Address: Quirino, Bacnotan, La Union

Date Visited: October 21, 2013

I.

Introuction
A. Vission
To provide foundations for society's future.
B. Mission
To be the world's most respected and attractive company in our industry - creating
value for all our stakeholders.
C. Company Profile
Holcim was founded in 1912 in the village of Holderbank, Canton Aargau,
Switzerland. in 2001, the name of the group was changed from Holderbank to
Holcim. Holcim Philippines, Inc. is the leading cement manufacturer in the
Philippines
Holcim is one of the world's leading suppliers of cement and aggregates
(crushed stone, gravel and sand) as well as further activities such as ready-mix
concrete and asphalt including services.
The Group holds majority and minority interests in more than 70 countries on all
continents.

II.

Products and By-products

The main product of Holcim Philippines is Cement, a binder - a substance that
sets and hardens independently, and can bind other materials together. Cements used
in construction can be characterized as being either hydraulic or non-hydraulic,
depending upon the ability of the cement to set in the presence of water.

Holcim produces different types of cement which include Holcim Excel, Holcim
Wallright, Holcim 4x and Holcim Premium. Holcim Excel is a special formulation of
Portland cement with advanced mineral additives, conforming to both ASTM C595
and PNS 063. Primary application of Holcim Excel cement is for construction of
concrete floor slabs, columns, beams, walls and pavements. Holcim WallRight is a
masonry cement conforming to PNS ASTM C91 Type S specifications. Holcim
WallRight is used for hollow block laying and filling, plastering, and finishing.
Holcim 4X is an ASTM C150 high performance Portland cement. It is specially
formulated for ready mix concrete applications. It has high compressive strength,
high workability and is compatible with commonly available admixtures. Supplied in
bulk, Holcim 4X is mainly used for high-rise buildings and vertical structures that
require high-strength cement. It is ideal for construction that requires optimized
concrete mix designs and fast construction cycles. Holcim Premium Bulk is an ASTM
C 150 high perfomance Portland cement specially formulated for general
construction. It has high workability and is compatible with commonly available
admixtures.
The production of cement is generally made up of 3 stages: the production of (1)
raw meal, (2) clinker, (3) cement. Limestone is quarried in quarrying sites, crushed
and stored in storage areas. The crushed limestone is ground into raw meal. The
addition of additives such as silica and pyrite result in the desired chemical
composition. The raw meal is then fed to the pre-calciner and kiln to produce clinker.
Cement clinker is generally made up of these chemical compounds: Tricalcium
aluminate(Ca3Al2O6 or C3A), Tetracalcium aluminoferrite (Ca4Al2Fe2O10 or C4AF),
Belite or dicalcium silicate (Ca2SiO5 or C2S) and Alite or tricalcium silicate(Ca3SiO4
or C3S). The composition of these compounds in the cement clinker will depend on
the desired quality of the cement. The cement clinker is then grinded together with
gypsum and other additives to produce the desired type of cement.
The manufacturing process of cement consists of a calcination process where lime
and carbon dioxide are produced. Also, Carbon Dioxide is produced from the
combustion process of the fuel used in the calcination.

III.

Environmental and Energy Aspects

Manufacturing plants are known to be the biggest contributors to pollution. For
Holcim, a cement processing industry, the pollution they emit consist of Dust, CO2,
SO2 and NOx.
2

