ZENITH FOODS CORPORATION: JOLLIBEE COMMISSARY

Carmelray Industrial Park I, Integrity Ave., Canlubang, Laguna

January 23, 2015

I. Introduction

Mission

To serve great tasting food, bringing the joy of eating to everyone.

Vision

It is the vision of JFC to become one of the three largest and most profitable
restaurant companies in the world by 2020.

Corporate Profile

Jollibee is the largest fast food chain in the Philippines, operating a nationwide network
of more than 750 stores. A dominant market leader in the Philippines, Jollibee enjoys the lion’s
share of the local market that is more than all the other multinational brands combined. The
company has also embarked on an aggressive international expansion plan, and currently has 80
stores outside the Philippines-USA (26), Vietnam (32), Brunei (11), Jeddah (7), Qatar, Hong
Kong, and Kuwait (1 each), firmly establishing itself as a growing international QSR player.

Jollibee was founded by Tony Tan and his family with its humble beginnings as an Ice
Cream Parlor which later grew into an emerging global brand. At the heart of its success is a
family-oriented approach to personnel management, making Jollibee one of the most admired
employers in the region with an Employer of the Year Award from the Personnel Management
Association of the Philippines, Best Employer in the Philippines Award from Hewitt Associated
and a Top 20 Employer in Asia citation from the Asian Wall Street Journal.

Aside from promoting a family oriented work environment, the brand’s values also
reflect on their advertising and marketing. Jollibee knows their target audience very well: the
traditional family and all communication materials focus on the importance of family values,
making Jollibee the number one family fast food chain in the Philippines and a growing
international QSR player.

Jollibee Foods Corporation (JFC) operates the largest food service company in the
Philippines with six brands in the country (Jollibee, Greenwich, Chowking, Red Ribbon, Mang
Inasal, Burger King) and three in China (Yonghe King, Hong Zhuang Yuan, and San Pin Wang).
It operates over 2,800 restaurant outlets in the Philippines, the United States, China, Brunei,
Vietnam, Hong Kong, Saudi Arabia, United Arab Emirates, Qatar, Oman, Kuwait, and
Singapore. In 2013, it generated system-wide sales of Php104.1 Billion and net income of Php4.6
Billion.

JFC also has a 50% interest in joint ventures for Highlands Coffee (Vietnam,
Philippines), Pho 24 (Vietnam, Indonesia, Hong Kong, China, Cambodia and Philippines) and 12
Sabu (China).

JFC also operates commissaries or manufacturing plants to support the continued growth
of its retail chain. It has 12 commissaries and a distribution center in the Philippines. Abroad, it
has 3 commissaries in China, 3 in the United States and 1 in Vietnam.

As a responsible corporate citizen, JFC is also committed to serve its host communities
through socio-civic projects through the Jollibee Group Foundation. The Foundation has focused
its work on feeding programs for under-nourished children in poor communities, developing
farmers to become better entrepreneurs and suppliers of agricultural products and providing
disaster relief for calamity-stricken regions.

Jollibee Foods Corporation has grown brands that bring delightful dining experiences to
its customers worldwide, “Spreading the joy of eating to everyone.”

Technical Description

Jollibee Foods Corporation’s (“JFC” or the “Company”) core business is the

development, operation and franchising of its quick-service restaurant brands. It offers a wide
variety of affordable and delicious dishes and great tasting food prepared to satisfy customers of
all ages and from all walks of life.

Food quality, service, price-value relationship, store location and ambience, and efficient
operations continue to be critical elements of the Company’s success in the quick-service
restaurant industry.

Plant Facilities

With over 500 Jollibee stores nationwide serving millions of customers daily, preparing
500,000 hamburgers, 350,000 Chickenjoy meals and 100,000 pocket pies every single day is no
easy job.
 This task, however, is efficiently carried out by utilizing the six-hectare state-of-the-art
manufacturing and logistics facility known as the Zenith Foods Corp Commissary, a fully owned
subsidiary of Jollibee Foods Corp., located in the Carmelray Industrial Park in Canlubang,
Laguna.

The commissary, which was designed to meet the requirements of 800 Jollibee stores, is a
high-capacity plant facility where all the burger patties, Chickenjoy, sauces, hotdogs and meats,
frozen pies, bread as well as spices and blends are prepared.

