Notre Dame University College of Engineering Cotabato City

On the Job Training Report

Submitted by: Dante Braceros Jr. RasolKamsa Submitted to: Engr. Danilo C. Padas

Table of Contents

Company Values Organization Chart Company Overview The Corn Wet Milling Process Products of the Company Development Plan Observation and Recommendation Daily Activity Report

3 4 5 6 7 9 9 10

Company Values
We believe in Teamwork in being united and having a spirit of cooperative relationship.

We believe in Honesty in being truthful in our work, and in accepting one's mistakes and responsibilities.

We believe in Professionalism in managing our time, and valuing the time of our co-employees and business partners.

We believe in Loyalty in being faithful to our work and in being dedicated in the performance of our duties.

We believe in Responsiveness in having initiative in responding to those we serve and in being mindful of their needs.

We believe in Efficiency in producing effectively with less expense, waste, and effort, and with good craftsmanship.

Organizational Chart

BOD

FINANCIAL ADVISER PRESIDENT

PLANT MANAGER

ASSISTANT PLANT MANAGER

HR/OD MANAGER

HR ASSIT. SECURITY OFFICER PLANT ENGINEER PRODUCTION MANAGER

MECHANICAL MAINTENANCE SUPERVISOR

FACILITIES MAINTENANCE SUPERVISOR

ELECTRICAL & INSTRUMENTATION SUPERVISOR

UTILITIES SUPERVISOR

PRODUCTION SUPERVISORS

Q.A. SUPERVISOR

RM WAREHOUSE SUPERVISROR

ASST. MECHANICAL MEANTENANCE SUPERVISOR

ASST. UTILITIES SUPERVISOR CIVIL WORKS ELECTRICIAN

y BOILER /BIOGAS OPERATORS y UTILITY VEHICLE OPERATORS

P.M. OFFICER

ASST. Q.A. SUPERVISOR

SENIOR STOCKMAN

SHIFT SUPERVISOR

ASST. RM WAREHOUSE SUPERVISROR

UTILITY MEN
y MECHANICS y WELDERS y LATHE MACHINE OPERATOR y OILER

LABORATORY ANALYST

STOCKMAN

FINISHED GOODS WAREHOUSE SUPERVISOR

TRUCKING SUPERVISOR

ADMIN. SERVICES SUPERVISOR

BAGGING SECTION-INCHARGE

y SCALE OPERATOR y CORN CLASSIFIER y CORN CLEANING OPERATOR

y FG/WH CLERK y CHECKER y FORKLIFT OPERATOR

y PERSONEL CLERK y MEDICAL STAFF

PRODUCTION OPERATORS

Company Overview
LAMSAN INCORPORATED is the foremost corn wet milling company in the Philippines. Its products include cornstarch, corn gluten feed, corn gluten meal and corn germ. It has been in the business since 1971 and has steadily grown to become the industry leader today. The main manufacturing facility is located in the Municipality of Sultan Kudarat, Province of Maguindanao. It also has offices in Cotabato City and in Metro Manila. Lamsan's products are reputed to be the best in the country by constantly and consistently conforming to international standards. Cornstarch, the main product, enjoys a wide application in the food industry like in the manufacture of noodles, candies, marshmallows, processed food and also in other industries such as the manufacture of alcohol, plastic, paper and packaging materials. The by-products, on the other hand, are commonly used in the animal feed and pet food industry and also in the corn oil industry. Brief History LAMSAN, Inc., formerly known as Lamsan Trading, Inc., was incorporated way back in December 1965. The company was so named because in Chinese, it means "Southern Mountain." The company's manufacturing facility is situated in Sultan Kudarat, Maguindanao, which is in the Southern Philippines. The business back then was purely trading of agricultural products such as corn, rice and copra. The original LAMSAN Plant in 1971.

In 1969, Mr. Robert Lu thought of venturing into the corn wet milling business. And so, with the invaluable help of his brothers, the Lamsan cornstarch factory was put up and started operations in 1971. Although immediately faced with enormous difficulties during the martial law years due to the dramatic peso devaluation, business steadily improved such that it warranted a capacity expansion in the early '90s. The expansion, which was completed in 1994, doubled the annual production capacity. At the turn of the millennium, blindsided by the sudden influx of imported cornstarch and caught in the shifting sands of a fast changing marketplace, Lamsan yet again faced great challenges. Recognizing the peril of inaction, Lamsan took the introspective approach. First, looking no further than to its core belief that the success of an organization lies within itself, organizational development programs were quickly instituted. Second, a fundamentally different business strategy was then employed. In 2006, the company formally changed its corporate name to Lamsan, Inc., marking the start of a new and progressive company. Also in 2006, new plant improvements and facilities were put in place as well as the commencement of the drive to establish a quality management system that conforms to ISO 9001 standards.

In 2008, Lamsan embarked on another plant capacity expansion that will boost production capacity by fifty per cent. Coupled with that is a co-generation plant that will provide both steam and power to the factory. These are due to be completed by the first quarter of 2010. In August 2009, Lamsan's QMS was certified as conforming to ISO 9001:2008 standards by Certification International Philippines (CIP).

