MEMBERS:

BONIFACIO, Jardine C.
FLORDELIZA, Vanessa Mae M.
RELIGIOSO, Ariana Nicole A.
TOLENTINO, Chelsea S.

SECTION: 4ChEB
GROUP: 2
DATE SUBMITTED: May 10, 2019 (Friday)
PLANT/INDUSTRY: Food and Beverage Industry – PCPPI Cabuyao Snacks Plant

I. OBJECTIVES

 Cite the common manufacturing industries where a chemical engineer might be

involved and explain how each industry functions
 Understand the fundamental unit operations, reactions, and processes involved in the
different chemical and manufacturing industries
 Discuss with the help of relevant flow diagrams, equations, operating conditions and
equipment principles, the manufacture of some chemicals / products
 Learn the processing of raw materials into usable and profitable products
 Integrate chemical engineering concepts in the solution of real industrial chemistry
and engineering problems
 Work and communicate well in a team

II. INTRODUCTION

a. Company Profile

Pepsi-Cola Products Philippines, Inc. (PCPPI) was established in 1989 as Premier

Beverages by Luis Lorenzo, Sr. to acquire the bottling and distribution rights
to PepsiCo beverages in the Philippines. It was incorporated and registered with the Securities
and Exchange Commission (SEC) on March 8, 1989 primarily to engage in manufacturing, sale,
and distribution of carbonated soft drinks and non-carbonated beverages, and confectionery
products to retail, wholesale, restaurants, and bar trades. Moreover, PCPPI is a licensed bottler
of PepsiCo, Inc. and Pepsi Lipton International Limited in the Philippines and is also a licensed
snacks appointee of The Concentrate Manufacturing Company of Ireland in the Philippines. Lotte
Chilsung, one of the biggest beverage companies in South Korea, is the lead shareholder of
PCPPI as an independently-listed company and co-manages it together with PepsiCo.

The Company manufactures carbonated soft drinks, non-carbonated beverages, and

snacks that include brands such as: Pepsi, Pepsi Light, Pepsi Max, 7 Up, Mountain Dew, Mirinda,
Mug, Lotte Milkis, Non-carbonated:, Tropicana, Mirinda Fun Mix, Lipton, Lipton Sparkling,
Gatorade, G Active by Gatorade, Sting Energy Drink, Aquafina Purified Drinking Water, Premier
Drinking Water, Lotte Let’s Be, Milkis, and Cheetos.
On August 27, 2014, the SEC approved the amendment of PCPPI's primary purpose to also
engage in the manufacturing, sale, and distribution of snacks and food products. In May 2015,
PCPPI announced that it would begin the manufacture and distribution of Cheetos snacks in the
Philippines by the end of the year, in line with its goal to become a premier food and beverage
company here in the Philippines. At present, they produce internationally-renowned snacks
products for the Philippine market which is the Cheetos. PCPPI commenced production at its new
facility located in #3 Fusion St., Light Industry Science Park 1, Brgy. Diezmo,
Cabuyao, Laguna on February 2016. The plant was designed to be a world-class foods
manufacturing facility, fully compliant with the quality and safety standards set internationally by
its parent brand PepsiCo. They manufacture exciting variants of Cheetos at affordable price points
and within reach of the snack-loving Filipino consumers.

The Company also employs its own sales force, consisting largely of supermarkets,
restaurants and convenience store chains. Most of these sales are credit sales. In addition, it sells
products to third party wholesalers and distributors, which sell them to retail outlets. PCPPI has
established manufacturing facilities across the country, serving at least 500,000 outlets and
providing employment through its extensive distribution network.

b. About the Product

(Brief History, Uses/Applications, Economics, Leading Companies)

Cheetos were invented in 1948 by Fritos creator Charles Elmer Doolin, who cooked early
test batches in the Frito Company’s Dallas, Texas -based research and development kitchen. The
cheese-flavored snack sold quickly, but Doolin did not have the production and distribution
capacity to fund a nationwide launch, which eventually led him to partner with potato chip
businessman Herman W. Lay for marketing and distribution, hence, Cheetos were introduced
nationally in the U.S. in 1948, along with a potato product called Fritatos. The success of Cheetos
prompted the two businessmen, Doolin and Lay, to merge their two companies in 1961, forming
the now-called Frito-Lay Inc.

