Trust International Paper Corporation

Address: TECO Industrial park in Bundagul, Mabalacat, Pampanga

Date Visited: February 1, 2016

I.INTRODUCTION
Mission
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 operate.

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 cost-effective, safe and environment-friendly operating processes.

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 Company Profile

Trust International Paper Corporation (TIPCO) is a major player in the

paper manufacturing industry in the Philippines. A multi-billion peso
company, TIPCO is equipped with technologically advanced paper machines, de-
inking plants and environmental management facilities.

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.

In 1995, with the vision of achieving global competitiveness, TIPCO

ventured into a third paper machine (PM3) acquiring a J-Former machine from
Avenor, Canada with a capacity to 350 metric tons per day. The J-Former, a twin-
wire paper machine, was the first of its kind installed in the country. Compared to

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the usual less efficient conventional fourdrinier type, the machine has advanced
J-formation and sheet stability, the qualities required for copy paper, 4-color
printing and high-speed printing. PM3 was officially declared on commercial
operations in January 1998.

TIPCO adopts the latest in paper making technology using the first twin-
wire newsprint paper machine in the country.

TIPCO's reputation for product excellence is anchored on its goal to

continuously increase its production capacity and efficiency through investments
not only in the production facility but also in the maintenance facilities. Its
Computerized Numeric Control (CNC) Roll Grinder is another first of its kind in
the Philippines.

II. MANUFACTURING PROCESS

TIPCO uses 100% recycled paper to manufacture high quality paper.

Raw Materials Warehouse Department

processes imported and locally sourced
recovered paper by sorting, conveying
them into pulpers and converting them into
fibrous, cellulose mass.

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.

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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.

Logistics Department handles all

finished goods for careful piling, storage
and loading into trucks for delivery to
local and offshore clients.

Products and By-products

TIPCO uses 100% recycled

paper to manufacture high quality paper.
The plant processes imported and locally sourced recovered paper by sorting,
conveying them into pulpers and converting them into fibrous, cellulose mass.
The newsprint and brown paper products are of standard quality designed to
meet the stringent demands of our printing and publishing clients. TIPCO now
also produces brown paper to meet the packaging needs of its clients.

III. ENVIRONMENTAL AND ENERGY ASPECT

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.

Its ISO 14001 Certified Environmental Management System guides all

efforts toward the transformation of process by-products into treated, recycled,
safe and reusable forms.

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 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.

Also, as a responsible member of the community, TIPCO takes to heart its

corporate social responsibility by initiating various programs geared toward
preserving the environment and touching base with the people in the neighboring
barangays and other localities.

Employee volunteers take part in CSR programs such as tree planting,

river clean-ups, Adopt a River drives, nutrition and feeding campaigns, school
painting activities, donation drives, medical missions, and livelihood teaching
sessions to promote the Companys goal of strengthening and sustaining
partnerships with the local communities.

IV. ROLES OF CHEMICAL ENGINEER

Chemical Engineers supervise and monitor each department. They

develop new procedures and researches on raw materials and chemical process,
which will increase and improve the plant efficiency. They are also present in
Quality Assurance department where they conduct specific laboratory tests to
see if the products to be transported follow certain standard specification.

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 V. OBSERATIONS AND RECOMMENDATIONS
When we enter TIPCO, I have observed that they provide civic amenities
such as accommodation and recreation in the facility of the plant for their
workers. Employees have also good work ethics since some of them volunteer to
conduct the lecture even if they are already done on their shift.

The plant employs a product layout type of manufacturing plant layout.

Various operations on a product are performed in a sequence and the machines
are placed along the product flow line.

The plant also employs a semi-automated control. They have separate

control room for deinking plant and paper machine department. The Deinking
Plant monitors the cleaning, screening, de-inking and washing out all
contaminants from the paper stock. At this stage, production process aims to
produce 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 product is high quality
finished paper that is prepared for wrapping and shipping out to their customers.
The Logistics Department is in-charge to all finished products for careful piling,
storage and loading into trucks for delivery to local and offshore clients.

They implement more of transmission barrier for their safety control mainly
engineering and management control. For the engineering control they installed
barriers and safety lanes for operators and personnel and personal protective
equipment (PPE) for the management control. They are required to wear ear
muffs, imposed by the plant administration to abide to a standard protocol.