The cement processing industry consists of several crushing and grinding

equipment, which are sources of dust emissions. Dust emissions are present in every
part of a cement industry, from the quarry to the bag house. Excessive dust emission
not only puts environmental and employees health and environmental conditions at
risk but also poses negative impacts on the process such as increase in equipment
wear and downtime, and increase in cleaning and maintenance cost, thus having a
need for its control. In Holcim, dust control is done by the installation of dust
collecting equipment.
One of these equipment is the electrostatic precipitator. An electrostatic
precipitator uses a negative voltage of several thousand volts to give the dust particles
a negative charge. These negatively charged particles are then collected by positively
charged metal plates. Another equipment is the Bag filter. Dust-laden gases enter the
baghouse and pass through fabric bags that act as filters. Dust collected in these
equipments are returned back to the process.
Carbon Dioxide in cement industries come from the calcination process and the
combustion of the fuel for the kiln. In Holcim, the control of CO2 is done by the
optimization of the process. Process equipments are made sure to work efficiently
especially the burner. Holcim has a program in place to utilize Alternative Fuels and
Raw Materials (AFR) these materials are used to substitute for the fossil fuels
(specifically coal) that is being used in the combustion process in the kiln or calciner.
Since thermal NOx increases with temperature and O2, its control is mainly done
by avoiding high temperatures and peaks, improving process stability, improving kiln
feed burnability, avoiding overburning, burner optimization. SOx control is done by
reducing non-sulfate S (pyrite) in raw material, increasing mill running time, reducing
/ homogenizing S-input by fuel and raw material, reducing sulfur volatility.
Holcim has been working with the International Union for Conservation of Nature
(IUCN) since 2007, striving to achieve better biodiversity conservation. This included
creating an indicator system to measure biodiversity changes at extraction sites and
guidelines for the cement and aggregates sector for integrating biodiversity
management into business operations.
IV.

Role of Chemical Engineer

For a cement manufacturing industry, roles of a chemical engineer may be that of
the process or the quality. Process engineers ensure that the plant is working at its
optimum condition maximum production at minimum cost. Process engineers
ensure that process equipments are working efficiently. In any instance that a problem
3

occurs in the manufacturing process, process engineers are to fix the problem in the
most economical way possible. They evaluate the plants economic performance and
make necessary adjustments to maximize plant profit. They also monitor emissions
and ensure that these emissions comply with standards.
Chemical engineers in Quality Control Labs tests and analyze the quality and
characteristics of the raw materials and products of the plant. They ensure that the
products are of standard quality. The results of the analyses that they make are
reported to the process department. The process department then makes proper
adjustments depending on the results of the analyses made.

V.

Observations and Recommendations

During our plant visit at Holcim, we were able to have a quick plant tour. Holcim
is very strict on Personal Protective Equipment. For that reason, we were only
allowed to have the plant tour by bus because of the lack of personal protective
equipments. Through the plant tour we were able to observe some of the equipments
and activites in the plant. We were also able to have a general overview of a cement
processing industry.
Holcim Bacnotan is located beside a sea shore which may not be ideal for marine
lofe leaving near the plant. However, Holcims located is beneficial for importing and
exporting products by means of travel by sea. We have observed a pier near Holcim
but it is not used. Opening this pier would provide an opportunity to export products
and import raw materials for lower transportation fees. However, cost for rebuilding
and opening the pier should be considered to determine whether it would be practical
or not. Also, the quarry site is home of many wildlife species. Restoration of former
quarry sites should be done.
Layout of plant equipments and facilities are important to plant efficiency. Holcim
is an example of an industry that has a product layout. Product layout is applied for
industries that go for mass production and standardized product quality. Process
equipments are close to one another. Maybe this is to prevent losses due to
transportation. Also, office buildings, except for the administration building, are
located within the operating area of the plant. This is convenient for employees
having periodic activities within the operating area of the plant.
As mentioned, Holcim is very strict when it comes to safety. Safety is one of their
top priorities. Employees are provided with their personal protective equipments and
they are required to wear them whenever travelling or working outside office

buildings. Whenever travelling by foot, employees are required to walk and cross on
designated areas only. Speed limits are also observed when using a vehicle.
Fuel is one most important resource in the cement industry. Its moisture content
is an important parameter especially to the kiln system. The coal storage facility of
Holcim is an open area. This is beneficial as it may provide sun drying as the main
method for reducing its moisture content. However, it may pose a problem during
rainy seasons. It may be beneficial to have an alternate drying system during rainy
seasons. It may also help in lowering the raw meal moisture content since exhaust air
coming from the kiln is used to dry the raw meal.

Address: Ciudad Industria, Barrio Bahay Pari Meycauayan City Bulacan

Date Visited: October 22, 2013
I.