At that time, Cheetos, Fritos, Doritos, and Tostitos, were the four large snack food brands
produced by the company, which totaled annual revenues of $127 million. Consequently, Frito-
Lay Inc. merged with the Pepsi-Cola Company to form PepsiCo in the year 1965 which prompted
further distribution of Cheetos outside of North America. Frito-Lay brought several iconic and
profitable snack brands to PepsiCo, including six of today's billion-dollar brands: Cheetos, Doritos,
Tostitos, Lay's, Walkers, and Fritos.

While Cheetos was the first snack food of its kind, competing products in the snack food
category including Utz Cheese Curls, Herr’s Cheese Curls and Wise Cheez Doodles, along
with Planters’ canned Cheese Puffs and Cheese Curls, have since emerged. Most of the
competing cheese-flavored snacks are distributed in specific regions of the U.S., and as of 2010
until present, Cheetos remains on top of the line for top-selling cheese-flavored snacks worldwide.
 In the year 2010, worldwide annual sales of Cheetos amounted to approximately $4 billion,
making it the 11th-largest PepsiCo brand along with the company’s other top grossing products.
And as of 2011, Cheetos are produced, marketed, and distributed under three different PepsiCo
operating divisions namely: PepsiCo Americas Foods, PepsiCo Europe, and PepsiCo Asia,
Middle East & Africa. Additionally, PepsiCo also granted a license to the Strauss-Elite company to
distribute the Cheetos snack.

At present, PepsiCo ranks second among the top food and beverage companies all over
the world with an annual revenue of $63,525, while Nestlé topped the list with an annual
revenue of $91,624.

Moreover, under PepsiCo Asia is the Pepsi-Cola Products Philippines Inc. (PCPPI) which
is its exclusive bottler here in the Philippines that recently has expanded to snacks food
production. The local snacks market is increasingly competitive, with Universal Robina Corp.,
maker of Jack n Jill; Liwayway Marketing Corp. of Oishi snacks; and Leslie Corp., maker of Clover.
Annual sales or revenue of PCPPI as of year 2018 amounted to P33,594 million, which increased
significantly compared to the previous year which has an annual revenue of P30,306 million,
having a sales growth of 10.35% from 2017-2018.

III. MANUFACTURING PROCESS

a. Raw Materials

The process of manufacturing Cheetos begins when the raw materials like corn meal and
cheese/barbeque/cheddar jalapeno mix seasoning arrives at the facility. These local suppliers are
selected based on PepsiCo’s global standards of safety and quality. Before the load is accepted,
samples are tested as for the protocol defined by the Quality Control (QC) Laboratory to ensure
samples match global standards and specifications for safety and quality from Frito-Lay
Manufacturer, which can be used to manufacture the product. The following are the different
testing done in QC Laboratory:

• MEAL QUALITY CHECK

• QUALITY CHECK AND OIL FFA CHECK
• SALT CHECK
• MOISTURE CHECK
•
In case of any variations, the whole shipment is rejected after getting a green flag given by
the QC Laboratory. Then, the materials tested are safely stored in a clean, hygienic, and dry
environment, which is their Storage Facility. PCPPI also assure that their production lines are
regularly sanitized every before and after the production of the Cheetos snack for Hygienic
purposes and compliance to Food Safety standards.
 b. Unit Operations and Unit Processes (Process Flow Diagram)

To produce the Cheetos snack, it undergoes five major steps, Figure 1 shows the schematic
flow diagram of Cheetos manufacturing.

Figure 1. Cheetos Manufacturing Flow Diagram

1) Mixing using a blender/vertical mixer

- The production proper starts here, wherein blending of corn meat at a certain ratio is done
and tested water is also added for a perfect extrusion afterwards. Feed mixer plays a vital role
when it comes to the efficiency, being the key to a good feed production. It serves as the tipping
point of the production since if feed is not properly mixed, then ingredients and nutrients will not
be properly distributed when it is about to be extruded.

