The tea beverage production and processing line is a systematic process of extracting and processing effective ingredients from tea leaves into commercial beverages. The specific steps include the following key stages:
2. Extraction: • Soaking extraction: Soak tea leaves in hot water to extract tea soup. Temperature and time are adjusted according to the type of tea to maximize the extraction of effective ingredients such as tea polyphenols and catechins Continuous extraction: In large-scale production, continuous extraction equipment may be used to improve efficiency.
3. Filtration and clarification: Use a multi-stage filtration system (such as diatomaceous earth filtration and membrane filtration) to remove tea residue and small particles, ensuring that the tea soup is clear and transparent Further purification may require centrifugal separation or the use of clarifying agents.
4. Blending and Seasoning: Add sugar, acidifiers, spices, or other additives to the tea soup according to specific blending directions to adjust the taste and flavor Conduct sensory tests on taste and color to ensure compliance with product standards.
5. Homogenization and Standardization: Use a homogenizer to evenly distribute beverage ingredients, especially for products containing milk or fruit granules Standardized processing ensures the consistency of ingredients in each batch of products.
6. Sterilization and Cooling: Using UHT (Ultra High Temperature Instant Sterilization) or pasteurization methods to eliminate bacteria and ensure the safety and shelf life of beverages Quick cooling to prevent bacterial growth and maintain the flavor of the beverage.
7. Aseptic filling and sealing: Fill into pre disinfected bottles, cans or paper boxes in a sterile environment, seal immediately to avoid secondary contamination.
8. Packaging and palletizing: The automatic packaging production line completes processes such as labeling, wrapping, and packing Use palletizing robots to stack finished products and prepare for shipment.
9. Quality control and inspection: Conduct microbiological and physicochemical index testing on finished products to ensure compliance with food safety standards and internal quality requirements of the enterprise.
10. Warehousing and Logistics: Store in a warehouse with suitable temperature and humidity, waiting for shipment Organize efficient logistics distribution to ensure timely delivery of products to sales points or customers.
The entire tea beverage production and processing line emphasizes automation and standardized operations to ensure production efficiency and product quality.
Equipment for tea beverage processing line
The tea beverage processing line involves various professional equipment to ensure that every step from raw material processing to finished product packaging is efficient and meets food safety standards.
The following is a list of core equipment:
1. Raw material processing equipment: • Tea screening machine: used to remove impurities and screen out tea that meets specifications Cleaning machine: Clean tea leaves to ensure the cleanliness of the raw materials.
2. Extraction equipment: • Continuous extraction machine: Soaking tea leaves through hot water circulation to continuously extract tea soup Extraction tank: used for batch extraction and temperature control to ensure extraction efficiency and quality.
3. Filtration equipment: • Diatomaceous earth filter: preliminary filtration of large particle impurities Membrane filtration system: Fine filtration, such as reverse osmosis membrane and ultrafiltration membrane, enhances the purity of tea soup.
4. Mixing system: • Ingredient tank: Accurately add sugar, acid taste agents and other auxiliary materials according to the formula Blender: Ensure that all components are evenly mixed.
5. Homogenizer: For beverages containing milk or fruit pellets, use a homogenizer to make the product texture uniform.
6. Sterilization equipment: UHT sterilizer: Ultra high temperature instantaneous sterilization, maintaining the original flavor of the beverage while ensuring safety Cooling device before aseptic filling: Quickly cool the sterilized tea soup to prepare for aseptic filling.
7. Aseptic filling machine: • Automatically completes filling and sealing, ensuring a sterile environment throughout the entire process.
8. Packaging equipment: • Labeling machine: Automatically apply product labels. • Film wrapping machine: shrink wrap the product to prevent dust and moisture Packing machine: Automatically loads products into cardboard or plastic boxes.
9. Stacking robot: responsible for automatic stacking of finished products to improve warehouse utilization.
10. Testing equipment: • Online monitoring device: monitors various parameters during the production process, such as temperature and pH value Laboratory testing equipment: microbiological testing of finished products, analysis of physical and chemical indicators, etc., to ensure product quality.
