COLLEGE OF ENGINEERING

BAMBANG CAMPUS
BACHELOR OF SCIENCE IN MECHANICAL ENGINEERING

LEARNING JOURNAL
MANUFACTURING AND INDUSTRIAL PROCESSES WITH PLANT VISIT

Name: ALWYN LANCE CZAREM A. LAITAN

Date of Field Trip: April 10-11, 2025
Visited Location: Quezon Memorial Circle, Presidential Car, Festo Inc, Union Galva Steel, Gardenia
Instructor/Superior: Engr. Simpher R. Guyong

DAY 2. GARDENIA

I. INTRODUCTION

Gardenia Bakeries Philippines, established in 1998, is a leading Filipino bread manufacturer

renowned for its commitment to quality and innovation. A subsidiary of Singapore-based QAF
Limited, Gardenia operates state-of-the-art facilities across the Philippines, including plants in
Laguna, Cebu, Pampanga, and Cagayan de Oro.
The company offers a wide range of bakery products, such as the iconic Gardenia Classic White
Bread, High Fiber Wheat Loaf, and Pandesal. Its dedication to freshness is exemplified by the G-
lock resealable packaging, ensuring that bread remains fresh for up to seven days.
Gardenia's operational excellence is underscored by its ISO and HACCP certifications, Halal
accreditation, and a robust distribution system that guarantees daily delivery of fresh products to
retailers nationwide.
Recognized as one of the Philippines' top employers in 2024, Gardenia fosters a workplace
centered on employee well-being, growth, and inclusivity.
With over two decades of service, Gardenia continues to be a trusted brand in Filipino
households, offering quality bread products that cater to diverse tastes and nutritional needs.
II. OBJECTIVES OF THE VISIT:

 To observe the modern bread manufacturing process and understand the stages from
ingredient preparation to packaging.

 To learn about the company’s quality control measures and how they ensure product
consistency and safety.

 To understand Gardenia’s food safety standards and certifications (e.g., ISO, HACCP, Halal).

 To explore the role of automation and technology in mass bread production.

 To gain insights into the supply chain and logistics behind daily nationwide bread distribution.

 To study the company’s sustainability and waste management practices.

 To identify key workplace practices and employee engagement strategies.

 To learn about Gardenia’s marketing and branding strategies that have made it a household
name.

 To understand the nutritional considerations in product development.

 To explore potential career paths or internship opportunities in the food manufacturing

industry.

Principles of Gardenia’s Manufacturing Process

1. Food Safety & Hygiene

o Operations follow strict food safety protocols, including HACCP (Hazard Analysis and
Critical Control Points) and ISO certifications.

o The factory layout is designed to minimize contamination, with segregated zones and
sanitation protocols.

2. Automation & Efficiency

o Gardenia emphasizes fully automated production, reducing human contact to maintain

hygiene and speed up processes.

o Machines handle everything from mixing, baking, slicing to packing.

3. Quality Control

o Every stage of production is monitored through quality checks to maintain product

consistency and freshness.

o Sensors and control systems are used to maintain exact temperatures, mixing times, and
weights.

4. Freshness Guarantee

o The G-lock packaging and efficient logistics ensure bread is fresh for up to 7 days.

o Products are delivered daily across the country using a robust distribution system.
 5. Sustainability and Waste Reduction

o Gardenia follows sustainable practices like water recycling, energy efficiency, and
responsible waste management.

6. Consumer-Centric Innovation

o The company continuously innovates to meet changing consumer preferences — from

whole grain options to fortified breads.

Process of Bread Production at Gardenia

1. Ingredient Preparation

o High-quality raw materials (flour, water, yeast, sugar, etc.) are sourced and pre-measured
by automated systems.

2. Mixing & Dough Forming

o Ingredients are mixed in large, automated mixers.

o The dough is then rested (fermentation) to allow yeast to rise.

3. Dividing & Molding

o The dough is divided into uniform sizes and molded into loaf shapes or rolls, depending
on the product.

4. Proofing

o Dough enters a proofing chamber where it is allowed to rise at controlled humidity and
temperature.