- The mixer has an initial food metal detection in it which is an essential part of the mixing
process, which is the major safety issue within the industry, not only for the manufacture’s
reputation, but also to the health and safety of the consumers. Thus, through the metal detector
in the mixer, metal particles are separated even before they are broken up into smaller pieces,
which will be harder to detect.

2) Extrusion using an extruder

- The blended corn starch is converted into Cheetos chips, which is referred to as collets,
uncoated and not fried chips (plasticized/gelatinized). These collets are heated under a high
pressure and temperature, as they pass through metal plates, in which the friction melts the corn
starch and heats up the moisture. Mixture is then push through the hole in a die and creates a
ball shape. When the corn starch reaches its boiling point, having contact with hot air, causing
the steam in the mixture to expand, the corn starch “pop” and creates the shape that is desired,
which in this case is a craggy collet. Then, these collets are cut out of the extruder and drop onto
a conveyor belt.

- Starch gelatinization prior to frying is observed in extrusion, which means it breaks down
the intermolecular bonds of the starch in the presence of water and heat, allowing hydrogen
bonding to engage more water, in which water acts a plasticizer.

Principle of Extrusion Cooking

-Raw materials are allowed into the extruder barrel and the screw(s) then convey the
food along it.
-Further down the barrel, smaller flights restrict the volume and increase the
resistance to movement of the food.
-As a result, it fills the barrel and the spaces between the screw flights and becomes
compressed.
-As it moves further along the barrel, the screw kneads the material into a semi-solid,
plasticized mass.
-If the food is heated above 100ºC the process is known as extrusion cooking (or hot
extrusion).
-Here, frictional heat and any additional heating that is used cause the temperature to
rise rapidly.
-High temperature of operation in presence of water promotes gelatinization of starch
components and stretching of expandable components.
-The food is then passed to the section of the barrel having the smallest flights, where
pressure and shearing is further increased.
-Finally, it is forced through one or more restricted openings (dies) at the discharge
end of the barrel as the food emerges under pressure from the die, it expands to the final
shape and cools rapidly as moisture is flashed off as steam.

3) Frying/Oven-Drying using a fryer

- The collets move through a piping-hot pan that is filled with vegetable oil, which not only
imparts fatty flavor, but also fries snack’s moisture content down to 2%, being a key component
for crunchiness of the snack, producing Cheetos chips. In the puffed product however, instead of
using drying process, oven-drying is used without the use of oil. Deep frying is known as an
immersion-oil frying, which is a method of choice for snack foods. Whereas oven-drying is through
evaporation, which uses convection that heats through air currents.

- Oil management in this process is necessary for the quality of oil has a paramount
importance when frying as the quality of the fried food depends on it, where the amount of oil
absorbed in different friend foods varies.
 4) Coating/Flavoring using a tumbler

- Cheetos chips are transferred to a large rotating drum, in which cheese/barbeque/cheddar

jalapeno mix seasoning is nozzle sprayed onto the chips. It is strategically mixed with palmolein
oil, to ensure that the seasoning powder remains intact and coated with the chips. The drum
rotates continually to keep the product moving, which ensures that each piece of the product is
evenly coated.

- At the last conveyor belt in the production, Cheetos chips are dropped and where the
remaining moisture is being steamed off, being cooled to room temperature. But before its final
departure, which is the packaging area, the product is scanned once again through a metal
detector to assure that no foreign particles have entered the product during the production
processes.

5) Packaging using a packager (Roto-clone machine)

- Cheetos chips are finally ready for packing. The corresponding packaging film laminate
used was quality tested in the QC laboratory before putting to use. The distribution conveyors for
the production flow follows a vibration mechanism for transport. It also has a weigher for the
desired amount to be placed on different variations of packaging, then coding and lastly, carton
tapping, which is manually packed in a box then will be delivered to the finished product
warehouse for dispatching.

- Cheetos chips are immediately packed to seal in freshness and distinctive taste the product.

