ECEN 3453

Plant Tour (A.Y. 2015-2016)

GARDENIA PHILIPPINES

New State-of-the-art Plant

Gardenias plant in Bian, Laguna showcases its world-class
bread manufacturing facility that is ISO and HACCP certified, giving
consumers the assurance of product quality and food safety in a wellsanitized bakery environment.
It is the companys pride and joy where, each day, hundred
thousands of loaves of bread and snack items are produced in a fully
automated facility, untouched by human hands.

Baking Breads Untouched

By Human Hands
The plant tour aims to impart to the students the knowledge
about modern bread production that is untouched by human hands.
Additionally, it promotes the importance of proper nutrition
and sanitation practices as foundations to a healthy mind and
body, and as well values education.
While Gardenias secrets to success will be shared to visitors
via an audio-visual presentation (AVP), the most exciting part of the
program is the actual catwalk tour of the visitors as they enjoy
viewing the complete plant facility and step-by-step process of
baking breads, the Gardenia way.
Making bread the Gardenia way is fascinating and educational for
kids and adults alike - to see how staple food, like bread, is made on
such a massive scale. To view thousands of loaves stacked in tiers on
two spiral coolers and be able to see automated handling process is an
awe-inspiring and fun learning experience. The bread making process
makes people appreciate the lengths the people of Gardenia go through
to make sure the bread they get is fresh, safe, delicious and nutritious.

Site Map

Location: Star Avenue, Laguna International Industrial

Park (LIIP), Mamplasan, Binan, Laguna

Gardenias Bread Factory

Gardenias Bread Factory

Gardenias Legacy
In the baking industry

Tracing Back Its History:

Gardenias Humble Beginnings
o Gardenia began as a humble in-store bakery in 1978 at Singapore.
o Gardenia opened its first-commercial bakery at Pandan Loop in March
1983.
o Gardenia has since been the market leader in Singapore and has
expanded its operations in different countries with the latest in the
Gardenia chain of bakeries here in the Philippines.
o In 1997, QAF Limited through Gardenia International Pte. Ltd.
established Gardenia Bakeries Philippines, Inc. at its bakery plant in
Binan, Laguna
o In 1998, Gardenia started its operation with its bread factory rated as
the most modern large scale bread manufacturing facility in the
country
o Over the years, Gardenia has gained wide acceptance and is now
considered as the most widely distributed loaf brand, reaching many

World-class Products:
Gardenias Steadfast Commitment to
Quality
GardeniaPhilippines offers a 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 transfat, 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.

World-class Products:
Gardenias Steadfast Commitment to
Quality
Gardenia has been awarded withInternational Organization
for
Standardization ISO 9001: 2000 certificationsfrom 2003 to 2009 and has now
upgraded toISO 9001:2008in 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 accordedSuperbrandsstatus by
Superbrands 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 theAnnual National Consumers Award (ANCA)as
theOutstanding Bread Manufacturerfor five straight years.

Moving to the Future:

Paving the way for Gardenias Continued
Success
Since the start of its operations, Gardenias distribution had
grown rapidly. Gardenia is now considered as the most widely
distributed loaf brand in Metro Manila to as far asIsabela, Abra,
Cagayan and Ilocos provinces in the North, Bicol and Sorsogon in
the South, and Negros, Samar, Antique, Aklan, Iloilo and Leyte in
the Visayas region. Increasing demand led Gardenia to reach
Cebu, Bohol, Butuan City, Iligan City, Misamis Oriental, Bukidnon
and Davao City in Mindanao.
From Gardenia's establishment in 1998, the brands
success has been starkly evident with its continuous
and rapid sales growth.

Vision
Our vision is 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.

Mission
Our mission is 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.

Core
Values
Customer
Driven-Wealways put the customer first in everything
we do.
Innovation We constantly initiate change and encourage
creativity.

Teamwork and Professionalism We are one company, one

team working together professionally.

Integrity We uphold honesty and objectivity in the things that we

do.

Excellence We relentlessly pursue continuous improvement and

aim for the highest standard in our work.

Stewardship We treat company resources with pride as if they are

our own.

Food Safety Policy

We, at Gardenia Bakeries Philippines, are committed to assure
customers and consumers that our products are produced with
superior quality ingredients and according to strict safety and
hygienic standards that comply with statutory and regulatory
requirements.