Introduction
A. Mission
To provide our country with world-class products and services by
innovating and adapting to changing customer needs while helping to protect the
environment
B. Company Profile
SteelAsia is a company born out of a partnership that started in 1965.
Filipino businessmen Benito Yao and Go Kim Pah joined forces to put up a
rolling mill called Island Metal.
In the late 1980s, under the leadership of successor Benjamin Yao, the
company would embark on an expansion and modernization of its manufacturing
capability, as a platform for helping the Philippine steel industry to become part of
the solution.
In 1994, a project to establish the Philippines first state-of-the-art steel bar
rolling mill was underway. Driving the endeavor, the SteelAsia Manufacturing
Corporation had envisioned a facility that would truly be a national asset; world
class steel products and services would lower the cost of construction, and help
spur economic growth.

II.

Products and By-Products

Steel billets are received and charged directly in a re-heat walking hearth
furnace through the charging door of the furnace. They are reheated for 75 minutes
to1100C using Bunker C (Type #6) fuel oil. Once billets reach the required
temperature for rolling, they leave the furnace through the discharging doors and are
rolled along a series of continuous rolling mill stands to obtain the desired size and
shape. Each rolling stand is controlled throughout the process by a computerized
control system. The bars are then cut to lengths required by customers. Samples are
subjected to physical, mechanical and chemical. Finally, the product is then bundled
and tagged before being placed in a storage facility. Rebar is the main product if

SteelAsia, but they have also introduced other products and services such as the cut
and bend and the mechanical couplers.
Rebar is the common name for cylindrical shaped steel bars with uniformly
spaced protrusions called lugs or deformations.
They are hot rolled from semi-finished steel
called billets. Rebar are the predominantly
consumed steel product of the construction
industry and are used specifically for concrete
reinforcement. Rebar creates tension in concrete
to help hold it in a compressed state. Reinforced concrete gives infrastructure,
buildings, bridges, houses, and other construction the necessary structural integrity as
required by Philippine law and building codes.
Cut and bend is a value added rebar
solution for the optimization and
fabrication of rebar in a factory
environment. Depending on the structural
design, rebar are cut and bent to specific
shapes. In the developed world, this
activity is done offsite in a factory
environment compared to the developing countries such as the Philippines which
predominantly work rebar at the construction site.
Steel Asia introduced Cut and Bend Services in the Philippines and is helping to
bring rebar solutions for the construction industry to world-class levels. Customers
benefit from: Zero wastage on cuts, Elimination of storage and related overheads,
Elimination of double handling, Elimination of site related damage and pilferage,
Safer construction site, Simplicity of management, Consistent and precise cuts and
bending, Zero damage to bars during bending
Mechanical
Couplers.
Lapped
splices are not always the most
economical solution for connecting rebar
in columns and beams. The overlapped
rebar represent wasted rebar material and
time consuming rebar fixing. The use of
mechanical couplers can create material
and time savings and simplify the
management of rebar fixing and installation.
Aside from the products of iron and steel manufacturing, it also has its byproducts. The main by-products produced during iron and steel production are slags
7

(90% by mass), dusts and sludges. Process gases, for example, from the coke oven,
BF or BOF are also important by-products. Slags are a mixture of silica, calcium
oxide, magnesium oxide, and aluminum and iron oxides. During smelting, slagging
agents and fluxes (mainly limestone or dolomite and silica sand) are added to the
blast furnace or steelmaking furnace to remove impurities from the iron ore, steel
scrap, and other ferrous feeds. The slags protect the liquid metal from outside oxygen
and maintain temperature by forming a lid. As the slags are lighter than
the liquid metal, they float and can be easily removed.
III.

