Product specifications

The tea comes from the steamed green tea leaves mixed with brown rice and red beans with a added tinge of dried chrysanthemum flowers.

Cereal tea color is green yellow due to the mixing of green tea leaves with roasted brown rice and red beans. Thus the tea has a strong roasted aroma and flavor.

That might not sound that appetizing to you, but don't knock it till you've tried it.

Product specification:• Japanese sencha (green tea leaves) mixed with cereal: pulse ratio• The light toasted aroma and flavor of the roasted brown rice is a nice

variation to plain green tea• High nutritive value- The antioxidants in green tea are believed to

reduce the risk of cancer and cardiovascular disease• Each carton box contains 20 individually aluminum sealed tea bags 

• PRODUCT TYPE- Cereal tea, blended tea • STYLE- In tea bags• PROCESSING TYPE- Steamed• SPECIALITIES- Health beverage, Organic tea• SMELL- High aroma, green tea mixed with cereal:

pulse• SHELF LIFE- Up-to 12 months• WEIGHT (g)- 2g per tea bag• GRADE- (F)-fanning• PACKAGING-1. Aluminum sealed packet size- 7.6* 6.5cm (4.5g)2. Carton size- 8* 10.6* 6.6cm (48g)

Green tea leaves processing

Raw material storage

(Warehouse and silos)

Weighing To weigh the

ingredient before going to the process

of sorting

Sorting Adequate uniformity

and selection for trade requirement

Shaping and cutting

Create a distinctive look- pointed shape Grading

Fanning (F)

Filling into tea bags (2g of green tea leaves and cereal: pulse)

Packaging (into aluminium sealed packets)(Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet)

Packaging (into carton boxes)(20 aluminium sealed packets placed into labelled carton boxes)

Brown rice processing

Raw material storage

(Warehouse and silos)

Washing and draining

In clean water

Weighing To weigh the ingredient

before going to the process of roasting

Roasting Roasting

temperature 200 c for 30mins

CoolingCooling process for

5mins

MillingMill sitting- 7

Sieving Sieve setting- 1mm

Filling into tea bags (2g of green tea leaves and cereal: pulse)

Packaging (into aluminium sealed packets)(Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet)

Packaging (into carton boxes)(20 aluminium sealed packets placed into labelled carton boxes)

Red beans processing

Raw material storage

(Warehouse and silos)

Washing and draining

In clean water

Weighing To weigh the ingredient

before going to the process of roasting

BlanchingBoiling temperature

100 c for 5mins

CoolingCooling process for

5mins

Roasting Roasting temperature 200

c for 30mins

CoolingCooling process for

5mins

MillingMill sitting- 9

Sieving Sieve setting- 1mm

Filling into tea bags (2g of green tea leaves and cereal: pulse)

Packaging (into aluminium sealed packets)(Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet)

Packaging (into carton boxes)(20 aluminium sealed packets placed into labelled carton boxes)

Chrysanthemum (dried flowers) processing

Raw material storage(Warehouse and silos)

Sorting Adequate uniformity and selection

for trade requirement

Weighing To weigh the ingredient before going

to the process of filling

Packaging (into aluminium sealed packets)(Along with the tea bag, 0.4g of the dried flower is placed into an air tight sealed packet)

Packaging (into carton boxes)(20 aluminium sealed packets placed into labelled carton boxes)

Equipment FlowchartRaw material(Brown rice)

Water spray nozzleTo clean and wash the raw material

Cabinet ovenRoasting temperature

200 c for 30mins

Weighing conveyorTo weigh the ingredient

before going to the process of roasting

Air blowerCooling process for

5mins

Hammer MillMill sitting- 7

Raw material storage

(Red Bean)

Water spray nozzleTo clean and wash the raw

material

Weighing conveyorTo weigh the ingredient

before going to the process of roasting

Blanching tankBoiling temperature 100 c

for 5min

Air blowerCooling process for 2mins

Cabinet ovenRoasting temperature 200 c

for 30mins

Air blowerCooling process for 5mins

Hammer MillMill sitting- 7

Sieving machine Sieve setting- 1mm

Raw material storage

(Green tea)

Weighing To weigh the ingredient

before going to the process of sorting

Sorting machine To obtain

consistent size of green tea leaves

Shaping and cutting machine

Obtain pointed shape

Grading separator

Fanning (F)

Raw material storage(Flower)

Sorting machine To obtain consistent size of dried flower

Weighing balance

To weigh the ingredient before

going to the process of filling

Packaging Machine

Equipment Description

• Brown rice & Red Bean production line equipment

•The weight of initial load of raw material is 75 kg. In order to produce 10,000 tea bags.

