated.
 V. ROLES/JOB OF CHEMICAL ENGINEERS

1. QUALITY CONTROL

-Accountable for sampling, sample preparation, testing, and report preparation.

-Supervising the conduct of mechanical, physical, and chemical testing of billets

and manufactured rebar to ensure adherence to quality assurance procedures

2. PROCESS ENGINEER

- Conducting inspection to ensure that equipment is in good working condition

- Ensuring the availability of all supplies required in the operation and

maintenance of laboratory equipment

- Maintaining testing equipment

- Reporting to the Plant Manager about key learning, analysis, observations, and
recommendations.

3. DESIGN

- CHECKS overall status of Electro-Mechanical equipment rehabilitation works,

buildings, and machineries erection and installation, piping and electrical works

- Communicating and supporting the Engineering department by providing

engineering drawings and technical reports

- Taking measurements as preparation for sketches/drawings of the fabricated parts

- Verifying measurements, quantity to be installed, and other data needed for

purchase requisitions

4. RESEARCH AND DEVELOPMENT

- Assisting Planning Engineers in the identification and availability of needed

tools or instruments, recommending action plans to address issues, and assisting
in the preparation of the equipment registry, specifications, and spares list

- Assisting Planning Engineers in the preparation of rolling mills operations and

maintenance budget.
5. WASTEWATER TREATMENT
- Sees to it that the water does not contain contaminants before pushing it back to
the coolers.
VI. RECOMMENDATION

VIII. APPENDIX

http://www.pagasasteel.com

https://www.google.com.ph/url?
sa=t&rct=j&q=&esrc=s&source=web&cd=6&cad=rja&uact=8&ved=0CDwQFjA
F&url=http%3A%2F%2Fen.lishi.in%2Fgrindingmachine%2F3682-iron-and-
steel-production-
philippines.html&ei=C9sfVYfxGYbf8AX2goD4CA&usg=AFQjCNGKwwcUDrU
81pSCbl0SjbSWD7pDvA&sig2=BKwmxbZHRDM-
vuWJrC_HjA&bvm=bv.89947451,d.dGc
 VII. RECOMMENDATION
1. NORTHERN CEMENT CORPORATION
The plantation was under construction during our visit so we really did not get the
opportunity to scrutinize the facilities. The site is really dusty and cement is flying all
over the place it is good that NCC conducts a check-up in the community regularly. Our
tour said that the dust is sometimes collected and processed again to increase
production yield. The only thing lacking during the tour is we cannot hear our tour guide,
maybe next time the company can spare some of their employees so we could
thoroughly understand the process of the industry.
Maybe the thing that I could recommend is that, the employees should
wear a mask to avoid inhaling the dust that may cause respiratory problems.

2. NATURES SPRING
The company is using an all machine process. The only thing that man power can
do is to check if the machine is working properly and help in the packing. It is good that
during the in-process there is no human contact which can reduce contamination. The
only thing that was amiss was that one of the tour guides told us that the bottle rejects
are to be disposed; maybe Natures Spring could devise a way to recycle the bottles.

3. GARDENIA
The company is so neat which is good because they are in the food industry and
their neatness depicts the cleanliness of their product. The waste products are turned to
fish food and those that did not pass the standard quality test are given to the
orphanage according to our tour guide.

4. Pag-asa Steel Corporation

The company was so welcoming and they divided us into smaller groups
so we could tour the facility and so we could hear our guides, which we really
appreciated because unlike the other companies we cannot hear the tour guides.
Maybe they could sometimes clean the facility because it is somewhat
messy and the other steels were starting to rust, would it not affect the outcome of the
bars they produce ?