The Corn Wet Milling Process

The corn-refining process begins with shelled yellow dent corn which has been removed from the cob during harvesting. 1. Inspection and Cleaning Corn classifiers inspect and classify arriving corn shipments. Various machineries are employed to clean the corn of any foreign materials. And then, the cleaned corn are weighed and transported to the silos.

2. Steeping Each stainless steel steep tank holds corn for 40 to 50 hours soaking in 50 degree Celsius water. The addition of 0.1 percent sulfur dioxide to the water prevents excessive bacterial growth in the warm environment. As the corn swells and softens, the mild acidity of the steep water begins to loosen the gluten bonds within the corn and release the starch. After steeping, the corn is coarsely ground to break the germ loose from other components. The ground corn, in a water slurry, flows to the germ separators. 3. Germ Separation Cyclone separators spin the low density corn germ out of the slurry. The germ, which contains about 85% of the corn's oil, is pumped onto screens and washed repeatedly to remove any starch left in the mixture.

4. Fine Grinding and Screening The corn and water slurry leaves the germ separator for a second, more thorough, grinding in an impact or attrition-impact mill to release the starch and gluten from the fiber in the kernel. The suspension of starch, gluten and fiber flows over fixed concave screens (illustrated) which catch fiber but allow starch and gluten to pass through. The fiber is collected, slurried and screened again to reclaim any residual starch or protein, which is then used as a major ingredient of animal feeds. The 6

starch-gluten suspension, called mill starch, is piped to the starch separators.

5. Starch Separation and Washing Gluten has a low density compared to starch. By passing mill starch through a centrifuge, the gluten is readily spun out for use in animal feeds. The starch, with just one or two percent protein remaining, is diluted, washed 8 to 14 times, rediluted and washed again in hydrocyclones to remove the last trace of protein and produce high quality starch, typically greater than 99.5 percent pure.

6. Dewatering and Drying After the separation of the various components of the corn kernel, the respective slurries are dewatered using dewatering centrifuges and decanters. And then, the starch and other by-products are dried up to the desired moisture level using flash dryers and tube bundle dryers to produce the final products ready for packaging.

Products of the Company

Cornstarch Cornstarch, as the name indicates, is the starch derived from the endosperm of the corn kernel. The starch is separated and refined through the use of cyclones and various stages of centrifuging. It is commonly used in the manufacture of noodles, biscuits, marshmallows, and other processed food. Other uses of cornstarch would be as caking agent, for sizing in the paper industry and as pasting material. It can also be used in making biodegradable plastic and beer. Physical Characteristics Color Yellow Aroma Odorless Texture Free-flowing, smooth, fine powder Chemical Characteristics Moisture Content 13% max. Protein Content <0.35% (Dry Basis) Sulfur Dioxide <50ppm (Dry Basis) pH 5.0 to 6.4 Viscosity 13,000 to 19,000 cps

10% slurry, dry basis; cooked at 82C; Brookfield viscometer using spindle #6; 10 rpm; result taken after 30 seconds.

Corn Gluten Feed Corn Gluten Feed is a product containing primarily corn fiber and steep liquor. It is a fine flake product. It is used as a feed ingredient for poultry, livestock rations, fish and pet foods. Chemical Characteristics Moisture Content 10% max. Crude Protein 18% min. Crude Fiber 10% max. (Dry Basis) Crude Fat 1% (Dry Basis) Mineral Ash <7% (Dry Basis)

Corn Gluten Meal Corn Gluten Meal is the refined, granular, product Chemical Characteristics derived from corn during the wet milling process, Moisture Content 10-12% max. corn gluten meal is noted for its high-energy Crude Protein 60% min. content and high methionine content. Corn gluten Crude Fiber <2.5% (Dry Basis) meal is used primarily as a protein source in Crude Fat <7% (Dry Basis) poultry, livestock rations, fish and pet foods Mineral Ash 1.8% max. (Dry Basis) because it supplies vitamins, minerals and energy. Pet food processors value it for its high digestibility and low residue, and it is also a good source of xanthophylls for use in broiler and layer rations.

Corn Germ Corn Germ is the reproductive part that germinates to grow into a plant; it is the embryo of the seed. Germ is often a by-product of the milling that produces refined grain products. Corn Germ is primarily used as a source from which vegetable oil is extracted, or used directly as a food ingredient.

Development Plan
A co-generation plant that will provide both steam and power to the factory is the latest development that the company has. It is still undergoes commissions for problem trouble shooting and preventive maintenance. Others are control system for the plant operation, warehouse expansion and production concerns like quality and output quantity.

Observation
Our training in Lamsan Inc. was so fruitful; this may be the best training that we students had encountered. Lamsan Inc. had given us lots of training schedule; like winding of motors, motor status monitoring, draw on AutoCa, interpret electrical diagrams, did some exercises on motor control diagrams, lastly joined in every trouble shooting and preventive maintenance. We think that Lamsan was a great training ground for a student like us. Lamsan trained us like what they did to their employees also, that s why this OJT was so full on inputs that we students may use in our future career.

Recommendation
We recommend that, Lamsan should cater students to be trained in their company, because for so many years, our batch was the first to undergo training under their company. For the OJT recommendation, we think that offering this company was a great opportunity for us to learn and we hope for that this company will be available for the student may choose for their training in the future.