Technological Institute of the Philippines

363 P. Casal St. Quiapo, Manila

Chemical Engineering Department

HCG Philippines
A Plant Visit Report
In Partial Fulfillment of the Requirements in
Chemical Engineering Laboratory 1

Submitted by:
HARO, April Joy M.
1420153

Submitted to:
Engr. Crizaldy V. Tugade
ChE Faculty

18 September 2015
I. INTRODUCTION:

HCG Philippines is located in various places around the country but the site
that we visited is located at Dasmarinas, Cavite, a few hours from Manila. A list of
their products includes toilets, wash basins, faucets, kitchen sinks, bathtubs, vanity
cabinets, etc.
Upon entering the lobby of the plant, I have felt the elegance of the company.
I was somewhat amazed at the venue where we were given a brief orientation.
II. PROCEDURES/PROCESSES:
The whole class was divided into four groups, with 8 students in each group.
The staff has given us each a face mask, which was really a great start. Our guide,
the one assigned in the packaging section, led us first into the raw materials
section. The plant was somewhat a bit wider than other plants we have visited as
we walked some few minutes to get to where the raw materials are being stored.
Upon reaching the raw materials section, we have seen a large pile of silica sand,
plaster of Paris, and clay. According to the guide, all the raw materials were
imported from China. I forgot to ask why not get them locally.
From the raw materials section, we were led to the ball mill where the raw
materials are being crushed. According to the guide, the ball mill contains pebbles
which aid in the crushing of the materials. Next is the slipping tank in which the
aging process takes place. Not far from these equipment is the section where the
glaze is being processed from silica sand. This is what gives the toilets and other
bathroom furniture its glossy finish. The mold, on the other hand, is made from the
plaster of Paris, of which I remembered was what we were using back in high school
to illustrate how fossils are being formed. Next, we were brought into the
pressurized storage tanks, and I was like wow, I have just seen these equipments in
pictures during our lectures.
Afterwards, we were brought to where the bathroom appliances, specially the
toilets, are being done. First is the molding section. This process is being done
manually by the workers. Upon reaching that section, I can already feel the heat
coming from the furnace, I guess. One thing I observed on the workers is that they
are no longer wearing certain PPEs, basically, the face masks. They are just wearing
the usual shirts being worn at home. Since they are exposed everyday to sands and
other air contaminants, they should wear face masks at least. They are not strictly
following the set standards in this area. There is just a few chemical processes
taking place, actually- most are mechanical operations. Upon undergoing drying,
each product is being checked for any error like cracks, etc. If does have, it is being
repaired immediately. Each must conform to the standards of the customers. After it
is checked, it undergoes the glazing section where the glaze is being sprayed (with
the proper amount and speed) on the product. At first I thought they were just
cleaning it with water. Only later did I realize that it was already the glaze that they
were spraying.

Next, we were led to the very long furnace where the products are being
passed through by set. According to the guide, an average of 70-90 toilet bowls are
being dried in that furnace for about 8 hours. They were using LPG as a fuel.
Temperature and pressure are being monitored as well. They were operating 24/7,
by the way, and I asked the guide when are they having a temporary shutdown of
the furnace. He said that only during Christmas season, and they will be operating it
again by the 20th of January. Upon reaching this stage, for any crack or other major
error in the product, it will no longer be capable for recycling. They are still able to
repair some minor defects (each defect is designated a number) but if not, it will
just be thrown away. Some of those are being used as a vibration absorber in the
trays that pass through the furnace.
Afterwards, the product will now go through various quality control testing
and procedures to ensure that a manufactured product adheres to a defined set
of quality criteria or meets the requirements of the client or customer. We enjoyed
this part as the quality control officer simulated the use of the toilet bowl using
improvised waste matter.
Sadly, we werent able to go to the wastewater treatment facility of the plant
because its at the other end, according to them. I was a bit disappointed because
this is one part I would really want to see in a plant.

III. RECOMMENDATIONS / REFLECTIONS

As you see their products as presented in their showroom, you can feel that
indeed, as stated in their tagline, I can live here.
I could only recommend that they strictly follow safety measures
implemented by OSHA and other local health and safety standard-implementing
bodies. Also, they must find other means to recycle discarded products so as to
reduce waste.
Another thing, I think they should at least assign a chemical engineer as a
guide, so as to be able to answer certain specific questions regarding equipment
and chemical processes.
IV. REFERENCE:
hcg.com.ph