The management did not required us to wear PPE as a part of safety

precaution they should require their visitors to wear it before touring the whole

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 plant. They should also focus on reforming the plant tour protocol to ensure the
safety of the visitors.

Since the plant uses a product layout one of its disadvantage is it creates
dull and repetitive jobs, to have improvement, I recommend that the employees
should undergo training on every part of the operation for them to be flexible in
every chemical process and operations. Proper sanitation is a must; the plant
should be strict in maintaining the plant
to be in order to be safer.

Address: Former SubCom Area, Rizal Highway, Subic Bay

Date Visited: February 1, 2016

I. INTRODUCTION
Mission
We are committed to continually exceed our customers expectations
through our quality water and services. We shall perpetually protect the
environment in all aspects of our operations.
We shall entrance, promote and live out our core values, and create a
healthy and safe working environment conducive to our growth and development.
In pursuit of these commitments and in full compliance with applicable
legal and other requirements, we shall become a benchmark of excellence in the
industry.

Vision
Beyond Quality Water and Services. A Benchmark of Excellence.

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Company Profile
Subic Water and Sewerage Co., Inc (SUBICWATER) is Southeast Asia's
pioneer company which introduced the first public-private partnership (PPP),
build-operate-and transfer (BOT) model in the water and wastewater services
industry. The company was formed in light of the impending water crisis in
Olongapo City during the '90s, and the growing commercial water requirements
of the booming Subic Bay Freeport Zone.
SUBICWATER is a consortium of D.M. Consunji Inc. (DMCI), a Filipino
construction firm; Sembcorp Industries Ltd., (sembcorp) a Singaporean water
utility specialist; the City Government of Olongapo; Subic Bay Metropolitan
Authority (SBMA), the agency that administers Subic Bay Freeport; and Maynilad
Water Services Inc. (Maynilad), the Philippines' largest water concessionaire in
terms of customer base.
The company was granted the exclusive right and privilege to operate,
maintain, and improve the water and sewerage systems of Olongapo City and
Subic Bay Freeport under a 30-year franchise term.
SUBICWATER officially commenced operations in April 1, 1997.
In pursuit of delivering world-class services to customers, SUBICWATER
became the first ISO-certified water utility in South East Asia.
At present, SUBICWATER is certified to comply with ISO 9001:2008
(Quality Management System), ISO 14001:2004+Cor 1:2009 (Environmental
Management System), and OHSAS 18001:2001 (Occupational Health and
Safety Management System).

Plant Facilities
Water Treatment and Distribution
SUBICWATER relies heavily on raw surface water to supply the needs of
the region. In fact, 99% of its raw water comes from rivers, thereby requiring a
multi-stage treatment process, as opposed to water from deep wells, which
require a minimal disinfection only.

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 SUBICWATER operates two conventional-type water treatment plants with
a combined daily production capacity of 77 million liters. The output from the two
plants is being augmented by four active deep wells located in various parts of
the franchise area.
In total, the companys water production capacity is at 84.05 MLD (million
liters per day).

Binictican Water Treatment Plant

Sitting peacefully at the foot of the Binictican Forest is the Binictican Water
Treatment Plant (BWTP).
This plant draws its raw water from six rivers cutting through this
Freeports virgin forests. Its total production capacity is 39 MLD, enough to
supply the full water requirement of this former US Naval Base and about half of
Olongapo Citys water demand. Two wells in the Freeport add a combined
production of 1.35 MLD on top of BWTPs output.
Located inside the BWTP compound is SUBICWATERs laboratory, where
all water quality testsphysical and bacteriological are being carried out.
All major components of the BWTP have been recently reinforced with
high-strength carbon composites and glass fibers to lengthen their lifespan.

Mabayuan Water Treatment Plant

This facility is situated at the northern part of Olongapo City. It draws its
raw water from two points of the Mabayuan River: at the Old Dam which
transports raw water through sheer gravity, and at the New Dam, which is in the
downstream portion of this water body.
The Mabayuan Water Treatment Plant (MWTP) can operate on a
maximum capacity of 38 MLD for distribution to seven barangays of the City:
East Bajac-bajac, West Bajac-bajac, Kalaklan, Mabayuan, Sta. Rita, Gordon
Heights, and Old Cabalan.