Quality Policy
We, at Gardenia Bakeries Philippines, are committed to delight consumers by
providing best quality bakery products.
We aim for excellence through innovation and continuous improvement of
our processes, products and services, ensuring compliance with our customers and
applicable statutory and regulatory requirements.
We are steadfast in our commitment that quality begins with each and every
one of us.

Achievements
Gardenias achievements are due to our beloved customers
continuous support and loyalty. Because of this, Gardenia will
continue to provide consumers with the best bread products that
they can enjoy anytime, anywhere.

Achievements

ISO (International Organization for Standardization) 9001:2008

Certified by Certification International Philippines, Inc.
2003 to present

Achievements
HACCP (Hazard Analysis and Critical
Control Points)
Certified by Certification International
Philippines, Inc.
to present
This International Standard specifies requirements for 2003
a food
safety
management system where an organization in the food chain needs to
demonstrate its ability to control food safety hazards in order to ensure that food
is safe at the time of human consumption. This certification is a proof of the
companys adherence to the systematic approach in the identification,
evaluation, and control of food safety standards.

Superbrands
By the Superbrands Asia
2004 to 2010
This prestigious distinction is given to the Philippines strongest and most
recognized brands that have met the standards of market dominance, longevity,
goodwill, customer loyalty and overall market acceptance.

Achievements

Annual National Consumers Awards (ANCA)

By the Consumers Union of the Philippines (CUP)
Outstanding Bread Manufacturer
2004 to 2008

The ANCA gives recognition to the Products, Services and

Individuals who continually endeavor for excellence in the products
that they make, and render the best service at all times. It is in this
manner that every year the consumer shows its token of
appreciation by way of a golden statuette that symbolizes HONOR
and PRESTIGE for the products and services chosen for its
manifestation of excellence that towers above all.

Products

Products

Manufacturing

Process

Automatic Blending
The production process begins with a
computerized blending of the exact
amount of quality ingredients needed.
This helps to ensure equal goodness in
every loaf.

Production of Sponge Mix

The specially formulated Gardenia enriched flour,
purified water, yeast, vitamins, and minerals are
added together to form the sponge which is
released into a trough.

Fermentation Room
The sponge dough is then kept in a fermentation
room, under controlled temperature and humidity
for 4 hours, so that Carbon dioxide is released, and
sponge can rise. This fermentation process helps
the sponge to develop a unique Gardenia bread
texture, aroma and taste.

Production of Dough Mix

At this stage, the sponge is mixed
other ingredients to form the dough.
on the type of bread to be baked,
include skimmed milk powder,
shortening, wheatgerm, bran, malt or

again with
Depending
these can
vegetable
honey.

Divider
The dough is then divided into the required
weight for each loaf and conveyed to a
rounder.

Rounder
At the rounder, each piece of dough is kneaded
so that Carbon Dioxide is trapped and the
bread can develop a soft texture when it is
baked.

Checkweigher
The dough pieces then go through the
checkweigher. Here, the pieces that are over or
under the required weight are automatically
rejected.

Intermediate Proofer
The dough is then left to rest in the intermediate
proofer for 10 minutes before being molded and
placed into the baking pans.

Moulder
Here, the dough is shaped according to the
desired configuration and then automatically
placed into the pans.

Automatic Lidder
The pans are lidded automatically to give
the bread its uniform rectangular shape.

Final Proofer
At this final proofer stage, the yeast is
allowed to rise further under controlled
temperature and humidity. Once the dough
has risen to the desired height, it is finally
ready for baking.

Tunnel Oven
Here, Gardenia breads are baked for about 20
minutes at a temperature of approximately 200
degrees Celsius in the state-of-the-art tunnel
oven.

Automatic Delidder and Depanner

Hot from the oven, the freshly baked loaves
are then removed by vacuum suction before
being conveyed to a bread cooler.


Bread Cooler
This bread cooler can hold up to 8000
loaves of bread per hour. The freshly baked
and hot bread loaves need to be kept in the
cooler for about an hour until slightly above
room temperature before it is ready for
packing.