The facility employs the latest in food preparation and handling technology, such that it
takes only 16 people per shift to grind high-grade beef from Australia, New Zealand and Brazil;
marinate, freeze and pack 175 tons of hamburger patties every week.

The other all-important component of Jollibee’s langhap sarap burgers – the buns – are
prepared and baked in undoubtedly the country’s largest integrated bun production line, with
about 450,000 buns and rolls produced daily.

The advances in technology also ensure the consistency in size and flavor of 20 tons of
marinated chicken cut-ups every day, or roughly 200,000 servings of Chickenjoy – a favorite of
millions of Jollibee’s loyal patrons.

The most flexible line in the Jollibee commissary is the sauce line. Here, various soup
bases, pie fillings and the distinctive sauces for Jolly Spaghetti and Palabok Fiesta are churned
out to perfection.

II. Manufacturing Process

Raw Materials

Jollibee’s main raw material is chicken. Agricultural products, such as green and red bell
pepper, lettuce, tomato and potato are one of Jollibee’s raw materials. Another of their raw
materials is flour for their buns.
Process Flowchart / Equipment

Blending Process Flow

Raw Materials
Preparation

Batch Weighing

Blending Operation

Packaging

Case packing

Finished Goods Storage

or Issuance to
Pie Process Flow

Preparation of Filling Preparation of Crust

Fold-over / Forming

Freezing

Preparation of Glaze Glazing

Surface Drying

Packaging

Case Packing

Finished Goods Storage

Hotdog Process Flow

Beef Stripping

Grinding

Other Materials
Preparation
Bowl Cutter Operation

Emulsification
Finished Goods Storage

Stuffing and Linking

Case Packing

Smoking / Cooking

Freezing

Water Chilling

Packaging

De - Linking
Sauce Process Flow

Raw Materials
Preparation

Sauteing

Steam Kettle Cooking

Packaging (Form-Fill-
Seal)

Freezing

Case Packing

Finished Goods Storage

Frozen Patty Process Flow

Beef Stripping

First Grinding

Other Materials
Preparation
Mixing with other
Ingredients

Final Grinding

Forming

Freezing

Case Packing

Final Goods Storage

Bun Process Flow

Raw Materials
Preparation

Sponge Mixing

Sponge Fermentation

Final Dough Mixing

Finished Goods Storage

Dividing / Make-up

Packaging

Intermediate Proofing

Cooling

Panning

Baking

Final Proofing
Finished Product

The Jollibee Group is currently reducing its use of styro packaging by shifting to
washable melaware for dine-in services and use of papers for to-go services.

III. Quality Control Procedures

In-process Testing
Zenith Foods Corporation: Jollibee Commissary makes sure that its working area is
clean. Hygiene monitoring is done to achieve this goal. Quality Assurance analyst assists in
formulating and determining new hygiene processes and effective hygiene systems. During the
process, quality assurance analyst report trends and validates corrective actions done in non-
conformances.

Finished Product
Quality Assurance analyst performs physico-chemical analysis of FGs (finished goods) or
finished products in a laboratory. And micro analysis is done by the use of 3M-MDS (Molecular
Detection System) as fast means of detecting and determining pathogens.

IV. Water and Wastewater Treatment (Ecology and Environment)

Jollibee Foods Corporation (JFC) has been cited by the Sagip Pasig Movement (SPM) as
one of the most improved companies with its implementation of a wastewater treatment system
and other measures for environmental protection.

JFC’s wastewater treatment system uses a highly-advanced biological treatment process

and Sequential Batch Reactor (SBR) capable of treating up to 325 cubic meters of wastewater
per day.

Sequencing Batch Reactor Process Cycles

The operating principles of a batch activated sludge process, or SBR, are characterized in
six discrete periods:

Anoxic Fill
The influent wastewater is distributed throughout the settled sludge through the influent
distribution manifold to provide good contact between the microorganisms and the substrate. The
influent can be either pumped in allowed to flow in by gravity. Most of this period occurs
without aeration to create an environment that favors the procreation of microorganisms with
good settling characteristics. Aeration begins at the beginning of this period.
Aerated Fill
Mixed liquor is drawn through the manifold, mixed with the influent flow in the motive
liquid pump, and discharged, as motive liquid, to the jet aerator . This initiates the feast period.
Feast is when the microorganisms have been in contact with the substrate and a large amount of
oxygen is provided to facilitate the substrate consumption. Nitrification and denitrification
occurs at the beginning of this stage. This period ends when the tank is either full or when a
maximum time for filling is reached.