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 A steel-bolted modular tank provides a two-million liter buffer supply for
MWTP. Should there be technical problems in the plant, this reservoir can
provide for the water requirements of the plants service area. In the dead of the
night, when demand for water is at its lowest, the electric pumps in the MWTP
can be completely shut down, resulting to significant savings in electricity and
repair costs, since these vital machines can take some rest.
Another significant feature of MWTP is its automated water quality
monitoring. Online analyzers were installed so that the MWTP can generate real-
time data on water turbidity, residual chlorine, and pH levelits acidic and
alkaline propertiesin all stages of the treatment cycle, from raw water
extraction to purification and filtration.

Sewerage Systems
The collection, treatment, and disposal of wastewater in Subic Bay
Freeport are accomplished through seven separate sewerage systems in the
areas of Central Business District, Enron, Binictican, Kalayaan, Boton, Cubi, and
Cubi Hospital.
Overall, the company operates and maintains seven sewage treatment
plants (STPs), 80 kms of sewer pipelines, 1,378 sewer manholes, and 32
sewage lift stations.
In Olongapo City, SUBICWATER offers sanitation services only. The
company, however, has a Sewerage Masterplan completely drawn up and
presented to the public in as early as 2006.
The significant effect on water tariff, and the major traffic disturbance that
the massive sewer pipeline laying would bring, are the major issues that have
been considered in the putting the masterplan in the sidelines.

II. MANUFACTURING PROCESS

Mixing

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 Chemicals are added to the raw water to remove impurities, bad taste,
and odor. Chlorine kills bacteria and other micro-organism, coagulants bind to
impurities, polymers aid coagulation, and lime controls acidity.

Coagulation and Flocculation

Water now goes to the flocculation chamber. The added chemicals
coagulate or bind to the impurities such as dirt, forming particles called flocs.
These flocs grow larger and heavier and eventually settle at the bottom of the
tank.

Sedimentation
Clear water is taken from the upper portion of the flocculation chamber
and is sent to the clarifier, where water stays for a relatively longer time. This
allows the finer particles not captured by the flocs to settle at the bottom of the
clarifier.

Filtration
Water from the upper part of the clarifiers is made to pass through the
filters to remove the finest impurities.

Disinfection
The right dosage of chlorine is added to keep the water free from bacteria.
The fully-treated water can now be distributed to households and business
establishments.

Water Quality Monitoring

Water samples from all over Olongapo City and Subic Bay Freeport are
being collected and brought daily to our DOH-accredited laboratory for physical,
chemical, and bacteriological testing.
PROCESS FLOW CHART
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 III. ENVIRONMENTAL ASPECT
In the absence of a sewerage system in the city, officials have passed
a resolution prescribing a standard septic tank design and the
frequency of septic tank cleaning to strengthen the implementation of
the Code on Sanitation of the Philippines.

IV. ROLE OF CHEMICAL ENGINEER

Chemical Engineers on the water treatment facility supervise the
chemical process wherein it requires monitoring the parameters to
meet the required standard in every stage of water treatment. Also,
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 they ensure that the water that undergoes the treatment will meet the
standard and laws imposed by Department of Environment and Natural
Resources.

V. OBSERVATIONS AND RECOMMENDTIONS

The water treatment facility has guardrails to ensure the safety of every
personnel which is one of the main priorities in every facility. It is a
good thing that the facility is a semi-automation control that helps to
monitor every parameter and also it increases the plant efficiency. But,
they still need to improve the process flow to optimize the plant
efficiency and production.

Also, the water facility needs to notify their customers that they also
need to help to remove their domestic waste such as diapers, sanitary
pads and etc. on their sewage water because it hinders and decreases
the flow rate.

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 Material Recovery Facility
Address: Sitio Tulay, Barangay Tandang Kutyo, Tanay, Rizal

Date Visited: February 2, 2016

I. INTRODUCTION

Mission
The Municipality of Tanays mission is to improve the socio-
economic condition of its population through sustainable development and
responsive management of its resources in active partnership with all
concerned sectors.

Vision
The Municipality of Tanays vision is to be regional tourism haven
with diversified, highly competitive economy, healthy, and sustainably
developed urban, rural and natural environments, a pro- active and
responsible governance and god-fearing, self-reliant and socially
responsive citizenry.