5. Baking

o The proofed dough is baked in large, tunnel or rotary ovens at precise temperatures and
durations.

6. Cooling

o After baking, bread is cooled at room temperature to prevent condensation in

packaging.

7. Slicing & Packaging

o Bread is sliced using high-speed slicers and packed using automated machines with
resealable G-lock packs.

8. Quality Check & Dispatch

o Final products go through quality inspection before being loaded into delivery trucks for
same-day dispatch.

Maintenance Procedures
Effective maintenance is essential to ensure smooth, uninterrupted operations and high product quality.
Gardenia likely follows a combination of these procedures:

1. Preventive Maintenance

 Scheduled checks and servicing of equipment to prevent breakdowns.

 Includes lubricating machinery, checking electrical systems, and calibrating sensors.

 Reduces unexpected downtime and extends the life of equipment.

2. Corrective Maintenance

 Performed after equipment failure to restore normal operations.

 May involve replacing worn-out parts, fixing electrical faults, or software resets.

 Maintenance teams must respond quickly to minimize production delays.

3. Predictive Maintenance

 Uses sensors and monitoring systems to detect early signs of wear or failure (e.g., vibration
analysis, temperature monitoring).

 Helps predict when a machine might fail so repairs can be planned in advance.

4. Cleaning & Sanitation (Sanitary Maintenance)

 Regular clean-in-place (CIP) and clean-out-of-place (COP) procedures to keep equipment and
work areas hygienic.

 Often done daily or in between shifts, especially in contact areas like mixers, slicers, and
conveyors.

5. Calibration & Validation

 Ensures machines (e.g., weighing scales, ovens, thermometers) are working accurately and
consistently.

 Done routinely as per ISO and food safety standards.

Safety Practices

Safety in a food manufacturing plant involves employee protection, product safety, and equipment
safety. Gardenia’s practices likely include:

1. Personal Protective Equipment (PPE)

 Workers are required to wear:

o Hairnets, gloves, face masks, and clean uniforms (for hygiene).

o Safety shoes, earplugs, and helmets (for physical safety in factory zones).

2. Machine Safety

 All machines have emergency stop buttons, guards, and lock-out/tag-out systems to prevent
accidental startups during maintenance.

 Only trained personnel are allowed to operate or fix machinery.

3. Fire and Electrical Safety

 Fire extinguishers, alarms, and sprinklers are installed.

 Regular fire drills and training are conducted.

  All electrical systems are properly insulated and grounded.

4. Food Safety Protocols

 Regular hand washing, sanitizing, and restricted access to sensitive production areas.

 Monitoring for cross-contamination and allergens.

 Compliance with GMP (Good Manufacturing Practices) and HACCP standards.

5. Health & Emergency Procedures

 First aid stations and trained responders on-site.

 Regular health checks for workers, especially those in food handling roles.

 Protocols in place for handling injuries, spills, or contamination incidents.

Here's a clear breakdown of a typical company and organizational structure for a manufacturing
company like Gardenia, along with the functions of each department or unit.

Key Departments and Their Functions

1. Executive Management (CEO/President)

 Oversees the entire organization and sets the strategic direction.

 Makes high-level decisions regarding company growth, investment, and market positioning.

2. Operations Department

 Ensures smooth coordination between different departments.

 Focuses on process optimization, efficiency, and overall factory performance.

3. Production / Manufacturing Department

 Manages the actual bread-making process — mixing, proofing, baking, slicing, and packaging.

 Ensures that production targets are met while maintaining quality and safety standards.

4. Quality Assurance & Food Safety

 Monitors all aspects of product quality and hygiene.

 Implements food safety systems such as HACCP, GMP, ISO standards.

 Conducts inspections, audits, and testing of products and raw materials.

5. Supply Chain & Logistics

 Manages procurement of raw materials, inventory, and warehousing.

 Ensures efficient distribution of finished goods to retailers nationwide.

 Coordinates with logistics providers and tracks deliveries.

6. Research & Development (R&D)

  Develops new products based on market trends and nutritional needs.