These devices are interconnected to form a complete automated production line, improving production efficiency and ensuring the quality and stability of tea beverages.
Information Technology of Tea Beverage Processing Line
The application of information technology in tea beverage processing lines mainly focuses on automation control, data collection and analysis, and quality traceability systems to improve production efficiency, ensure product quality, and achieve refined management.
Specifically, it includes:
1. Automation Control System (PLC/SCADA): Using Programmable Logic Controller (PLC) and Supervisory Control and Data Acquisition System (SCADA) to achieve automated control and monitoring of the production line. These systems can monitor the real-time operation status and production parameters of equipment, and adjust them in a timely manner to maintain optimal production conditions.
2. Enterprise Resource Planning System (ERP): Integrate information from production, procurement, inventory, sales, and other processes to optimize resource allocation and improve overall operational efficiency. ERP systems can also help management make more accurate decisions.
3. Manufacturing Execution System (MES): A system located between ERP and workshop level control, focusing on the management and optimization of the production execution process, including production scheduling, material tracking, performance analysis, etc., to ensure accurate execution of production instructions.
4. Intelligent sensors and the Internet of Things (IoT): Various sensors such as temperature, pressure, and flow sensors are deployed at key nodes of the production line to collect real-time production data and transmit it to the central management system through IoT technology, achieving remote monitoring and preventive maintenance.
5. Big data and artificial intelligence (AI): Using big data analysis technology to process production data, identify production bottlenecks, predict faults, optimize energy consumption, etc. AI algorithms can also be used for quality control, such as visual inspection of the quality of tea raw materials and consistency of finished product color.
6. Quality traceability system: By assigning a unique identifier to each product or packaging and combining it with an information system to record data from the entire production process, it achieves full chain traceability from raw materials to finished products, improves food safety levels, and quickly responds to market recall demands.
The integrated application of these information technologies enables the tea beverage processing line to achieve high automation and intelligence, enhancing production flexibility and response speed while ensuring product quality and safety.
The main raw materials for the tea beverage processing line include:
1. Tea: As a basic ingredient, different types of tea (such as green tea, black tea, oolong tea, etc.) give tea beverages unique flavors and colors.
2. Water: High quality water sources are crucial for the taste of tea beverages and usually require purification treatment.
3. Sugar: Used to regulate sweetness, it can be sucrose, fructose, or other sweeteners.
4. Sour agents: such as citric acid, malic acid, etc., used to balance the taste of tea drinks and make them more refreshing.
5. Spices and natural extracts: used to enhance or adjust the aroma of tea beverages, such as lemon oil, jasmine extract, etc.
6. Additives: such as preservatives, stabilizers, emulsifiers, etc., used to improve product stability and extend shelf life.
7. Nutritional Fortification Ingredients: Some health oriented tea drinks may contain added nutrients such as vitamins and minerals.
The final product comes in various forms, including but not limited to:
Bottled/canned tea beverages: the most common form, easy to carry and store, suitable for various consumption scenarios.
Tea concentrate: used in the catering industry to prepare tea drinks, ensuring consistency in taste.
Ready to drink tea: No need to brew, open the lid and drink immediately, convenient and fast Sugar free/low sugar tea drinks: Adapt to healthy eating trends and reduce sugar intake.
Functional tea drinks: added with specific ingredients claiming to have specific health benefits, such as aiding digestion, refreshing the mind, etc.
Fruit flavored tea drinks: Combining tea and fruit flavors, providing a more diverse selection.
The entire production process, from the selection of raw materials to the formation of the final product, reflects the pursuit of quality and innovation.
The environmental protection technology of the tea beverage processing line mainly focuses on energy conservation and emission reduction, resource recycling, and waste reduction. Specific measures include:
1. Energy management system: Adopt efficient and energy-saving production equipment, such as variable frequency drives, LED lighting, etc., to reduce electricity consumption. At the same time, establish an energy management system to monitor energy usage and optimize the energy structure, such as utilizing renewable energy sources such as solar and wind power.