Environmental and Energy aspects

Steel Asia is the first and only company in the Philippine steel industry to be
certified to ISO 14001 (Environmental Management Systems), and the first and only
as well to certified to OHSAS 18001 (Occupational Health and Safety Management).
Steel Asia mills have zero-wastewater. 100% of the water exiting the operations
line are not drained as effluent but rather channeled into a dedicated waste-water
treatment facility on the premises, and cycled back into operations.
Steel Asia has been on the cutting edge of resource-usage minimization. It has
implemented rainwater-collection, from the roofs of its buildings and roads at its plant
site. Rainwater is increasingly the main source of water for Steel Asia. Air-oil
lubrication is a new technology that Steel Asia has implemented. Lubrication is in a
closed system, rather than an external application of lubrication that latter of which
may result in ground contamination from used oil. Steel Asia uses automated
furnaces. Through sensors and automation, the optimum fuel-air mixed is achieved,
minimizing particulate emissions. This also ensures optimum burning saving fuel by
up to 30% compared to zero-automated furnaces. Hot-charging technology reduces
fuel consumption further by another 35% in SteelAsias mini-mill. Furnace stacks are
up to 50 meters high ensuring that with air dispersion, emissions stay well below the
allowable limits at ground level. The pioneering use of AC motors driven by
individual Process Logic Controls saves on power consumption by more than to 25%
and significantly reduces noise levels. In-line rolling stands increase the safety of the
mill compared to accident prone cross-country configurations. Steel Asia uses heat
recuperators to recycle energy and save on fuel and the use of LED technology to
reduce power consumption.

IV.

Role of Chemical Engineer

In any kind of production plant, a chemical engineer designs and controls the
process. In a steel production plant, chemical engineer also can play the main role in
quality control, testing of materials, estimating alloy properties and projects
managements. For more experienced chemical engineers, we can consider roles at
higher levels of supervisory and management. Chemical engineers may also be in
charge of environmental and energy aspects of the plant. They facilitate energy
consumption and environmental effects of the operation.
V.

Observations and Recommendations

During out plant visit at SteelAsia, we were given an opportunity to have a
plant tour. This experience gave us an opportunity to observe the plants location,
working environment, facilities and equipments, and operation. SteelAsia uses bunker
fuel in its operation. As a result, it also produces greenhouse gases and other harmful
pollutants. SteelAsia is located far from residential areas, which is proper as its
emissions may cause negative effects on human health.
Steel Asia also follows a product layout. The production of the Rebar is done
in mass production and of standardized quality. Equipments used are of modern
technology and process is well automated. All the operations are being monitored by
computers in the control room.
The main operation in Steel Asia is the production of Rebar from Steel Billets.
The main equipment for this is the furnace. Because of this, it is expected that the
working environment would be hotter compared to normal conditions. Also, it was
observed that PPE is not strictly employed even in the operating areas. Employees in
the field especially in the furnace are should be given an exposure limit since too
much exposure to heat may cause health problems. Also, employees should have
proper PPE whenever working in the operating area.
As observed during that time, a problem in the operation occurred and the
engineers responded systematically to the problem. Their engineers and operators are
well trained and prepared in troubleshooting problems that may occur in the plant

Address: Km 15 W Service Rd., Paraaque, Metro Manila

Date Visited: October 22, 2013
I.

Introduction
A. VISION
We aspire to have a Lamoiyan product in every home.
B. MISSION
10

We exist to improve the quality of life by bringing essential products within the
reach of the common people
C. Company Profile
In 1970, Aluminum Containers, Inc., owned by Dr. Cecilio Pedro,
becomes the major supplier of aluminum collapsible toothpaste tubes to ColgatePalmolive Co. Procter and Gamble Co., and the Philippines Refining Company
(PRC) now Unilever Group.
In 1988, Dr. Pedro decides to reopen his factory as Lamoiyan Corporation,
the first Filipino company to penetrate the toothpaste industry. With only less than
20 employees, the company produces world-class brands Hapee and Kutitap at
affordable prices.
Hapee toothpaste, the toothpaste brand of Lamoiyan Corporation, sponsors
the 1988 Philippine Olympic Delegation. Lamoiyan Corporation, a cosmetics
industry, is recognized as the official toothpaste of the Olympics to Seoul, South
Korea.

II.