Corporate Profile
Tanay Mountaineers Inc. is a non-profit organization that aims to
protect the environment. They are engaged in educating the people about
the environment. Through research and studies, they found out that
charcoal making in Tanay is one of the causes of deforestation which
endangers the environment. The Community Based Charcoal Briquetting

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 Project was created to save the trees in the forest. Charcoal briquetting is
a process of making charcoal without cutting any trees. This project not
only aims to protect the environment but also make the people in the area
aware of the causes of charcoal-making. This project also bring livelihood
to the people in the community.

The Tanay Mountaineers Inc. was able to provide free metal drums
or carbonizer to different hotspot areas in Tanay namely Barangay San
Andres, Sto. Nino, Mamuyao, Cayabu, Tinucan, Sta. Ines, Laiban,
Daraitan, and Cuyambay (Tablon). The members taught each community
the process of making charcoal with the use of agricultural waste. The
carbonized materials are then being sold by each community to Tanay
Mountaineers who will then finish the process at the Materials Recovery
Facility of Tanay. The finished products are sold by the members as part of
their advocacy and income generating project.
II. MANUFACTURING

Biomass collection Drying

Carbonization Preparation of Char

Powder Binder Preparation

Briquettes Production

Drying

.
For carbonization, loosely pack the collected biomass into
the kiln. The kiln will accommodate. After loading the biomass into
the kiln, close the top of the kiln with metal lid attached to a conical
chimney. Little amount of biomass is used in the firing portion to

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 ignite in the kiln and close the doors tightly to start the pyrolysis
process. After the biomass gets fully carbonized (~ 1-2 hrs;
depending upon the biomass), the lid is remove and water is
sprinkle over the char. The resultant char powder is use for the
preparation of briquettes. Though the carbonization process
produces @ 30-45% char powder on an average, the char yield
varies according to the biomass used. A binder is used for
strengthening the briquettes. The carbonized char powder can be
mixed with different binders such as commercial starch, rice
powder, rice starch (rice boiled water) and other cost effective
materials like clay soil and mixed in different proportions and
shaped with the help of briquetting machine.

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 Product and by-product
The final products of the Material Recovery Facility are the bio
charcoal, which is an alternative way not to cut trees to be made into
charcoal, and fertilizer, which comes from organic wastes. Residual
wastes like scrap cloths are given to the facility which cement plants pick
up to feed to their furnaces.

III. ENVIRONMENTAL AND ENERGY ASPECT

The Material Recovery facility used different kinds of agricultural
waste and domestic waste such as textile and paper in order to make the
charcoal to prevent deforestation.

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 IV. ROLE OF CHEMICAL ENGINEER

There is no chemical engineer present in the facility because it is a

project of the municipal government of Tanay, Rizal to prevent
deforestation and at the same time minimizing the waste produced.

V. OBSERVATIONS AND RECOMMENDATIONS

Upon entering the facility, it can be observed that there is an

undesired smell. This smell is cause by organic wastes in the facility. The
drum method, which is the first step in the briquetting process, produces
amount of smoke that could be a hazard. This smoke can add to air
pollution even if it comes from burning coconut husk. I would recommend
that they should develop a way to filter the smoke if it cannot be reduced
or prevented. They should also find a way to segregate plastics from the
organic wastes fed to the bioreactor as these plastics can damage the
bioreactor. The facility should also develop a method of properly and
effectively segregating of the waste. These plastics are also mixed with
the fertilizer produced that could decrease the effectiveness of the
fertilizer.

As a recovery facility, it does not have the complex equipment a

real plant has because it is just a municipal project. The facility has two
bioreactors for making fertilizer, and the necessary equipment needed for
charcoal briquetting. There is no wastewater recovered in the briquette
process or in the fertilizer production as both of these processes do not
require water.

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 Central Azucarera de Tarlac
Address: Barrio San Miguel, Tarlac City
Date Visited: February 3, 2016

I. INTRODUCTION
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
Vision
To go beyond sugar, food, renewable and land development for peace and
progress

Company Profile

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 Central Azucarera de Tarlac 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.

Central Azucarera de Tarlac traces its roots from a tobacco plantation, its
lands awarded to the Compaa General de Tabacos de Filipinas under royal
grant from the Spanish throne during the Spanish occupation. The Tabacalera, as
the company was more popularly known, concentrated its operations in Manila
when the tobacco monopoly was abolished in 1881. The company's governing
body sent Seor Lope Gisbert to find fertile areas for development and he
recommended the land surrounding the railroad that extended from Manila to
Dagupan. This land was acquired in 1907 after a long and tedious process. It
was registered as Hacienda Luisita, after Doa Luisa, the wife of the founder of
the Tabacalera.