Water spray nozzle washing:

brown rice is washed using a water spray nozzle to inject higher pressures of water to remove the unwanted particles

Weighing conveyor:The clean brown rice has been conveyed to the tray and ready to be roasted in the cabinet oven

Cabinet ovenThe maximum load of the product is 180 kg. The roasting condition for brown rice is 200 c for 30 mins.

Equipment Description

• Brown rice & Red Bean production line equipment

Air blowerair blower is used to cool the product instead of air-drying (used in the laboratory scale) to minimize the time consumption.

Hammer milling Capacity range is suitable for up to 200kg/hr. The grounded brown rice has to be sieved by using sieving machine.

Sieving machine:The brown rice has been sieved with 1mm sieving diameter, after which the material is conveyed to the filling plant.

Equipment Description

• Brown Rice & Red Bean production line equipment

Blanching tank:The red bean has been boiled under the heating conditions and then goes to roasting process at 200C

for 5 minutes.

Equipment Description

• Green Tea Production Line EquipmentTea sorting machine:

The tea size ranges from a speck of dust to a leaf size 4cm long and 1cm wide. These fractions are to be brought to a desired size to attain uniformity and requirements conforming to the trade.

Shaping and Cutting:Range of green tea shaping and cutting equipments

vary depending on the requirement. They mainly aid in the extraction process of the stalks and cellular matter present with tealeaves. Machines: savage tea cutter, cellular tea-cutting machine.

Equipment Description

• Green Tea Production Line Equipment

Grading separator:The separator can provide the grading diameter to fanning size.

Equipment Description

• Chrysanthemum flower production line equipmentSorting machine:

The dried flower size ranges from 1 cm to 2cm in diameter. These fractions are to be brought to a desired size to attain uniformity and requirements conforming to the trade.

Weighing balance:Approximately 0.4g of the dried flowers are

weighed and placed along with the tea bag to be air tight aluminium sealed.

Equipment Description

• Packaging Line EquipmentWeighing hopper:-The ingredient is weighed in gram unit (tea leaves, cereal: pulses and dried flowers)

Tea bag filling machine:-Filling by weight based on the formula specification

Aluminium sachet sealing machine:-The aluminium packing prevents the oxidation and maintains the tea, cereal and pulse aroma.

Carton box packing- The tea bags are packed into carton boxes.

Task 4: Screening experimentWhat is screening experiment for in this task?

• Determine the factors or parameters are most likely to affect our select responses

• Correlation between the HOWs and WHATs (significant)

What should we do in designing and selecting of the experiments and responses, respectively?• According to Unit 2 works to determine the following factors which

could significantly affect the quality

Task 4: Screening experimentWhat is screening experiment for in this task?• Determine the factors or parameters are most likely to

affect our select responses• Correlation between the HOWs and WHATs (significant)

What should we do in selecting and designing of the responses and experiments, respectively?• According to Unit 2 works to determine the following

factors which could significantly affect the quality• Used factorial design to identify the experiments (3

factors with 2 levels = 23 = 8 different samples per each, 40 assessors, total no. of samples = 8*40=320)

• The following 8 samples are:

1g tea leaves 1.5g tea leaves

Ratio 4:1 Ratio 1:1 Ratio 4:1 Ratio 1:1

1mm 1mm1mm1mm1.4mm 1.4mm 1.4mm 1.4mm

The samples were prepared as per requirement for the sensory test to determine the significantly affect factors for the quality or consumer acceptability by 9-point scale and using R project (ANOVA) to analysis the results.

However......

• It is failed to generate any significant change in the responses to the WHATs. • Moreover, the assessors have rated all the samples quite low and this proves to be a roadblock to the optimisation procedure. •The team has to look into the possible causes and repeat this task again at the beginning of the next unit.

Task 7: Legislations

The conformance of the production process was examined with regard to national, European and

international regulations (basic by the Codex Alimentarius and the FSA).

There were 4 processes relevant with regard to legislation• Storage:

Basic food law/commission regulations 2006 pointed that the amount of cereals (i.e. the maximum content of cereal should be 0.05 mg/kg wet weight). Codex Alimentarius (CAC/PCP 1- 1969) pointed the quality factors (i.e. the moisture content of rice is 15%m/m max).

• Washing: FSA guideline pointed out to remove the physical, chemical, and microbiological hazards from ingredients to increase the quality and safety.

• Blanching:FSA and Codex Alimentarius published pre-cooked by Blanching is in order to inactivate the enzyme and change the texture.

• Packaging:In the most recent study published in 2009, the level of aluminum sealed bags has recently been lowered. The content in the food by less than 1mg/kg and/ or less than 10mg/kg for 85% of foods.

What went wrong?

Temperature Troubles

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temperature-time profile (under normal conditions)

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The consumer & TEA

“ I want m

ilk

in my tea”“ I like black tea”

“ Green Tea is healthy”

“I want loads of sugar”

!DEA

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