Automatic Slicer and Bagger

When the loaves are sufficiently cooled, it is
then ready to be sliced, wrapped and made
convenient for consumption in attractive
Gardenia packaging mechanically sealed with
G-locks tags that are printed with use-by dates

Delivery
The freshly baked breads are then delivered to retail
outlets.

Policy on Safety and Health at Work

Gardenia Bakeries Philippines, Inc. is committed to protecting the
life and health of its employees. The goal of the companys occupational
and process safety policy is to identify and carry out preventive
measures aimed at reducing industrial accidents, occupational diseases
and other incidents. The company used and applied cutting edge
production technology and modern security measures for employee
safety.
manufacturing
process in order to minimize the risk and
was made to
be aThe
fully
automated production
hazards for the employee and to produce top quality loaves and breads to satisfy
the consumers. The continual improvement of the manufacturing process and the
safety management system minimizes the risks to the employee and the gives
the company a world-class process safety and production standards.
The company follows efficient production and engineering
process management practices and provide training to increase employee
proficiency though the production only uses minimal human intervention.
Its fully automated manufacturing system encourages and motivate a safe
working environment for the minimal number of employee on the
production process.

Safety is non-negotiable
At Gardenia, we believe that sustainable success can be reached
only through people. No other asset in the company is as important as
the people that contribute with their work to our culture and our
business results.
Therefore, we devote all the necessary energy and attention to protect
employees, contractors and any other people involved with the company along the
value chain, including suppliers, customers and the public.
This Policy on Safety and Health at Work is based on the Corporate
Business Principles and the Management and Leadership Principles, which
are binding for the whole company

Compliance
To be at the forefront of accident prevention in the industry, we
implement in all our sites the mandatory Occupational Safety and
Health

Management

System,

which

meets

or

exceeds

the

requirements of the health and safety laws applicable in the countries

in which we operate.

Strong safety and health organization

Gardenia believes that accidents are preventable and therefore one
accident is one too many.
We integrate Safety and Health in the management of our business in such a
way that all activities are considered with a perspective of prevention of all types
of accidents and protection of the people at work.
To advance a strong safety culture that effectively prevents accidents; we
establish local safety and health organizations that provide specialist advice to
managers and employees.
We commit to perform systematic identification of
hazards and to manage them with appropriate risk assessments and subsequent
actions to minimize danger.
We establish emergency and contingency plans to deal with residual risks.
This approach also minimizes threats to the business, protecting our shareholders
interests.

Continuous improvement
Our Occupational Safety and Health management system is
based on the concept of continuous improvement. We improve
constantly

our

performance

by

designing

and

adapting

processes, work practices and systems in the direction of better

ergonomics and greater safety.
We base our improvement on the monitoring of safety and
health performance as well as on the analysis of incidents that
produce injuries and of workplace activities whose cumulative
effects may lead to illnesses.

Leadership and participation

Our company recognizes the critical role of senior management
to ensure a safe and healthy work environment.
As an integral part of managing the business, managers at all levels
are accountable for managing workplace health and safety with strong
leadership and credibility. Their annual objectives include a contribution to the
safety culture and performance.
To reinforce an already strong safety culture, our company sets
ambitious goals and high standards, as part of its Occupational Safety
and Health management process.

Behavioral approach
Our company attributes the highest importance to peoples behaviors as the
main factor for the prevention of accidents.
We believe that every time an accident occurs, the root causes can be
traced to someones behavior. Therefore, we implement programs that
encourage employees to engage in dialogue with peers and management
about safe and at risk behaviors.

Communication, education and training

The company builds a proactive safety culture by:
driving the implementation and continual improvement of the
Occupational Safety and Health Management System through
communication with employees, contractors and other stakeholders;
educating, training and equipping employees to ensure that they are
empowered to avoid unsafe situations and to respond rapidly to
unexpected events;
influencing, training and education of contractors, suppliers and
community.

Implementation, certification and audits

Our company implements this policy through the Occupational
Safety and Health Management System, which includes periodic selfassessments and specific audits. Local management is accountable for its
implementation.
To ensure a consistent and coherent implementation worldwide,
Gardenia submits all its manufacturing sites to OHSAS 18001
certification by independent accredited bodies.

Community,
supply
chain,
contractors and other stakeholders
Our companys business model is based on the creation of shared value
for the company and the society. With our work to foster our companys safety
culture for example through safe driving programs for employees and
contractors we also act on the safety culture of the communities in which we
operate, both by giving an example of commitment and by reducing accidents
during business outside our sites.