2. Water resource recycling: Through an efficient water resource management system, the recovery and reuse of production water can be achieved. For example, using technologies such as reverse osmosis and ultrafiltration to treat wastewater to meet the standards of reuse, it is used for cleaning equipment or cooling cycles that do not directly contact products.
3. Greening of packaging materials: Use biodegradable or easily recyclable materials as product packaging, such as paper packaging, PLA (polylactic acid) bioplastics, etc., to reduce the generation of plastic waste.
4. Waste management and resource recycling: Implement waste classification management, comprehensively utilize tea leaves, filter waste, etc. generated during the production process, such as converting them into organic fertilizers, biomass fuels, etc.
5. Emission control and purification treatment: Ensure that the discharge of exhaust gas and wastewater meets environmental standards, and use advanced exhaust gas purification systems and wastewater treatment facilities, such as installing wet dust collectors, activated carbon adsorption devices to treat VOCs (volatile organic compounds), and biochemical treatment technologies to reduce COD (chemical oxygen demand).
6. Environmental Management System Certification: Implement the ISO 14001 environmental management system, continuously improve environmental performance, conduct regular environmental impact assessments, and ensure that production activities minimize their impact on the environment.
The application of these environmental protection technologies not only helps to protect the environment, but also enhances the corporate social responsibility image, which is beneficial for sustainable development in the long run.
The installation and debugging of a tea beverage processing line is a complex and precise process, typically involving the following key steps:
1. Preliminary planning: Develop a detailed installation plan based on factory layout, production capacity requirements, product types, etc. This includes production line layout design, water and electricity supply planning, environmental hygiene considerations, and safety compliance assessments.
2. Infrastructure construction: Ground leveling and moisture-proof treatment shall be carried out in the designated area, and necessary infrastructure such as drainage system, electrical wiring, and compressed air supply shall be constructed.
3. Equipment entry and assembly: • Equipment inspection: Before the equipment arrives at the site, an open box inspection is carried out to confirm that the equipment is intact and the accessories are complete Lifting in place: Use professional equipment to lift large machines such as extraction tanks, filling machines, etc. to the predetermined position Fine assembly: Assemble each component according to the manufacturer's drawings and instructions, including pipeline connections, electrical wiring, etc.
4. System integration: Ensure that all standalone equipment is properly connected, including material conveying systems, CIP (CIP) systems, steam and cooling water systems, automation control systems, etc., and perform interface testing.
5. Single machine debugging: Conduct separate functional tests on each device, such as running no-load tests to check whether the motor operation, valve switches, sensor feedback, etc. are normal.
6. Linkage test run: After successful single machine debugging, conduct a whole line linkage test run, observe the coordinated operation between various equipment, adjust parameters to achieve the best matching state.
7. Production test: Input a small amount of raw materials for actual production tests to inspect product quality, such as color, taste, microbial indicators, etc., while verifying the stability and efficiency of the production line.
8. Performance optimization and calibration: Based on the trial production results, fine tune the production line, which may include adjusting equipment parameters, optimizing process flow, etc.
9. Operation training: Provide training to operators on equipment operation, maintenance, troubleshooting, and other aspects to ensure that they are proficient in operating the new production line.
10. Acceptance and Delivery: After completing all debugging and achieving the expected goals, the final acceptance will be organized, with the participation of the manufacturer, customer, and third-party organizations. After confirmation, the product will be officially delivered for use.
The entire installation and debugging process requires close cooperation between the manufacturer, equipment supplier, and customer to ensure that the project is completed on time and with quality.
Shanghai Beyond Machinery Co., Ltd.
Beyond Machinery specializes in the design and manufacturing of tea beverage processing line.Please contact us now, and ourprofessional technical engineers will customize the equipment plan for tea beverage processing line and provide a quotation.Please contact us now to obtain the latest equipment plan and quotation.
