GARDENIA

ME 158/MEPC 109
PLANT TOUR

OUTLINE OF REPORT

I. BRIEF HISTORY

Gardenia's roots go back to Singapore where, in 1978, it began as a humble in-store bakery.
Increasing demand led to the opening of Gardenia's first-commercial bakery at Pandan Loop in
March 1983. Gardenia has since been the market leader in Singapore and has expanded its
operation in Asia to such countries as Malaysia and Thailand with the latest in the Gardenia
chain of bakeries here in the Philippines.

Established in 1997, Gardenia Bakeries Philippines, Inc. started its full operations in 1998 using
the largest, most advanced, large-scale bread manufacturing facility that is fully automated and
computer controlled. Its highly-automated and major equipment come from the best bakery
equipment suppliers from Germany, Holland, UK and USA making it the leading bread
manufacturing company in the Philippines.
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ORGANIZATIONAL STRUCTURE

III. FLOW CHART

  Processes
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 Equipment and Specifications

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.

features conveying belts that transport the product while a ventilation system cools it down,
thanks to the internal structure characterized by the spiral, with circular sections to prevent
product stagnation and ease the washing process.

The spiral belt allows to cool the product and take it up to facilitate the packaging process.
The ventilation system is made of a battery functioning with freon/glycolyzed water and
ventilators controlled by inverter for air cooling (the 6-meter version has 2 ventilation systems).

In order to ease the washing process, the machine features a stainless-steel structure and rinsing
ramps to reduce machine washing time. Openable lateral panels hinged for accessibility. The
entire structure is designed to guarantee high accessibility and facilitate the washing operations,
avoiding product stagnation.
The air flows are optimized to guarantee equal temperature in the whole spiral length.
It is possible to use belts with reduced curve in order to decrease the spiral footprint.

Cut dough that are over- or underweight drop from the conveyor belt into a pan.

spiral cooler that has several open and turning circles, allowing air to freely go

around the hot bread to cool it down prior to being packed and sealed. I watched

like a child at the two giant mountains of bread slowly turning and turning. It was

a fascinating sight.

The cooled loaves travel through an automatic slicer, then move on to an automatic

bagger that stuffs the sliced bread into its familiar packaging.

 Raw Materials

Raw materials i.e Wheat flour, Sugar, Salt and fermentation agents are sourced
from suppliers locally as per demand forecast by productionplant. There are
primarily two suppliers, domestic and international

 Suppliers

Gardenia uses the traditional American Sponge and Dough bread-making method
to bake you that soft-textured loaf with a tender crust and distinct taste. (Gardenia,
2014). Gardenia uses exact amount of ingredients to ensure the softness and
goodness in their breads. They use flour which they bought from Malayan Flour
Mills (Bhd). To ensure quality to its finest, Gardenia Company buys milks related
products from Australia and New Zealand rather than China. A lot of other raw
materials being used such as yeast, wheat, honey, protein, sugar, vegetable fat,
dough conditioners, salt, calcium salt, raisin juice, vinegar and zine. Vitamins are
also included in the breads of Gardenia such vitamin A, vitamin E and Vitamin C.

In the Gardenia bread products, the ingredients used in thier bread are sourced
only from certified suppliers with high standards of food safety assurance
programmes, and these are subject to incoming quality inspections and tests to
ensure that they conform to Gardenia‟s quality and safety specifications.
Gardenia is a food processing which transformed from raw material (Flour) to
final product (bread). Gardenia Bakeries Philippines inc. (GBPI) are using import
milk only from particular countries such as USA, Australia and New Zealand.
Gardenia only uses premium ingredients from all over the world that under
strictly checking and testing to ensure the high-quality and safe bread product. In
Malaysia, Padi Beras Nasional Bhd was the main supplier of flour to Gardenia
 Malaysia which associated with Bernas Malaysia whose also the part of rice
supplier in Malaysia.

All equipment, machines and baking technologies are sourced from the best baking
equipment suppliers from all over the world including Germany, the Netherlands,
Japan and the U.S.A.

 Capacity

IV. MAINTENANCE PROGRAM

V. HEALTH AND SAFETY PROGRAM

 VI. HIRING AND TRAINING PROGRAM

VII. WASTE MANAGEMENT PROGRAM

Company recalls excess, leftover or damaged products (if any) from retailers and supply it
tofisheries as part of contract

Gardenia also 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.