Products and by-products

Lamoiyan Corporations main product is Hapee Hapee Toothpaste which is
available in a variety of flavors. They are available in 150ml, 100ml, 50ml, and 25ml
tubes as well as in 33g and 60g sachets. Every toothpaste contains the following
ingredients: binders, abrasives, sudsers, humectants, flavors (unique additives),
sweeteners, fluorides, tooth whiteners, a preservative, and water.
After transporting the raw materials into the factory, the ingredients are both
manually and mechanically weighed. All the ingredients are mixed together in the
mixing vat. The temperature and humidity of vat are watched closely. This is
important to ensuring that the mix comes together correctly.
After the ingredients are mixed together, the tubes are filled by the filling
machine. Then the tube is filled by a descending pump. After it is filled, the end is
sealed closed. The tube also gets a code stamped on it indicating details of
manufacture.
11

Lamoiyan also manufacture Dazz Dishwasihing Aids, Licealiz and The Hapee
Therapeutic Line which is specially formulated for the care of sensitive teeth and
bleeding gums.
III.

Environmental and Energy Aspects

Lamoiyan Corp., manufacturer of world-class quality oral, household and
personal care products, is responsible enough to note that above everything else, be it
profit or fame or both, taking care of the environment should always be a priority.
One aspect, he says, is the proper disposition of chemical by-products during the
manufacture of their famous Hapee toothpaste and all other products.
Water is also an important resource that Lamoiyan Corp. values as well.
Establishing a water treatment facility during the latter part of the decade, the
company believes that it is important to be able to recycle and reuse its waste water
for other non-drinking purposes and at the same time save on their voluminous
consumption of that precious resource.
Aside from their internal efforts on environment protection, Lamoiyan Corp. is
also an active participant in environment-related activities spearheaded by causeoriented groups, government and non-government organizations and even other
private entities.
In 2006, Lamoiyan Corp. partnered with the ABS-CBN Foundation through its
Bantay Kalikasan project. Together, the two mounted a tree-planting activity at the
La Mesa Watershed of the La Mesa Reservation Area. Also, Lamoiyan Corp. joined
another significant event, the 10.10.10 Run for Pasig River 2010 held at various
places around Metro Manila.

IV.

Role of Chemical Engineer

A chemical engineer in the field of cosmetics has a wide range of roles. Chemical
engineers may be in charge of the overall process of the operation. They measure
process parameter and ensure equipments are running properly. They are responsible
for optimum plant operation. Chemical engineers may also be in charge of testing and
analysis of material coming in and out of the plant such as raw materials and
products. These analyses are critical to plant operation as they dictate the conditions
needed for the producing standard quality products and proper plant operations. Waste
management and energy conservation are very important in which chemical engineers
may take part in. They are involved in efforts to improve recycling, waste disposal,
public health, and water and air pollution control. In the field of research and
development, chemical engineers develop technologies which may eventually lead to
12

new products and support existing ones.

V.

Observations and Recommendations

Lamoiyan Corporation manufactures toothpaste, dishwashing agents and
shampoos which inloves the use of many chemicals. Chemicals used to manufacture
these products are stored properly which decreases the possibility of hazards to occur
due to these chemicals. It was observed that sanitation is well observed throughout
the plant. Workers are equipped with clothing suitable for cosmetics industry. All
equipments observed were clean and automated.
Class windows are provided for visitors to see the process. Through this, visitors
do not direct contact with the chemicals or vapors produced in the operation. It also
ensures that the equipments are protected from unwanted objects that visitors may
have.
Since the operation deals with chemicals, proper storage should always be
observed to avoid not only contamination of the chemicals, but also to ensure the
safety of workers and employees.

Address: TECO Special Economic Zone, Mabalacat, Pampanga

Date Visited: February 1, 2015
I.