IV. COMMON MANUFACTURING PROBLEMS AND PROPOSED SOLUTION

a. PROBLEMS
i. Quality Issues

According to Oxford, quality is the standard of something as measured against other things
of a similar kind. In food industry, food quality means that the quality characteristics of a food
product is acceptable to consumers. It is a measure of excellence. A state of being safe for the
consumers (chemically, microbiologically, physically, etc.). Food products must satisfy the
consumers’ nutritional needs, and should have acceptable appearance (size, shape, color, gloss,
and consistency), texture, and flavor. Food quality is an important requirement in food and
beverage industry, because food consumers are susceptible to any form of contamination that
may occur during the manufacturing process. As part of food quality, ingredients present in a food
product are necessary to be identified by the consumer through manufacturing and processing
standards due to nutritional requirements (kosher, halal, vegetarian), or medical conditions (e.g.,
diabetes, or allergies). Food quality is brought about by strict and consistent commitment to
certain standards that achieve uniformity of a product. Good Manufacturing Practice Regulations
promulgated by the US Food and Drug Administration, require that manufacturers, processors,
and packagers of drugs, medical devices, some food, and blood take proactive steps to ensure
that their products are safe, pure, and effective. It ensures the integrity of the food manufacturing
process as well as an ideal working environment for clean, safe, and high-quality food products
for consumers. When it comes to food and beverage packaging, each product must be tightly
sealed and stored at the correct temperature to maximize shelf life and prevent spoiling.

In relation to the plant visit conducted by the group, the PCPPI Snack Plant encounters
quality issues concerning salt content, and packaging of the food product. According to the Quality
Assurance manager, the salt content problem in the product may be due to machine/equipment
defects encountered in the food processing. At one instance, the pump which supplies the
seasoning for the product in the rotating drum has a tear on the tube which causes spillage of the
seasoning where the pressure decreases and salt application on the products is also decreased.

ii. Overproduction

Another manufacturing problem encountered by the PCPPI Snack Plant is the

overproduction of the food product. Overproduction is defined as production that exceeds
demands from the customers. It also refers to the production of goods before they are required.
Both activities enhance the possibility of producing inaccurate goods, product obsolescence as
well as the need to offer products at a discount.

b. PROPOSED SOLUTION
i. Quality Control

The quality management combines commitment, discipline and a mix and growing effort by
everyone involved in the production process which includes the employees, management, and
administration, with the goal of continuously improving all processes and products. Quality control
is a system of maintaining standards in manufactured products by analyzing the quality a sample
of the output against the specification. ISO 9000 defines quality control as "a part of quality
management focused on fulfilling quality requirements". Quality control includes inspection and
analysis of the raw materials, production processing, and packaging.

Quality of the raw materials are important because raw materials are the foundation of the
manufactured food product. Raw materials in the food manufacturing industry are not only the
ingredients that are used to make the food product, but it also includes the packaging materials
and processing aids. Processing aids are substances used to enhance food safety by reducing
potential contamination in food during processing (antimicrobials) or facilitating an easier removal
of impurities (flocculents). Other functions that processing aids serve include a pH control agent,
a catalyst, or a clarifying agent. These raw materials must meet the regulatory requirements (safe
and legal for your intended use) and company’s specifications which will contribute to functionality
and quality of the product. Ingredients quality control includes corn meal quality check, quality
check and oil Free Fatty Acid (FFA) check, salt check, and moisture check.

Quality control of the production process is important, because it ensures that the process
in the production of the products is being done correctly and at the right condition in accordance
to specification of the process. In the sampling system, samples from the production are being
taken every two hours or three times per shift. Salt content is also analyzed every hour. Other
parameters that are being checked are the moisture content upon mixing and frying, the FFA
value of oil, the salt content, and the fat content.

