MANLY PLASTIC INC

(M.H. Del Pilar St., Malabon City) Mrs. Melissa Austria December 13, 2013 Personnel who conducted the tour: Mhelbert Ponce Michelle Uy Majinder Chohan Ian Cunanan History: Manly Plastics, Inc. is known to be the leader in plastic products manufacturing. It has earned an ISO 9001:2008 accreditation for quality and fine workmanship including Environmental Management System 14001:2004 certification for its compliance to environmental regulations and preservation. A Filipino-Chinese family whose ancestral roots can be traced in mainland China, where their grandfather brought in trade to Manila in nineteen twenties. As an apprentice to his father's store of automotive parts, the young Co Bun Ting (Virgilio's father) displayed interest in mechanical works. Equipped only with a 2nd year high school education, he started his own small machine shop that makes molds. Then he started injecting plastic for shoe heels on Manly Shoes, situated in the busy street of Carriedo, Manila in the mid 60's. This started their small business that grew into six big companies. Manly Plastics, Inc. Royal; Manly Plastics, Inc. Judge Luna; Centennial Plastics Corp. Sucat; Centennial Plastics Corp. Bagbaguin; Sentinel Plastic Manufacturing Corp. Malabon; and Filpet, Inc. Malabon, and M-Plus, Laguna consigned in injection molding and injection-stretch blow molding of plastic, from consumer and industrial products to home furniture. A mould shop in Quezon City was set up by Mr. Co Bun Ting, founder of MANLY PLASTICS, INC., in 1963. The transformation of MANLY came about in 1965 with the installation of the first injection machine for the plastic shoe heels of the MANLY shoe store. On a continuing basis, additional and bigger injection machines were bought in the 70s up to the latter part of the 80s to serve the needs of the appliance and industrial sectors. The second plant, CENTENNIAL PLASTICS in Valenzuela, Bulacan was put up in 1983 to service the "brown lines" of the appliance industry. While the third manufacturing area, called the Judge Luna plant was set up in Quezon City in 1987. In 1989, to support the growing needs of the appliance industry, a fourth plant, also called the 2nd CENTENNIAL PLASTICS, was installed for the "white line," in Paranaque, south of Metro Manila.

A much bigger plant, the SENTINEL PLASTICS, INC., with injection machines of higher tonnages for monoblocs and softdrink crates was inaugurated in 1992 in Malabon, north of Metro Manila. In 1994 MANLY ventured into the packaging industry with the acquisition of FILPET, INC., a PET bottle manufacturing plant in Laguna, from the Jardines Davies Group. 1995 was a "quality year" for the MANLY PLASTICS GROUP with five (5) plants receiving their ISO 9002 certifications.

MANLYs progressive thinking saw, in 1996, the need for the more technologically advanced gas-assisted injection process. The establishment of the mould engineering plant in Malabon 1997 was a dream come true for the MANLY PLASTICS GROUP clamoring for the CAD/CAM technology for precision moulds. The continuing quest for new markets came about in 1998 with the fabrication of parts for the automotive industry and the strategic partnership with SANKO of Japan for the materials handling (pallet and crates) business.

In 1999, the latest subsidiary, M-PLUS was put up in the Science and Technology Park in Laguna to manufacture 3-layer extrusion sheets for refrigerators. From 2001 onwards, MANLYs focus will be on increased utilization of assets, investment in additional capacity to support its growth targets and on key acquisitions that will significantly enhance its local and regional market position in the appliance, food and beverage packaging and automotive industries. I never thought that the plastic or products that we are using in our house is made by Manly Plastic Inc. I was so lucky that I saw their factory and I saw the actual process on how they made their products. Here are some pictures of Manly Plastics Inc Products.

SAN ROQUE DAM

(Pangasinan) January 17, 2014 Personnel who conducted the tour: Dave Labadan Rene Louis Orlando Ignao Regie Cabatic Roger Pachicoy

The San Roque Dam, operated under San Roque Multipurpose Project (SRMP) is a 200 meters tall, 1.2 kilometer long embankment dam on the Agno River. It spans the municipalities of San Manuel and San Nicolas, Pangasinan and is nearly 200 km north of Metro Manila. The dam impounds a reservoir with a surface area of about 12.8 square kilometers extending North into the municipality of Itogon, Benguet. A gated spillway protects the dam from overtopping. Each wet season, the run-off is stored for later release via water turbines to generate power and irrigate crops. Agno River is the third largest river in the Philippines with a total length of 221 kilometers and a drainage basin at the Project site of 1,225 square kilometers. The river originates in the Cordillera Mountains, initially flows from north to south, divides into several channels in the flat central plain of Luzon and meanders westerly through the provinces of Pangasinan and Tarlac before emptying into the Lingayen Gulf. San Roque Power Corporation (SRPC) financed and constructed the SRMP under a power purchase agreement (PPA) with the National Power Corporation (NPC) on a Build-Operate-Transfer (BOT) basis. SRPC substantially completed the SRMP at midnight, February 14, 2003, at which time its peaking power, irrigation, flood control and enhanced water quality benefits became available to the surrounding regions, which include the Northwest Luzon Economic Growth Quadrangle. In reality, all but its power benefits have been available since mid-2002 when the dam and spillway were completed. Ownership of the dam and spillway was transferred to NPC upon construction completion, as it contributed funds for the non-power components on behalf of several agencies. SRPC will own and operate the power generating facilities for 25 years, after which their ownership transfers to NPC. The dam is being developed as a Build-Operate-Transfer project, awarded to the San Roque Power Corporation. The project started construction in May 1998 and is scheduled for commercial operation by the year 2004.