Introduction
A. Vision
TIPCO is a world-class manufacturer of paper products that meet international
quality standards and satisfy customers' specifications, by utilizing 100% recycled
raw materials, employing competent and efficient workforce and adopting costeffective, safe and environment-friendly operating processes.
B. Mission

13

Our primary purpose is to produce quality paper products that meet stringent
customers' requirements. To this end, shareholders, management and employees are
committed to:

Operate efficiently and profitably, continuously seeking ways to improve the

quality of work processes and cost-competitiveness of our products;
Deliver the products to customers on time, with consistent quality and within
stated specifications;
Provide a safe, clean and wholesome workplace that is conducive to productivity
and the continuous growth and development of its people;
Deal with our business partners with integrity, transparency and fairness;
Uphold our corporate responsibility to the environment and the communities in
which we perate.

C. Company Profile
TIPCO is TRUST INTERNATIONAL PAPER CORPORATION. Its name
is the embodiment of the ideals and working philosophy guiding the Company's
business conduct. The name reflects the foundation on which the working
relationship between the Company and those it is dealing with is built - TRUST.
TIPCO started the construction and installation of the first paper machine
(PM1) in July 1987 and formally inaugurated the mill site and PM1 on December
13, 1988. In 1993, the Company constructed a second paper machine (PM2)
purchased from Quebec Canada. In 1995, with the vision of achieving global
competitiveness, TIPCO ventured into a third paper machine (PM3) acquiring a JFormer machine from Avenor, Canada with a capacity to 350 metric tons per
day. TIPCO now also produces brown paper to meet the packaging needs of its
clients.

II.

Products and By-Products

TIPCO specializes in the production of quality newsprint, printing and writing
paper and packaging, utilizing 100% recycled paper. It is the only paper manufacturer
in the country that exports newsprint and printing and writing paper, principally to the
Asian region.
Its newsprint paper comes in varying grammage measurements, mainly 45 and
48.8 grams per square meter. As for the length and width measurements, TIPCO's
14

production technologies allow it to specifically customize the paper rolls according to

the customers' required dimensions.
Primary users of TIPCO products can be grouped broadly into two (2) sectors: the
publishers and the converters. The first group refers to the clients who publish
newspaper broadsheets, tabloids, magazines and books. The second group refers to
the firms that further cut and process the paper rolls into products like notebooks,
school pads, school workbooks, office bond paper.
With the growing environmental awareness on the need to reduce or eliminate the
use of plastic packaging, TIPCO responded by adding a brown paper packaging line
to meet the rising demand for more ecologically safe packaging alternatives.
With its close proximity to the market, TIPCO delivers paper rolls promptly, thus
reducing unnecessary storage and carrying costs for the customer. With the high
quality of TIPCO products, customers are assured of getting the exact specifications
following strict standards. TIPCO also provides after-sales service through regular
visits of its technical staff to monitor product performance at the customers'
production floor and offer suggestions for possible improvements in operating
processes or practices. TIPCO uses 100% recycled paper to manufacture high quality
paper.
TIPCOs Raw Materials Warehouse Department processes imported and locally
sourced recovered paper by sorting, conveying them into pulpers and converting them
into fibrous, cellulose mass. The Deinking Plant takes over to clean, screen, de-ink
and wash out all contaminants from the paper stock. At this stage, production process
aims to come up with the cleanest and best consistency stock. The Paper Machine
Department converts cleaned pulp into finished sheets through forming, pressing,
drying, calendering and winding processes. The end result is high quality finished
paper that is prepared for wrapping and shipping out to customers. The Logistics
Department handles all finished goods for careful piling, storage and loading into
trucks for delivery to local and offshore clients.
III.

Environmental and Energy Aspects

Cognizant of its stewardship role in preserving the country's natural resources,
TIPCO uses 100% secondary fiber and state-of-the-art environmental management
facilities to ensure compliance to all applicable environmental laws and regulations.