Sodium is an essential mineral by the body to control blood pressure and help the nerves
and muscles to function properly. However, high sodium intake can cause health problems such
as high blood pressure and cardiovascular diseases, which include heart, stroke, and blood
vessel disease. In food industry, salt improves the product shelf life, and texture. Therefore, too
high and too low in the amount of salt can compromise flavor, texture, or shelf stability. Auto-
titrator is an equipment used to analyze salt content. Oil and moisture is important in food
processing because it affects the taste, texture, weight, appearance, and shelf life of the product.
Too much oil & moisture mean that the product is undercooked which will affect the shelf-life
because it will stale faster, and it will also have a poor taste. When the oil & moisture is too low
the product may be overcooked, this means additional energy for the frying thus higher cost. It
will also compromise the consistency of the product as well as taste, texture, and appearance.
On the other hand, most food products do not contain Trans Fat (zero gram), trans fatty acids are
not essential and provide no known benefit to human health, whether of animal or plant origin. It
increases levels of low-density lipoprotein (LDL, often termed "bad cholesterol") and also lower
levels of high-density lipoprotein (HDL, often termed "good cholesterol") thus increasing the risk
of coronary artery disease. According to the 2006 New England Journal of Medicine (NEJM)
scientific review, it states "from a nutritional standpoint, the consumption of trans fatty acids results
in considerable potential harm but no apparent benefit.”

Food packaging primarily serves to protect food against exposure on the outside
environment and damage during storage and transportation. It also ensures that food has a longer
shelf life by containing it in an appropriate atmosphere. Product safety equipment that include
magnets, metal detectors and screens to detect and prevent foreign matter contamination.
Labelling is also important in packaging, because some food product may contain allergen which
can be harmful for the consumers. Primary packaging includes inspection of the printing and
sealing, condition of the packaging, dimension and net weight, headspace gas, foreign bodies.
Headspace gas analysis is to test the gas composition at the top of the package. Oxygen and
water vapor are the main factors that influence the shelf life of products. Oxygen can provide
conditions that enhance the growth of microorganisms. Research indicates that the shelf life could
be extended, and the product quality could be guaranteed in storage by controlling the headspace
of the package. When the percentage of oxygen content is less than 2% and carbon dioxide
content is more than 7%, food and bacteria are in a state of “hibernation”, so the shelf life of food
could be extended effectively. Secondary packaging inspection includes strength test, traceability
- by way of bar codes or serial numbers, and duct tape bases on production month. Every item
should be documented and tracked.
 ii. Equipment Condition Monitoring

A well-maintained machine is obviously one of the most important aspect in the any industry.
Manufacturing equipment are company’s investment. Keeping the equipment running without
interruption and failure will ensure efficient production. Equipment maintenance is done to ensure
that all the machinery and equipment required for productions are operating at the highest
possible efficiency all the time. And the maintenance process should be on a regular basis to
ensure smooth manufacturing.

Condition monitoring can be described as ‘assessing the current state and estimating the
future state of a system by means of measurements and calculations. The results of condition
monitoring can be used to take corrective actions, to plan the availability and maintenance, and
to optimize the plant’s performance. It is a major component of predictive maintenance. The use
of condition monitoring allows maintenance to be scheduled, or other actions to be taken to
prevent consequential damages and avoid its consequences. Predictive maintenance is a method
in which the service life of important parts is predicted based on inspection or diagnosis to use
the parts to the limit of their service life. It is an effective means to eliminate potential failures,
ensure stable equipment operation and improve the mission reliability of manufacturing systems
and the quality of products, which is the premise of intelligent manufacturing.

iii. Production Planning

Some of the causes of overproduction in food manufacturing industry includes large batch
sizes and excessive raw materials, distrust in the reliability of the processes and plan to allow for
interruptions in the flow of production thus resulting to unstable schedules, and lastly, working to
inaccurate information about consumer demand therefore giving not the actual demand.

Using smaller, simpler, dedicated machines rather than “super machines” that have to
handle every product in the factory, utilizing enough raw materials supply, and having an accurate
history and data of costumers’ demand (when or what) are some ways to reduce overproduction.
Planning the production includes determining quantity based on the accurate data of consumer
demands, and scheduling batch production. Once the schedules have been made the production
should follow it accordingly.

iv. Sanitation

Foodborne illness can be caused by poor sanitation and food hygiene including poor
personal hygiene and contamination of equipment and/or environments. The correct practice of
food safety and sanitation can greatly improve efficiency, keep productivity up, workers safe and
consumer confidence high, as well as meeting or surpassing standards and thus avoiding
untoward incidents such as having not only non-compliance fines or a potential shutdown. Some
PepsiCo have discussed the Six Basic Hygiene rules that were followed by employees of the
company. As a food manufacturing industry, the company is strict on implementing these rules.
They also provide a personal hygiene checklist to the employees to ensure that they do not forget
any of the hygiene rules. Most of these rules are implemented to prevent cross-contamination.
Cross- contamination is the transfer of harmful bacteria to food from other foods, cutting boards,
utensils, etc., if they are not handled properly as defined by the US Department of Agriculture.