Jos Cojuangco, Sr. (father of former president Corazn Aquino) led a

group of Filipino investors in the negotiations for the purchase of both Hacienda
Luisita and Central Azucarera de Tarlac from the original Spanish owners in
1957, and Cojuangco, Sr. succeeded on 9 April 1958. The company that this
purchase bore is known as Jos Cojuangco & Sons Organisations, and it
expanded the Azucarera's products to include molasses, liquid carbon dioxide

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and yeast, and its operations to selling sugar to both domestic and international
markets.

II. MANUFACTURING
After the cane arrives at the mill yards, it is mechanically unloaded,
and excessive soil and rocks are removed. The cane is cleaned by
flooding the carrier with warm water (in the case of sparse rock and
trash clutter) or by spreading the cane on agitating conveyors that pass
through strong jets of water and combing drums (to remove larger
amounts of rocks, trash, and leaves, etc.). At this point, the cane is
clean and ready to be milled.
After being purified, the clear juice undergoes vacuum evaporation to
remove most of the water. In this process, four vacuum-boiling cells
are arranged in series so that each succeeding cell has a higher
vacuum. The vapors from one body can thus boil the juice in the next
one, a method called multiple-effect evaporation. Next, the syrupy
solution is vacuum-crystallized to form sugar crystals. The remaining
liquid is removed using centrifugaling and drying, and the sugar is
packaged.

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Products and By-products
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
by-product. 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.

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 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.

Carbon Dioxide

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 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 ASPECT

During milling season they produced 70% to 80% of their own energy
requirements from the steam produced in the boilers that gives energy to power
the turbines. Boiler fuels are from bagasse. This reduces their waste and
consumption, and helps conserve energy that made a way to lessen their
expenses.

During fermentation process the plant uses yeast. The yeast becomes a
waste, they recover it use as an animal feed supplement. It is still employed in
the plant facility even the recovery process is expensive because it helps on the
plants waste management.

IV. ROLES OF CHEMICAL ENGINEER

Chemical Engineers on the plant supervise the chemical process wherein
it requires to know the job of every personnel under his/her supervision and in
order to implement corrective and disciplinary actions. They still need to improve
the process flow to increase the plant efficiency and production.

V. OBSERVATIONS AND RECOMMENDATIONS

Central Azucarera de Tarlac has two seasons, milling and repair. Milling
season start if sugarcane is ready for harvesting which starts on November and
lasts for about 5 to 6 months. Repair season is for preventive maintenance.

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 During milling season they produced 70% to 80% of their own energy
requirements from the steam produced in the boilers that powers the turbines.
Boiler fuels are from bagasse.

The plant uses Product Layout in their production since the machines are
arranged according to the needs of the product and in the same sequence as the
operation are necessary for manufacture.

After seeing the whole process for the production of sugar, I recommend
that they develop a process for the cleaning and disinfecting of sugarcane to
remove the microorganism in order to make the product to be cleaner and safer.
They could develop a way for the farmers to follow during their harvest period to
achieve good quality and cleaner sugarcane. By this they may reduce the usage
of chemicals that are used in the production of white sugar. The company could
conduct seminars and trainings for the farmers in order to increase the
production of the sugarcane to meet the demand of the production of sugar.

The smoke coming out of the factory is thick and this is from the boilers.
They already used wet scrubbers to trap dust and ash particles from boilers. I
recommend that they improve the scrubbing process in order to meet the
standards impose by Department of Environment and Natural Resources. Since
the plant is old it is more of a manually operated plant. I recommend that they
should shift their operation to semi-automated process to increase the plant
efficiency. Through sensors and manual operation optimum production will be
achieved. Most of the plants practice semi automation that gives better outputs
therefore CAT will be assure that it will give the same output to them.

I recommend that CAT should shift their plant layout into Combination
type of layout because flexibility is also an important factor to be considered,
layout should be such which can be molded according to the requirements of

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industry, to lessen the expenses of the operation that leads to higher revenue. If
the good features of all types of layouts are connected, a compromise solution
can be obtained which will be more economical and flexible.

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