15

Its ISO 14001 Certified Environmental Management System guides all efforts
toward the transformation of process by-products into treated, recycled, safe and
reusable forms.
In recognition of its commendable environment management performance,
TIPCO was awarded the Gold Rating by the Environmental Management Bureau of
the Philippine Government's Department of Environment and Natural Resources
(DENR).
Aside from the local recognition of the companys environmental commitment,
TIPCO is also hailed as the first Philippine company found compliant to manufacture
products that are FSC and PEFC certified. The certifications from Forest Stewardship
Council (FSC) and Program for the Endorsement of Forest Certification (PEFC)
assure our clients that our products are environment-friendly and are produced in
ways that conserve the Earths resources so that future generations can continue to
enjoy the bounty of our forests.
IV.

Role of Chemical Engineer

A chemical engineer in this field may assess the process, take measurements and
interpret data. Chemical engineers also manage cost and time constraints, perform
risk assessments, provide process documentation and operating instructions. In the
quality department, chemical engineers perform roles as QA analysts. They test
products, systems and materials to make sure there are no defects, and make sure
that it is made to company standards. Chemical engineers may also work as
environmental engineers where they provide technical support for environmental
remediation projects and legal actions, monitor progress of environmental
improvement programs and inspect industrial and municipal facilities and programs
to ensure compliance with environmental regulations.

V.

Observations and Recommendations

TIPCO mainly produces quality newsprint, printing and writing paper and
packaging from recycled paper. In the process of deinking, bleaching agents are used,
which in high concentration may have negative effects to health. TIPCO ensures the
safety of employees, not only in the deinking unit but throughout the entire plant.
Employees are equipped with proper PPE. Workers are not that exposed to the
equipments and their operating conditions since automated control is employed
within TIPCO. Process conditions are monitored by computers in control rooms.

16

Designated ares for walking and crossing are provided. Safety warnings near
dangerous areas are highly visible.
The equipments and facilities used by TIPCO are of modern technology.
Automated control is employed to ensure that the plant operated at its full efficiency.
Also, it was observed that the equipments are clean and well maintained.
Employees of TIPCO are well taken care of. Employees are given benefits such as
housing near the vicinity of the plant. This provides convenience in living and
transportation for the employees.
It was observed that some equipments lack guard systems. This may pose a
hazard to workers that may be working or passing by the equipment. Proper safety
system should be installed in every part of the operation to provide adequate working
conditions for employees. Although monitoring is already done in the control room,
the facilities inside the control room can still be improved or updated. Improved
facilities may increase monitoring and response efficiency of workers.

Address: Luisita Agro-Industrial Complex in San Miguel, Tarlac City, Tarlac.

Date Visited: February 3, 2016
I.

Introduction
A. Mission

Bringing
peace
and
prosperity
to
the
countryside
Connecting Farmers to the rest of the world while connecting the world to our
Farmers. One Farmer, One Hectare One Community at a time.
17

B. Company Profile
Central Azucarera de Tarlac, a sugar and sugar refining industry, was incorporated
in 1927 and renewed in 1976. It operates a sugar mill and refinery, distillery and
carbon dioxide plants in Barrio San Miguel, Tarlac City. The sugar cane milled is
sourced within the Tarlac district and nearby towns of Pampanga.
II.

Products and By-Products

Central Azucarera de Tarlacs main products are raw and refined sugar. In the
production of these products, molasses is also produced as by-product. These
molasses are further processed in distilleries to produce alcohol. The various types of
alcohol regularly produced and sold are rectified spirits (purified alcohol), absolute
alcohol and denatured alcohol. The by-products of the alcohol production are further
collected to produce liquid carbon dioxide.
Raw and Refined Sugar
The Companys sugar mill and refinery has a capacity of 7,200 tonnes cane and
8,000 50-kg bags per day respectively. The sugar cane is initially processed to
produce sugar of which 31% represents the companys mill share, 69% belongs to the
planters. Most of the raw sugar produced is further processed in the refinery to
produce refined sugar. For the refining process, tolling fees are collected from
customers upon withdrawal of refined sugar from the Companys warehouse. In
addition to raw and refined sugar, the mill and refinery produces molasses, a byproduct. The molasses produced in the mill is likewise shared between the mill and
the planter using the same sharing ratio while the refinerys molasses production is
solely owned by the refinery.
The mills raw sugar sales and the refinerys tolling fees represents about 58% and
23% respectively, of the Companys total operating revenue for the last three years.
The raw and refined sugar produced is generally sold to industrial users thru traders.
The company normally operates for about 5 to 6 months while the refinery, about 8 to
9 months.