Communicate with local communities and their emergency services,

providing them with adequate health and safety information on our
operations;

Encourage employees to apply their safety and health learning in

their private life, at home and during leisure.

The Gardenia plant is ISO 9001: 2008 certified & HCAPP (Hazard Analysis
and Critical Control Point) certified proof that the company strictly adheres to
the highest standards of food quality & safety.

ISO 9001:2008

ISO 9001:2008 certification has been in place for over a decade now and is
used by both customers and companies as a method of controlling their
quality.
The Standard provides a framework to manage your business and ensure a
philosophy of continual improvement in all aspects of your business.
It is externally assessed on an ongoing basis to ensure these business
practices are maintained.

Benefits of ISO 9001:2008

Involves Top management in the improvement of the Quality management
System Facilitates the organization to become a customer-focused
organization.
Ensures sustained customer satisfaction by producing, delivering services and
providing support functions that meet customer's needs and expectations.
Increases the effectiveness and efficiency of the organization through
continual improvement in systems and products /services quality.

HACCP Certified
(Hazard Analysis Critical Control Point)
HACCP (Hazard Analysis Critical Control Point) is internationally accepted as
the most cost-effective method of preventing food contamination from chemical,
microbiological and physical hazards.
HACCP audits focus on the potential causes of food safety hazards by
assessing the entire production process, and then applying preventative controls
at critical points. Critical control points may include equipment, the supply chain
of raw materials or employee training and supervision.
By using the HACCP system, control is shifted from end product testing
(corrective) into the design and manufacturing of products (preventive) and can
be applied to a specific product or to an existing or new process.
HACCP has international recognition as the most cost-effective means of
controlling food borne disease and is endorsed as such by the Joint FAO/WHO
Codex Alimentarius Commission.

Personal Protective Equipment (PPE)

Gardenia uses a small number of employees on their production
process due to their fully automated system of manufacturing. That
small number of employees on the production stage were there
basically to monitor and check the production. All the process in
manufacturing loaves/breads are on the machines and equipment, as
of the companys less human intervention system implication. But
those employees on the production were still required to use the
designated PPE for food industries for the employees and consumers
health and safety, and since Gardenia is a HACCP certified, it strictly
follows the standards given for the food industry.

Personal Protective Equipment

(PPE)
Protective clothing performs several functions in the Food
Industry:

Legal Various Regulations prescribe the type of clothing which must

be worn by food workers;
Safety When a product has to be used which is potentially harmful to
the user, adequate personal protection must be provided;
Production protection In addition to meeting the legal requirements,
most food manufacturers, especially those making high risk products,
adopt a much wider approach when choosing garments, and major
retailers may have their own requirements for suppliers;

Personal Protective Equipment

Denoting
place of work This is of particular importance where
(PPE)

cross contamination of processed food from raw food must be

prevented. A worker who has crossed to another area without
changing his overall is immediately apparent if he is wearing a
or trimIt or
from the different
others incolour
that area.
is style
strongly recommended that there is a
different colour coding for high care and low risk production areas
including the changing rooms.

Encouraging clean working It may not be possible to enforce

pride in the uniform in the same way as in the forces but if a worker
is provided with well-fitting, comfortable clothing which bears the
company logo and is regularly laundered, he will know that his
employer is concerned about cleanliness and hygiene. (Company logos
also are recognized by the major retailers and suppliers.

Legal
Food
Safety (General Food
Requirements

The
Hygiene) Regulations state that Every
person working in a food handling area shall maintain a high degree of personal
cleanliness and shall wear suitable, clean, and where appropriate, protective
clothing. These Regulations also state that adequate changing facilities for
personnel must be provided where necessary.
The Health & Safety at Work Act gives an employer the general duty of ensuring
the health, safety and welfare of all his employees. Health and Safety Regulations can
be made under this act Imposing requirements with respect to the provision and use in
specified circumstances of protective clothing - including clothing affording protection
against the weather.
The Control of Substances Hazardous to Health Regulations (COSHH) stipulate that
where the use of such substances cannot be controlled by other means,
The employer shall provide those employees with such personal protective
equipment as will adequately control their exposure to substances hazardous to
health. Certain cleaning compounds and insecticides are obvious examples of
where special clothing is necessary for those using them. However, common
ingredients in bulk may be irritant or have other characteristics that make the
wearing of protective clothing a wise precaution.