(Our whole ME Elective 4 class, (1st day) San roque dam)

AGUA GRANDE MINI HYDRO POWER PLANT

(Ilocos Norte) January 18, 2014 Engineer Renato Balintec ILOCOS NORTE, Philippines (Mindanao Examiner / June 4, 2011) - Way before the building of the first Philippine wind farm in the province in 2005, Ilocos Nortes status as a center for clean, cheap and renewable energy can be traced as far back as the 1980s. The mini-hydro power plant, built by the Ilocos Norte Electric Cooperative along the Agua Grande River along the Pancian and Pasaleng rivers in this town, supplies power to more than 17,000 households in Pagudpud and nearby villages in Bangui, Pasuquin and Bacarra towns. Engineer Renato Balintec, Inec general manager, said the amount of water flow is not enough to power all the five turbines. A study has been commissioned for the putting up of another hydro power plant to harness water resources from the Pagudpud rivers. Built in the 1980s, the run-ofthe-river type plant generates power depending on the volume of rainfall that flows down the reservoir. Power produced from the hydro power plant is cheaper by 40 percent. Fifty-one hydropower plants operate across the country, with a combined capacity of 82.07 megawatts, a mere 7.2 percent of the identified potential. Aside from opportunities to develop new mini-hydro projects, the government has also encouraged investments in the rehabilitation of existing plants to raise efficiency. A proposed program encourages private developers to enter into an implementation scheme with owners of mini-hydro plants.

Actual pictures inside the plant:

HOLCIM
(La Union) January 17, 2014 Holcim Philippines operates 4 major areas: La Union, Bulacan, Davao City and in Lugait, Misamis Oriental. The plants account for installed clinker production capacity of 7.2 million metric tons and cement production capacity of 8.7 million metric tons per year. Holcim is one of the worlds leading suppliers of cement and aggregates (crushed stone, gravel and sand) as well as downstream activities such as ready-mix concrete and asphalt. The Group holds majority and minority interests in more than 70 countries on all continents. Holcim Philippines, Inc. (HPHI) is a Philippines-based cement manufacturer and a member of Holcim Group. Holcim Philippines is involved in the manufacture, sale and distribution of cement to the omestic and export markets. The Company produces four cement products: Holcim Excel, Holcim WallRight, Holcim Premium Bulk and Holcim 4X. Its products are sold in bags, jumbo bags and in bulk. Holcim Philippines operates four cement plants in La Union, Bulacan, Misamis Oriental, and Davao. It currently has more than 1,700 employees in the Philippines Premium quality general purpose cement, Holcim Excel is a special formulation of Portland cement with advanced mineral additives, conforming to both ASTM C595 and PNS 063. Holcim Wall Right is a masonry cement for hollow block laying and filling, plastering, and finishing. It has superior bond strength, increased water retention, and smoother texture compared to ordinary cement applied as a finish.

Process Description: Part 1 - raw materials extraction 1.Quarry Quarry - typically limestone, marl and clays as well as other materials containing the required proportions of calcium, silicon, aluminium and iron oxides are extracted using drilling and blasting techniques.

2.Crusher Crusher - the quarried material is then reduced in size by compression and/or impact in various mechanical crushers. Crushed rock is reduced in size from 120 cm to between 1.2 and 8 cm. Drying of raw material may also be necessary for efficient crushing and pre-blending. 3.Conveyor Conveyor - raw material is then transported from the quarry using conveyors, rail wagons or other suitable logistics solutions specific to the cement plant.