Alcohol
The combined captive molasses of the mill and refinery is processed further in the
distillery to produce alcohol. The distillery has a production capacity of about 65,000
18

gauge liters per day. The various types of alcohol regularly produced and sold are
rectified spirits (purified alcohol), absolute alcohol and denatured alcohol. These
alcohol products are sold to various reputable distillers of wine, manufacturers of
alcoholic beverages and the small portion goes to producers of pharmaceutical
products.
In addition to alcohol sales, tolling fees are also earned from various distillers
whose molasses are processed by the distillery. In the last three years, the distillerys
contribution to the Companys operating revenues was about 16%. The distillery
normally operates for about 4 to 5 months of the year in tandem with the refinery
operations.

Carbon Dioxide
The slops from the distillery are captured by the carbon dioxide plant to produce
liquid carbon dioxide also in tandem with the distillery. The plant has a capacity of
30,000 kilos per day and normally operates for about 4 to 5 months of the year.
Carbon Dioxide sales account for about 3% of the Companys total revenues in the
last three years. The carbon dioxide produced is usually sold to industrial users.
III.

Environmental and Energy Aspects

Central Azucarera de Tarlac(CAT) not only focuses on making profit but also on
how to reduce the negative impacts of their operation to develop a safe and healthy
environment. Achieving this will not only provide higher income to the plant, but will
also provide a safe, clean and healthy environment for its employees and community
where they operate.
CAT continuously strives to improve their sustainability by developing and
incorporating controls and procedures to conserve water, energy and other resources.
Proper water consumption is practiced within the plant and water conservation
programs are established. All chemical wastes are ensured to be treated before
disposal to the environment to prevent or reduce harmful impacts. CAT is also
committed in complying with local environmental standards, rules and regulations.
CAT regularly monitors their emissions and ensures that emissions comply to
standards, rules and regulations.
CAT has also delveloped facilities to further process by-products. Through this
CAT has reduced the amount of wastes they discharge to the environment. CAT seeks
to further improve their process and develop sustainability within their and
environment.
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IV.

Role of Chemical Engineer

In the field of sugar and sugar refining industries, chemical engineers may play a
variety of roles. One of which is a process engineer. Process engineers are in charge
of the whole operation of the plant. They measure process variables, interpret data
and make necessary adjustments to operate the plant at maximum level. They are also
in charge of troubleshooting in case there are malfunctions in the system. Process
engineers also evaluate the economic performance of the plant and maximize profit.
A chemical engineer may also play the role of an environmental engineer.
Environmental engineers monitor emissions made by the plant and make sure that
they comply to environmental standards. They also develop plans on how damaged
resources by the plant may be recovered.
Chemical Engineers in the Quality Assurance department tests and analyze inputs and
outputs of the plant. They ensure that raw materials and products are of standard
quality. Process variables will depend upon the analyses made by the QA department.

V.

Observations and Recommendations

Central Azucarera de Tarlac produces raw and refined sugar as their main
products. As observed, the equipments used to produce these are old and rusty. Also,
the equipments doesnt have automated control systems installed. Almost all
equipments are handled manually.
At the storage facility, raw sugar is transported from a conveyor to the floor with
no cover. Also, the storage facilitiy is prone to pest infestation since the facility is not
fully walled. This could be dangerous as contamination may occur and consumers
health may be put at risk.

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The equipments and facilities used for the alcohol and carbon dioxide production
are clean and new since these departments are relatively new compared to that of the
raw and refined sugar production units.
To maximaize efficiency and production of the plant, I recommend that automated
control systems be installed and that equipments be replaced or properly maintained.
Also, sanitary measures should be observed not only at the storage but also
throughout the whole plant. Floor covers can be installed to prevent dirt
contamination to the sugar.

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