Personal Protective Equipment

(PPE)
Head Coverings
The hair represents a source of both foreign matter
contamination and bacterial contamination. It therefore
follows that hats should be worn in food premises and
that the hair should be entirely enclosed. It should be
explained to the wearers to why there is a need for hair
covering. Remind them of their hygiene training and the
need to be aware of the risks of foreign bodies and
pathogens from their hair. Many customer complaints
involve finding hairs in food).

Personal Protective Equipment

(PPE)
Overall
s
The body is commonly covered by one of three
types of overgarment; a coverall (boiler suit);
separate jacket or shirt and trousers; or a coat
overall perhaps with overall trousers. The coat
overall has the advantage of being suitable for wear
over a skirt. In Gardenia, they are using different
color of coverall per day, they have designated color
each day and it is numbered on the right side of the
sleeve.

Personal Protective Equipment

(PPE)
Footwear
Gardenia follows the requirement of Occupational
Safety and Health Administration (OSHA), they ensure
that employees use protective footwear while working
on the manufacturing areas.
Their safety shoes come in many styles both
formal and informal. However, workers require reliable
and durable work shoes for their safety. Traditional
safety shoes are steel toed, but it can also be made of
composite materials such as thermoplastics and
aluminum.
Following considerations are to be made for selecting right type of safety
shoes for the workers:
o Work environment and associated hazards
o Material used in safety shoes and their effectiveness to resistant hazards
o Water, heat and cold resistance
o Electric resistance, puncture and cut resistance

Personal Protective Equipment

(PPE)
Gloves
Better clean hands than dirty gloves is a saying
with a certain amount of truth in it. It is obvious when
hands feel sticky or look dirty, it is not so obvious when
gloves are in that condition.
Wearing gloves is never an excuse for not washing
them and the hands. It has been found that wearing
impervious gloves can cause the skin to perspire, bringing
bacteria to the surface. Should the glove become
punctured, the result can be contaminated food. Many
companies carry out hand hygiene spot checks. This
proves a valuable tool when the operative believes he or
she would rather wear gloves this can be easily done with
glo-germ kits.

Number
of
Required

Fire

Extinguisher

1926.150(c) (1) (i)

A fire extinguisher, rated not less than 2A, shall be provided for each 3,000
square feet of the protected building area, or major fraction thereof. Travel
distance from any point of the protected area to the nearest fire extinguisher
shall not exceed 100 feet.

1926.150(c) (1) (iv)

One or more fire extinguishers, rated not less than 2A, shall be provided on
each floor. In multistory buildings, at least one fire extinguisher shall be
located adjacent to stairway.

Using a Fire Extinguisher (Gardenia

Policy/Guideline to follow)
The following steps should be followed when responding to incipient stage
fire:

Sound the fire alarm and call the fire department, if appropriate.
Identify a safe evacuation path before approaching the fire. Do not
allow the fire, heat, or smoke to come between you and your
evacuation path.
Select the appropriate type of fire extinguisher.
Discharge the extinguisher within its effective range using the P.A.S.S.
technique (pull, aim, squeeze, and sweep).
Back away from an extinguished fire in case it flames up again.
Evacuate immediately if the extinguisher is empty and the fire is not
out.
Evacuate immediately if the fire progresses beyond the incipient stage.

Most fire extinguishers operate using

the following P.A.S.S. technique:
1. PULL... Pull the pin. This will also break the tamper seal.
2. AIM... Aim low, pointing the extinguisher nozzle (or its
horn or hose) at the base of the fire.
NOTE: Do not touch the plastic discharge horn on CO2
extinguishers, it gets very cold and may damage skin.
3. SQUEEZE... Squeeze the handle to release the
extinguishing agent.
4. SWEEP... Sweep from side to side at the base of the fire
until it appears to be out. Watch the area. If the fire reignites, repeat steps 2 - 4.
If you have the slightest doubt about your ability to fight a
fire....EVACUATE IMMEDIATELY!

Thanks!
Submitted by:
BSECE V (A.Y. 2015-2016) Students

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