Part 2 - blending and clinkerization 4. Mixing bed Mixing bed - the crushed limestone and clay is homogenized by stacking and reclaiming in a long layered stockpile. This material is then ready for milling and drying in the kiln. 5.Raw mill Raw mill - the raw materials are milled and dried in a roller mill. Heavy rollers are held over a rotating table and the coArse material is milled until it is fine enough to be carried by air to a homogenizing silo. 6.Filter bag Filter - bag filters comprise filters of either woven fabric or needle felts to remove particles from kiln exhaust. The exhaust gas from many kilns is used for drying raw materials, thus improving the energy efficiency of the plant. 7.Preheater Preheater - cyclone preheaters enable the raw material of cement production to be preheated before entry into the kiln. This increases the energy efficiency of the kiln as the material is 20-40% calcined at the point of entry into the kiln. 8.Kiln Kiln - the kiln is designed to maximize the efficiency of heat transfer from fuel burning to the raw material. In the preheater tower the raw materials are heated rapidly to a temperature of about 1000C, where the limestone forms burnt lime. In the rotating kiln, the temperature reaches up to 2000C. At this high temperature, minerals fuse together to form predominantly calcium silicate crystals - cement clinker.

9.Cooler Cooler - the molten cement clinker is then cooled as rapidly as possible. The ambient air used to cool the clinker is then fed into the kiln as combustion air - ensuring high utilization of the heat produced.

Part 3 - grinding and distribution 10.Clinker silo Clinker silo - clinker may be either stored on site in preparation for grinding to form cement, or transported to other sites. 11.Cement mill Cement mill - finish milling is the grinding together of cement clinker, with around 5% of natural or synthetic gypsum. Other cementitious materials such as slag, flyash or other pozzolans may also be incorporated into the final cement powder. 12.Logistics Logistics - final cement may be transported pre-bagged or as a bulk powder. The method of transport selected varies according to location - and may include transport via truck, rail or ship.

Here

are

the

sample

flowchart

on

cement

testing:

Holcim La Union 2,400 MTPD Schematic Diagram

And here are some pictures of actual view of Holcim in La Union:

VIFEL (Navotas) February 7, 2014 Personnel who conducted the tour: Godfrey San Pedro Jojemar Banag Ace Manzano Jeremy Christian Catua

Strategically located in the industrial area of Navotas, Vifel Ice Plant & Cold Storage Inc. is indeed at the peak of its responsive and efficient services with its two cold store facilities Vifel I and Vifel II. Vifel I started its operations in cold storage in the early 80s. However, in late 1996, Vifel I underwent major c hanges which include the acquisition of the most advanced refrigeration system, upgrade of its equipments and renovation of its building. It has been consistent in providing its clients with efficient services. To date, it has two units of blast freezers with 2 x 30 tons capacity and twenty seven holding rooms with an average capacity of 150 tons each.

Vifel II, on the other hand, was introduced in 1995 as the most advanced and the largest cold storage facility in Asia. It was designed in accordance with the Standards of Sabroe Refrigeration A/S of Denmark. With this world class refrigeration system, this cold store can chill / freeze all types of products at optimized conditions. This cold store has flexible/dual rooms which can be converted from chilling to freezing rooms with a temperature range of +5C to -25C depending on the requirement of the products. Also, it has four blast freezers with a 4 x 25 tons capacity which ensures quick freezing. Equally important to note is its advanced rack system which allows a uniform air circulation and ensures that all products are chilled/frozen in the same way no matter where they are placed.

Vifel I and II boast not only of their state of the art technology but their large storing capacity as well. Close to Manila Harbor, both are specifically aimed at product handling, chilling, freezing and storing various products ranging from milk, cheese and ice cream to meat, poultry products, fruits and vegetables. With these remarkable features, products stored at Vifel are guaranteed to maintain their high quality. To say the least, Vifel means the right business move towards greater profitability.

(MACHINE ROOM)

(HALLWAY)

Steel Asia (Meycauayan City) February 14, 2014 Personnel who conducted the tour: Aldrin Alcantara Mark Evangelista

Steel manufacturing is one the most power intensive processes among all industries. Operations of the scale of SteelAsia require more than 60 MW, which is larger than the capacity of many of the Philippines' power generation facilities, and comparable to the power requirements of some provinces. Because power generation can potentially have a significant impact on the environment, alternatives to fossil fuels such as oil and coal are being developed. The Philippine government has passed the Renewable Energy Act which encourages the development o frenewable energy power generation, and its usage. As a large power user, SteelAsia helps protect the environment by maximizing the use of renewable energy sources, such as geothermal and hydrothermal energy. More than 90% of SteelAsia's power needs are from renewable energy sources, thereby reducing our country's carbon footprint. And with more renewable sources becoming available in the future, including solar and wind power, SteelAsia hopes to be in a rare class - 100% green. To help conserve and protect the environment, steel production must adhere to the process that consumes less power and fuel inputs. State-of-the-art steel manufacturing technology increases efficiency by significantly reducing fuel power and fuel consumption per metric ton of steel produced. SteelAsia operates world-class facilities using the latest technological advances and innovations. Its low emissions, fuel efficiency and power savings have been recognized by monitoring agencies, as the best in its industry.