The Six Basic Hygiene Rules are the following:

1. REPORT ANY HEALTH CONCERN

- Report any health concern to immediate supervisors – to prevent contamination and
infect other employee
- All employees are required to undergo medical exam – should have a clearance to
work from the physician.
- When it comes to cuts and wounds– two dedicated bandages are allowed to be used:
a metal detectable bandages (mandatory for personnel working in the production
areas), and brightly colored bandaged for visual identification (for personnel working
outside the production areas). These are provided by the company to make sure
employees are not using unauthorized bandages
2. REMOVE UNNECESSARY PERSONAL BELONGINGS
- All types of foreign bodies are not allowed in the production. (e.g jewelries, loose
screws, keys, for eyeglasses, strings are provided for the employees). Any company
is not exempted when it comes to foreign body contamination. This can affect
company branding, reputation as well as financial lost for the company.
3. EAT ONLY IN PERMITTED AREAS
- Food are consumed (eating) on designated areas only (like canteen, pantries,
conference room, sometimes lobby if there are events). Eating is not allowed inside
the laboratory, production, warehouse, and all other areas not designated by the
policy. This is to avoid pest from being attracted to the product (pest control) as well
as to avoid contamination which can cause consumer complaint.
- Pest Sighting Log was also provided at different section in the production area it
includes information such as the date & location of sighting, pest description, no. of
pests, and employee’s name & signature.
4. ALWAYS WASH AND SANITIZE YOUR HANDS
- Everyone is highly encouraged to always wash and sanitize their hands. This is to
avoid proliferation of microorganisms like fungi, bacteria, viruses on the production
which will contaminate the product.
5. ALWAYS WEAR CLEAN AND PROTECTIVE CLOTHING
- Always wear proper protective clothing. Employees are exposed to the outside
environment, like dirt and smoke, wearing proper protective clothing like lab gown,
face mask, hair net, and shoe cover prevents these from contaminating the food or
cross contamination.
6. KEEP AREAS CLEAN AND TIDY
- Areas should be cleaned when it comes to hygiene, workwear, personal belongings.
 v. Zoning

As part of keeping the areas clean and tidy, Zoning map is also implemented as the plant
itself is potential for microbiological cross contamination. It is important because it ensures that
equipment that used in raw product handling areas is not used where ready-to-eat products are
handled. It also prevents or minimizes dust movement and establishes appropriate cleaning and
hygiene procedures. The company has four areas categorized under this hygienic zoning map:

 GRAY, Non-manufacturing – In this area, there is no production like utilities,

engineering, canteen, lobby.
 GREEN, Basic GMP (Good manufacturing practice): This consists of production
areas including warehouses, raw material warehouse, packaging material
warehouse, and the finished good warehouse.
 YELLOW, Transition areas: These are the areas between zones, areas which we
need to provide protective clothing to prevent carrying germs and foreign bodies to
the production area.
 BLUE, Primary Pathogen Control: This is a highly sensitive area, the area after
the kill step – relative to the product are steps where pathogens/bacteria are killed
e.g. after frying packaging.

Figure 2. Cheetos Snack Plant Hygienic Zoning Map

V. PRODUCT AND/OR PROCESS INNOVATIONS

i. Process Innovations:
 Large Rotating Drum (Nozzle Spray): Unlike other food manufacturers that use the
simple spray dryer, PCCPI uses a rotating drum for an even distribution of flavours.
  Palm Olein Oil: Palm Olein oil is used to improve the aroma of the flavour and for the
powdered flavourings to remain intact with the collets/chips.

ii. Product Innovations:

 Flavours: There are many flavours to choose from:

 Shapes: Shapes vary from the classic crunchy ones to their innovative mustache and in
some other instances, Cheetos even gives rewards to consumers who have the oddest
Cheeto shape from their snacks.