React
During this period aeration continues until complete biodegradation of BOD and nitrogen
is achieved. After the substrate is consumed famine stage starts. During this stage some
microorganisms will die because of the lack of food and will help reduce the volume of the
settling sludge. The length of the aeration period determines the degree of BOD consumption.

Settle
Aeration is discontinued at this stage and solids separation takes place leaving clear,
treated effluent above the sludge blanket. During this clarifying period no liquids should enter or
leave the tank to avoid turbulence in the supernatant.

Decant
This period is characterized by the withdrawal of treated effluent from approximately two
feet below the surface of the mixed liquor by the floating solids excluding decanter [1]. This
removal must be done without disturbing the settled sludge.

Idle
The time in this stage can be used to waste sludge or perform backwashing of the jet
aerator. The wasted sludge is pumped to an anaerobic digester to reduce the volume of the sludge
to be discarded. The frequency of sludge wasting ranges between once each cycle to once every
two to three months depending upon system design.

Part of Jollibee Group water management practice is the use of hygienic waterless urinals
in our stores. This odorless facility uses a special liquid sealant to prevent odors from escaping
and funnel pure urine down the drain. Each waterless urinal saves around 150,000 liters of water
a year.

Jollibee Group also take our responsibility in waste management very seriously, in full
support and compliance to the Ecological Solid Waste Management Act. The Jollibee Group is
currently reducing its use of styro packaging by shifting to washable melaware for dine-in
services.

Jollibee Group also practice solid waste segregation through a comprehensive sorting
process that begins at the store and continues to secondary facilities for material recovery and
reprocessing.
 From the store, segregation already begins through separate trash bins for biodegradable
or organic waste and non-biodegradable waste. These waste materials are bagged, collected and
transported in sanitary closed vans to the Materials Recovery Facility, where secondary
segregation takes place. Here the waste is further sorted into styro, paper, plastic cups, spoons,
forks and straws, food waste, and residual or non-recyclable waste.

Styro goes through reprocessing where it is safely melted and reshaped into blocks that
are shipped overseas for further processing to produce new commercial and industrial
applications.Plastics also undergo a recycling process where they are ground, extruded into
sheets, and thermoformed, producing new items for the market.

Paper goes to another site for reprocessing into new items, while food waste is transferred
to composting and hog-feeding facilities.

V. Roles / Job of Chemical Engineers

Quality Control
Chemical engineer as a quality control analyst ensures the quality of their product.
Quality control analyst makes sure that their product is free of any hazardous chemical or any
bacteria and makes sure that the products reach its standards.
Process Engineer
Chemical engineer as a process engineer ensures that the process will run smoothly.
Process engineer helps in troubleshooting specific equipment that needs to be fixed and sees to it
that the whole process is working properly.
Design
Chemical engineer as a design engineer concentrates on how the equipments will be
arranged on the working area.
Research and Development
Chemical engineers under Research and Development are making researches for the
improvement of their products quality and develops process that will make have a better results.
Wastewater Treatment
Chemical engineers makes sure that wastewater are being treated before disposing.
VI. Appendix
Documentation: Plant Tour Pictures

Bibliography

http://www.jollibee.com.ph/about-us/

https://news.google.com/newspapers?nid=1370&dat=19970601&id=kZMVAAAAIBAJ&sjid=-
AoEAAAAIBAJ&pg=4409,112974&hl=en

http://www.rpi.edu/dept/chem-eng/Biotech-Environ/Environmental/Steps/EnvSysSBR.html

http://www.newsflash.org/2004/02/be/be003324.htm

http://jollibeefoundation.org/our-programs/other-programs/

http://www.philippinecompanies.com/companyprofile/35558/zenith-foods-corp-

https://ph.linkedin.com/pub/jerome-michael-montaner/49/181/56b

http://www.academia.edu/8364414/JOLIBEE_FOOD_CORPORATIONS_as_of_27_08_2014

http://bayanihan.org/2012/04/24/nswmc-jollibee-partner-on-managing-solid-waste-water/