Manufacturing Process of Gardenia Philippines

School of Graduate Studies Central Philippine University Jaro, Iloilo City

“MANUFATURING PROCESS OF GARDENIA PHILIPPINES”

Presented to: Dr. Hernani B. Miralles, CPA. Faculty, College of Graduate Studies Central Philippine University Iloilo City

In partial fulfilment Of the Course Requirements In Production and Operations Management MBA 723

Submitted by: Joynen A. Baldevarona March 20, 2017

MANUFATURING PROCESS OF GARDENIA PHILIPPINES Company Overview Gardenia Bakeries Philippines, Inc. operates as a bread manufacturing company. It offers various bakery products, including loaves, buns and toasts, and snack cakes through supermarkets, groceries, convenience, and variety stores. The company was founded in 1997 and is based in Biñan, the Philippines with additional operations in Singapore, Malaysia, and Thailand; and Asia. Gardenia Bakeries Philippines Inc. operates as a subsidiary of QAF Ltd. (Bloomberg.com) 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.

Process Flowchart

Ingredient Preparation

Sponge Mixing

Fermentation

Dough Mixing

Dividing

Rounding

Intermediate Proofing

Moulding

Final Proofing

Baking

Depanning

Cooling

Slicing

Automatic Bagging

G-Lock

Metal Detection

Distribution

Sealing

Production Line 1.Ingredient Preparation

2. Sponge Mixing

50% of the bread's ingredients are mixed and fermented in a cold room to develop the bread's aroma. Once fermented, the other 50% of the ingredients are added in and mixed with the fermented dough. 3. Fermentation

4. Dough Mixing

5. Dividing

6. Rounding

7. Intermediate Proofing

8. Moulding

9. Final Proofing

10. Baking

11. Depanning

12. Cooling

Baked loaves are placed on a 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.

Slicing, Bagging, Packing The cooled loaves travel through an automatic slicer, then move on to an automatic bagger that stuffs the sliced bread into its familiar packaging. The G-lock is also attached at this point to seal the loaf. The bagged bread then moves to the final stage where these are placed on trays and sent to a distribution center where it is held prior to being loaded into feeder trucks. 13. Slicing

14. Automatic Bagging

15. G-lock Sealing

16. Metal Detection

17. Distribution

Quality Control/Assurance 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.