VI. CONCLUSION

Food industry is a complex network of farmers and diverse businesses that together supply
much of the food consumed by the world population. It covers all aspects of food production and
sale. Pepsi Cola Products Philippine Inc. (PCPPI) – Cabuyao Snack Plant which manufactures
CheetosⓇ is a part of the food industry. The unit operations involved in the manufacturing of
CheetosⓇ are mixing, extrusion, frying/oven, and coating. Corn meal and water are feed into the
mixer at certain ratio then is heated under pressure, and then extruded through a die. The texture
of the snack is formed as a result of contact with hot air, causing steam in the mixture to expand
and creating its characteristic texture. Then, the collets are fried in palm-olein oil. After oven-
drying or frying, the product is then tumbled in a rotating drum with the desired flavor components
being sprayed in the product. The quality assurance lab team inspects the product and the
process. Analysis of the moisture content, the FFA value of oil, the salt content, and the fat content
are made to ensure that the product is meeting the food quality standards. PCPPI Cabuyao Snack
Plant is strict in implementing food safety and sanitation. The correct practice of food safety and
sanitation can greatly improve efficiency, keep productivity up, workers safe and consumer
confidence high, as well as meeting or surpassing standards and thus avoiding untoward
incidents such as having not only non-compliance fines or a potential shutdown.

PCPPI-Cabuyao Snack Plant also introduced product and process innovations to improve
and make the product exceptional such innovations are the equipment used for seasoning, the
raw material, and the product appearance. As chemical engineering students, plant visits are
integral in exposing future engineers in the industry. Through this manufacturing plant tour at
PepsiCo. Cabuyao Snack Plant the group have successfully fulfilled the objectives of the plant
exposure activity of the course.

VII. INDIVIDUAL REFLECTION

BONIFACIO, JARDINE C.

Plant visits have their own importance in a career of a student who is pursuing a professional
degree especially in engineering. Going to a plant tour provides an opportunity to observe how
the work was actually done. Even the most lucid description of how work flows are managed
around the plant or how I use charts and diagrams to solve problems in school is no substitute for
seeing things happen in practice.

When we visited the plant, I finally got an insight of how the actual work is done in the
industry and hence, a glimpse on what would my life be after I leave college. It gave me the
knowledge and exposure needed to grasp certain engineering techniques for easier
understanding and I was able to recognize certain process units and further understood how the
product of the manufacturing plant is interfaced to the world.

I have learned that theoretical knowledge is not enough for making a good professional
career. With an aim to go beyond academics, visiting PCCPI gave me a practical perspective on
the world of work. It provided an opportunity to learn practically through interaction, working
methods, as well as employment practices. It gave me the exposure to current work practices as
opposed to possibly theoretical knowledge being taught at college. This plant visit provided an
excellent opportunity to interact with industries and know more about the real industrial
environment.

FLORDELIZA, VANESSA MAE M.

Manufacturing plant tours are important vehicle for new knowledge in the field and
understanding how a specific industry works. It exposed me, as a chemical engineering student
to actual, real-time workplace situations. In this food manufacturing plant visit, we were able to
observe food products being manufactured and the processes it undergoes before we can be
able to consume it.
 Before the tour at the production area of the plant, the Quality Assurance manager and the
Health and Safety Officer discussed important reminders and rules to be followed inside the plant.
From this, I learned that as a food manufacturing industry, Pepsi-Cola Philippines Inc. Snack Plant
– Cabuyao, Laguna, strictly and consistently commits to certain standards to achieve and produce
quality food products. Being trusted by the consumers because of the quality of product the
company produces will create loyal customers, increasing the company’s integrity. Food safety
and sanitation is the primary priority of the company. If practiced correctly it can greatly improve
efficiency, keep productivity up, workers safety and consumer confidence high, as well as meeting
or surpassing standards. These means that incidents such as having not only non-compliance
fines, consumer complaint, and other potential lawsuits but as well as potential shutdown can be
prevented.