Process Description: Preheating: Steel billets are received and charged directly in a re-heat walking hearth furnace through the charging door of the furnace. They are reheated for75 minutes to 1100C using Bunker C (Type #6) fuel oil. The furnace can reheat billets at a maximum rate of 65 tons per hour. Rolling: Once billets reach the required temperature for rolling, they leave the furnace through the discharging doors and are rolled along a series of 18 tandem (horizontal/vertical) continuous rolling mill stands to obtain the desired size and shape. Each rolling stand is controlled throughout the process by a computerized control system. Cutting and Testing: The bars are then cut to lengths required by customers. Samples are subjected to physical, mechanical and chemical tests in a fully equipped laboratory certified to ISO 17025. Instruments used for quality control include a spectrometer and two universal testing machines. Bundling and Tagging: Finally, the product is then bundled and tagged before being placed in a storage facility.

SEMINAR: AIR CONDITION (MPH) February 22, 2014 Engr. Ernesto Layno Ponce

AND REFRIGERATION PROCESS

Personnel who conducted the seminar: Mark Joseph Rivera Elmer Tampil

Air-conditioning Basics
Most people think that air conditioners lower the temperature in their homes simply by pumping cool air in. What's really happening is the warm air from your house is being removed and cycled back in as cooler air. This cycle continues until your thermostat reaches the desired temperature. An air conditioner is basically a refrigerator without the insulated box. It uses the evaporation of a refrigerant, to provide cooling. The mechanics of the refrigerant evaporation cycle are the same in a refrigerator as in an air conditioner. DIAGRAM OF TYPICAL AIR CONDITION

This is how the evaporation cycle in an air conditioner works. The compressor compresses cool refrigerant gas, causing it to become hot, highpressure refrigerant gas (red in the diagram above). 1. This hot gas runs through a set of coils so it can dissipate its heat, and it condenses into a liquid. 2. The refrigerant liquid runs through an expansion valve, and in the process it evaporates to become cold, low-pressure refrigerant gas (light blue in the diagram above). 3. This cold gas runs through a set of coils that allow the gas to absorb heat and cool down the air inside the building.

Mixed in with the refrigerant is a small amount of lightweight oil. This oil lubricates the compressor.

Schematic Diagram of Air Conditioning Process

Refrigeration / Process Cooling

Like air conditioning, refrigeration and process cooling uses refrigerant vapour expansion/compression (RVEC) for specialized purposes. Refrigeration allows for low temperature cooling that is generally used for long term storage of food perishables or in ice manufacturing. Process cooling provides solutions where cooling is required at a specific location in manufacturing or some other form of industrial process. How It Works Refrigeration is typically direct expansion (DX), including an evaporator & fans system inside an insulated box or display centre, with a remotely located compressor/condenser. Most fans run continuously to maintain a consistent temperature throughout the controller container, while the refrigeration process operates intermittently to control the required amount of heat rejection. Refrigeration systems are readily available as commercial systems in sizes to suit the need, and includes a defrost control system that eliminates the need to transfer stored articles for manual defrost maintenance. Design of process cooling systems is largely dependent on use. Hydronic systems use chilled water, glycol, high-temperature brines, or other solutions depending upon the required temperature within the process. The refrigerant is chilled then circulated to the point of use. RVEC are now commonly used in newer systems, allowing the refrigerant to circulate multiple times through the system. In comparison many older systems use single-pass (potable) water where the byproduct of the process (water) is flushed down the drain. Many building owners elect to replace these older systems because of their wastefulness- both in terms of money spent on unnecessary utilities and the quantity of water used, which is considered environmentally damaging

Schematic diagram of Refrigeration System:

Actual pictures on seminar held last February 22, 2014:

SEMINAR:

Occupational Health and Safety

(EN 113- Engineering Building) January 27, 2014 Engr. Dennis Aquino Personnel who conducted the seminar: Lemoni Avila Jb Lailo Paul Angel Patrick Quebral Jay Rhalf Feudo

Occupational safety and health is an area concerned with protecting the safety,health and welfare of people engaged in work or employment. The goals of occupational safety and health programs include to foster a safe and healthy work environment.OSH may also protect co-workers, family members, employers, customers, and many others who might be affected by the workplace environment. Occupational safety and health can be important for moral, legal, and financial reasons. All organizations have a duty of care to ensure that employees and any other person who may be affected by the companies undertaking remain safe at all times. Moral obligations would involve the protection of employee's lives and health. Legal reasons for OSH practices relate to the preventative, punitive and compensatory effects of laws that protect worker's safety and health. OSH can also reduce employee injury and illness related costs, including medical care, sick leave and disability benefit costs.
This is just all about SAFETY. Like others said, SAFETY FIRST.