Gardenia Bakeries Philippines, Inc

Prepared by: GROUP 4 CHEM 171

I. Company Profile II. Chemical Process Technology a. Process Flow Chart b. Production Line III. Quality Control/Quality Assurance IV. Waste Management V. Documentation

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Gardenia Bakeries is a company started way back in the year 1973 in Singapore, where it started as an in-store bakery. Gardenia became the market leader in Singapore and by then it has expanded its operations in Asia The first commercial bakery was then opened in March 1983 in Pandan Loop, Singapore. Gardenia Bakeries Philippines was established in 1997 and then immediately the plant’s construction was started in Binan, Laguna . Then, it was in the year 1998 where Gardenia Bakeries Philippines started its operations using state-of- the-art large scale bread manufacturing facility in the country.

Gardenia Bakeries Philippines offers a wide array of superior bakery products such as white, wheat and health breads, flavored loaves, pandesal and snack items like snack cakes, muffins and toasts.  Their breads are known for their good taste, freshness, softness, oven-baked aroma and nutritive value.  One popular product is the Classic White Bread, which is a cholesterol free and bromate free bread. It has zero transfat, and is vitamin and mineral fortified, exceeding DOH recommendations. 

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The vision of Gardenia Bakeries is to become the premier company on the baking industry and the related food and beverage industry. Also to become known and emulated for their best quality products that delight the consumers. Their mission on the other hand, is to serve the consumers with the best quality assortment of greattasting bakery and related food and beverage products, using world-class manufacturing facilities and an efficient nationwide distribution network, thereby providing a fair return on shareholder investments.

Gardenia Bakeries Philippines Plant in Binan, Laguna

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.  HACCP (Hazard Analysis and Critical Control Point) certified since 2003 to present.  accorded Superbrands status by Superbrands Ltd., from 2004-2010.  Annual National Consumers’ Award (ANCA) as the “Outstanding Bread Manufacturer” for five straight years, was also awarded to the same company. 

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Gardenia runs a machine that can produce 6,000 loaves of bread AN HOUR! In the same plant, they have a machine that can do 4,000 loaves/hour as well as a machine that can do 2,000 loaves/hour.

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Feeder trucks go out every day to different locations where smaller trucks meet them to further deliver the bread to the retail outlets so that consumers get them fresh every day.

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Every day also (esp for big retail outlets), unsold bread is taken back by Gardenia and brought to a holding area in the plant. There, contractors buy all the unsold bread. These are processed and broken down as fish meal. No returned bread is resold for human consumption. The holding area is thoroughly cleaned after all the bread is taken so that no chances of bacteria or molds can get into the production area.

Ingredient Preparation

Rounding

Depanning

Sponge Mixing

Intermediate Proofing

Cooling

Fermentation

Moulding

Slicing

Automatic Bagging

Dough Mixing

Final Proofing

G-Lock Sealing

Dividing

Baking

Metal Detection

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Ingredient Preparation

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Sponge Mixing

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Fermentation

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Dough Mixing

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Dividing

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Rounding

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Intermediate Proofing

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Moulding

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Final Proofing

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Baking

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Depanning

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Cooling

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Slicing

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Automatic Bagging

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G-lock Sealing

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Metal Detection

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Distribution

White bread

Hi-Calcium Milk bread

High Fiber Whole Wheat bread

High Fiber Wheat Raisin

Honey Oat Loaf

Sugar-Free 12grain loaf

Slim n Fit Wheaten bread

Whole Wheat Bun

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Throughout the manufacturing process, several techniques are included to assure the quality of the bread. In the dividing/rounding stage, cut dough are passed through a check weigher so that every loaf weighs the same. Cut dough that are over- or underweight drop from the conveyor belt into a pan. The dough collected here is put back into the mixer. In every 1000 loaves baked, one is randomly selected for quality check. Here, several parameters are tested (e.g. temperature). This bread is also sent to the laboratory and is subjected to several tests. In the packaging system, visual and physical testing is done by the QC analyst Before the slicing stage, every bread is passed through a metal detector to ensure that the bread are free of metal contaminants(e.g. Lead) Gardenia has been ISO 9001:2008 certified and HACCP(Hazard Analysis and Critical Control Point) certified since 2003.

Gardenia staffers remember the codes this way -- TOY-BGRW

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Indirect firing system is used during oven baking wherein environmental fuel is used As the loaves leave the automatic slicer, some are not properly sliced and some are accidentally dropped on the floor. These unwholesome bread are collected and are later sold as fish meals. Since one of Gardenia’s missions is to serve only the best quality of bread to its consumers, it ensures that all of its products are guaranteed fresh. And to do this, Gardenia collects all of its products from the market every three days after its release even though it has not reached its expiration date yet.

Oh we love Gardenia! -end-