At the production area while we were having the actual processing tour, I was completely
engaged and totally immersed in the processes of the food production, equipment, process
conditions, and other significant factors. Questions were answered directly by factory personnel.
Design concepts do not always translate through diagrams and photos, in-person discussions
while looking at an actual equipment, can be useful and powerful when it comes to having a better
understanding. The company also gathers deeper insight into customer needs which can cause
product changes and innovation.

PCPPI Snack Plant was the very first manufacturing plant that I have visited. I know that for
the succeeding years, I will be able to visit and immersed myself deeply to the different industry,
but this experience is the very highlight of being a chemical engineer. Chemical Engineers are
equipped with the knowledge of science and engineering to convert basic raw materials into a
variety of useful products and deal with the design and operation of plants and equipment. Being
a Chemical Engineer in the future, I will be honored to be part of this community in order to
produce products and process which will have great impact to the humanity.

RELIGIOSO, ARIANA NICOLE A.

As a chemical engineer in the making, I was lucky and honored, along with my other
groupmates, for an opportunity to experience an on-site visit in Pepsi-Cola Products, Inc.- Pepsi-
Cola Products Philippines, Inc. (PCPPI) ‘s Snack Plant in Cabuyao, Laguna, a manufacturing
facility that produces internationally-renowned snacks products, specifically Cheetos, for the
Philippine market, as they move toward their vision of becoming a premier food and beverage
company in the Philippines.

For our onsite plant visit, we got to tour around their production plant. There, everything was
so strict, clean, and organized. They really comply to their PPEs and do follow all the rules,
specifically regarding Hygiene, as they are a food industry. We also had a Process overview of
the Cheetos production, discussed by Mr. Raymon A. Castillo. With that bonus experience, I have
appreciated my course even more. With all they have discussed, all the learnings instilled in us
for the past four years were very relevant in the field.
 It felt good that I really did understand the processes they were mentioning not just as a
visitor who listens, but we were having an interaction with him as he asks us for technical terms
and principles that are observed in the entire Cheetos production. This exposed me to a food
industry and engaged me into thinking about how I could transfer our classroom learnings to my
future in chemical engineering. It was such a nice opportunity, for this time, curiosity hit me. I have
raised questions about the manufacturing and production processes, which I have understood
fully and made me realize that these terms, concepts, and topics are what I will surely love to
encounter in the future. It made me see the processes and operations in actual, and not just
through theories and imaginations, and with that, I know, that I will fully recall what I have seen
and learned, especially because I am a visual learner, that is why I like plant tours that
incorporates the lessons from our different courses.

TOLENTINO, CHELSEA S.

Having the opportunity to visit PCPPI Cabuyao Snacks Plant in Laguna is both a privilege
and an honor for a Chemical Engineering student like me. Not only that we were able to gain
relevant knowledge about the different processes in food production, but we were also given the
chance to witness personally how the Cheetos snack is manufactured.

Before entering their manufacturing plant where the Cheetos snacks are produced, Mr.
Raymon Castillo, the Quality Assurance Manager, briefed us about the rules and regulations that
we must follow in order to not contaminate the products inside. In the industry, especially in the
food industry, it is the company’s top priority to provide a safe and clean snack to the people.

Upon witnessing the manufacturing process of Cheetos, it made me appreciate more the
course that I have taken up and all the learnings that I have acquired from the classroom. I got to
witness how the different equipment that we discussed only in the classroom work in an actual
process. It was like turning imaginations into visions of reality. It felt great to be able to finally
relate to or understand the things they are discussing, for example, the different unit processes,
and also being familiar with the different equipment inside their manufacturing facility. It gave me
a glimpse of what awaits us once we finally become licensed Chemical Engineers and decide to
work in the food industry.

In conclusion, it was indeed an educational exposure for us Chemical Engineers in the

making, who, few years from now, will work in the different fields. The learnings and experiences
I have gained from this plant tour will be beneficial once the time comes that we will have to
immerse ourselves in the different industries.
 VIII. APPENDIX

Interview with the PCCPI’s Safety Officer Mr. Roseller Sarmiento

A group photo after the tour together with

PCCPI’s employees and Chester Cheetah!

The QA Manager orienting us regarding

the plant’s processes and hygiene plans

And a photo of us bringing home some snacks! :D

IX. REFERENCES

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