 Works with marketing and production to test and launch new items (e.g., whole wheat, gluten-
free bread).

7. Sales & Marketing

 Promotes Gardenia products through advertising, in-store promotions, and partnerships.

 Gathers consumer feedback and analyzes market trends.

 Manages sales teams and customer accounts.

8. Finance & Accounting

 Manages budgeting, payroll, financial reporting, and taxation.

 Prepares financial statements and ensures compliance with accounting standards.

9. Human Resources (HR)

 Handles recruitment, training, employee relations, and benefits.

 Promotes workplace safety, culture, and development programs.

 Ensures compliance with labor laws and company policies.

10. Information Technology (IT)

 Maintains all technical infrastructure, including factory automation systems and databases.

 Supports cybersecurity, software development, and system upgrades.

11. Maintenance & Engineering

 Ensures that all machinery and equipment are functioning properly.

 Conducts preventive and corrective maintenance.

 Works closely with production to minimize downtime and ensure safety.

III. DURATION OF PLANT VISIT

IV.
1. Background / Development of the Company

Gardenia Bakeries is a well-established brand known for its bread and bakery products. It started in the
Philippines in the late 1990s and has grown to become one of the leading bread manufacturers in the
country. The company is recognized for its advanced baking technologies and commitment to quality.

2. Plant Operations

During the factory visit, the plant operations showcased a highly automated and hygienic production
environment. The workflow followed a systematic process from dough preparation to packaging. Safety
protocols, including sanitation areas and PPE requirements, were strictly implemented and observed.

3. Mechanical Systems

The facility used various automated machinery such as:

 Dough mixers and dividers

 Proofing machines

 Tunnel ovens

 Cooling conveyors

 Automated slicers and packagers

These machines played a crucial role in ensuring consistent product quality and efficient production.

4. Material Handling & Processing

Raw materials like flour, yeast, sugar, and other ingredients were stored in silos and transferred through
automated systems. The entire process from mixing, proofing, baking, cooling, slicing, and packaging was
streamlined and mechanized to reduce manual handling and contamination risks.

5. Energy Efficiency & Sustainability

Engineers discussed the use of energy-efficient ovens and LED lighting in the facility. Water recycling
systems and proper waste segregation were also implemented to minimize environmental impact. The
factory emphasized reducing food waste and optimizing resource use.

6. Areas / Concerns Needed for Improvements

 Further automation in material loading/unloading to reduce labor strain.

 Exploring renewable energy options like solar panels for additional sustainability.

 Increasing recycling efforts for packaging materials.

Here's how you can fill out the information based on a field trip to the Gardenia factory, following the
structure from the image you shared:

V. Key Takeaways:
  The importance of preventive maintenance in ensuring consistent machine performance and
reducing downtime.

 Mechanical engineers play a critical role in process troubleshooting, maintenance planning, and
optimization of bakery machinery.

 Increased use of automation and robotics in dough handling, baking, and packaging processes
improves efficiency and hygiene.

VI. Visual Documentations:

VII. Reflection and Conclusions:

The visit to the Gardenia factory was a unique opportunity to observe the real-world application of
mechanical engineering in a high-volume food production environment. Seeing how machinery,
automation, and control systems work together to produce bread efficiently helped deepen my
understanding of mechanical systems and industrial operations.

This experience reinforced the importance of:

 Safety through proper machine guarding and PPE enforcement.

 Efficiency through automation and continuous production flow.

 Innovation in using modern baking technology and energy management practices.

I was particularly inspired by a discussion with a plant technician about how predictive maintenance and
sensor-based monitoring are used to reduce downtime. It highlighted how mechanical engineers are not
only problem solvers but also innovators driving improvements in production and sustainability.

VIII. Recommendations for Future Field Trips:

 Include more hands-on interaction with the equipment, possibly through demos or controlled
activities.

 Arrange Q&A sessions with engineers and supervisors to discuss challenges in production,
equipment maintenance, and process optimization.

 Visit emerging technology facilities, such as smart bakeries with IoT integration or factories
exploring renewable energy solutions.